Carville Plastics is a leading contract manufacturer specializing in precision CNC plastic machining and high-accuracy, multi-layer diffusion-bonded manifolds. Serving demanding sectors such as medical devices, life sciences, diagnostics, and industrial applications, Carville is known for its ability to deliver intricate plastic components with tight tolerances and high performance.
To support their high-precision operations, Carville relies on vacuum systems to securely hold plastic plates in place during CNC machining. As their product mix evolved and the demand for vacuum across multiple machines increased, their existing setup—based on Venturi vacuum generators using compressed air—became increasingly inefficient.
Challenge
Carville’s vacuum systems were powered by compressed air via Venturi devices. While this method initially met their needs, it eventually became unsustainable due to:
- Excessive energy consumption from constantly running compressors
- Increased maintenance demands and wear on the compressed air infrastructure
- Growing demand for vacuum across a larger number of machines
As Carville’s facility expanded its vacuum requirements, the inefficiencies of the Venturi system multiplied, placing added strain on their compressors and driving up operational costs. Carville sought a more energy-efficient and reliable vacuum solution that could scale with their manufacturing needs.
Solution
The Becker team conducted a full site survey to evaluate Carville’s energy use, maintenance practices, and production requirements. Based on our findings, we proposed replacing the Venturi-based vacuum system with a centralized vacuum solution. The new design included:
- Four VARIAIR BCV 300 Claw Vacuum Pumps, equipped with integrated inverter drives
- A central ring main connecting all 22 CNC machines to the new vacuum system
- A VARIAIR Controller+ to automatically regulate pump speed based on real-time demand
The BCV 300 Claw Pumps were selected for their oil-free, contact-free compression chambers, offering a reliable, low-maintenance solution ideal for continuous use in a precision manufacturing environment.
To ensure a smooth transition, the installation was planned in two phases, minimizing disruption to Carville’s production schedule. Carville and Becker worked closely throughout the design and installation process to align on logistics and performance expectations.
Results
Carville’s new central vacuum system delivered measurable improvements:
- Significant reduction in energy consumption
- Substantial decrease in maintenance costs due to the low-maintenance design of the claw pumps
- Return on investment in under two years
- Improved operational efficiency and reliability across all CNC machines
Vince Ellis, Managing Director at Carville, shared, “We worked closely with Becker in designing the installation, and the entire process went very smoothly. From our experience with Becker, I would definitely recommend them.”
Maximize Your ROI with a Centralized Vacuum System
By transitioning from a compressed-air Venturi system to a centralized vacuum solution from Becker Pumps, Carville Plastics achieved major gains in energy efficiency, maintenance savings, and long-term sustainability. The partnership exemplifies our commitment to helping manufacturers reduce operational costs and optimize performance with tailored vacuum solutions.
Considering a vacuum system upgrade? Contact us today for a complimentary site audit and see how a centralized system can improve your facility’s energy efficiency and bottom line.
