Pneumofore
Pneumofore

Understanding the Power Consumers in Can Manufacturing

In any 2-piece can factory, the largest portion of electricity usage - and therefore the biggest share of the energy bill - comes from air compressors and vacuum pumps. These two utilities dominate power consumption, making them the most critical to monitor and optimize.

At recent can industry events in Europe - the CanMaker Conference (Barcelona, November 2024) and the CanTech Grand Tour (Brussels, April 2025) - participants heard a compelling address from Ms. K. Kazaschka, CEO of Metal Packaging Europe (MPE). She presented the EU’s Clean Industrial Deal and explained how it supports the broader Green Deal, aiming to transform Europe’s economy into a climate-neutral, resource-efficient system by 2025.

This makes analysing CO₂ emissions per kilowatt-hour (kWh) in can production not only practical but urgent. Lowering energy use reduces both costs and environmental impact. Given the high energy demands of pneumatic equipment, it is essential to assess their long-term efficiency with precision.


Choosing the Right Equipment


Among the many global manufacturers of compressors and vacuum pumps, only a few demonstrate a genuine commitment to environmental responsibility. These companies engineer machines with long-lasting energy efficiency and offer extended warranties - some as long as 10 years - not just for performance but for efficiency itself.



Durability, Performance and Efficiency: Fundamental Concepts


Durability is measured over time; energy efficiency, however, is not time-dependent. Product catalogs and standard legal warranties, often limited to one or two years, offer little assurance over extended periods. While a machine’s performance might appear constant over time, the crucial question remains: does it maintain the same energy efficiency as when first installed?

In today's industrial context - where sustainability is not only an environmental priority but also a societal one - manufacturers must adopt a responsible approach. In this article, we focus on a key environmental metric: CO₂ emissions, a leading driver of global warming.

One of the most effective strategies to reduce CO₂ emissions is by minimizing energy consumption. For high-energy-demand equipment, such as compressors and vacuum pumps, long-term energy efficiency is essential to maintain electricity usage in proportion to throughput capacity.

The environmental urgency is not new. As early as the late 20th century, scientists issued dire warnings about global ecological imbalance. Given Earth’s age of 4.5 billion years, it is striking that just 200 years of industrial civilization have substantially altered the planet’s climate. With a human lifespan averaging 80 years, this burden of responsibility falls on just the last few generations.


A Legacy of Engineering Excellence


The name Pneumofore, derived from Ancient Greek - pneuma (air) and phoros (bearer) - reflects the Company’s identity. Since its founding in 1923 by Swiss engineers, Pneumofore has remained consistently focused on rotary vane technology for industrial vacuum pumps and air compressors.

Unlike diversified competitors, Pneumofore's commitment to a single technology has enabled deep specialization - and with it, the confidence to offer a 10-year guarantee on energy efficiency.

Performance evaluation of vacuum pumps and compressors depends on the ratio of absorbed power (kW or hp) to output capacity (m³/h or cfm). If this ratio remains stable, efficiency is preserved. If power consumption rises while output remains the same, energy efficiency has decreased, often signaling the need for an overhauling of the pumping unit - the machine’s core.

This reduction in energy efficiency increases both CO₂ emissions and the customer’s electricity expenses.


CO₂ and Global Temperature


Reducing CO₂ emissions is more than an ethical goal - it is a scientifically grounded imperative. Agencies across Europe and the United States continue to monitor global temperatures. A 1.5°C rise, now a recorded reality, leads to serious consequences: biodiversity loss, polar ice melt, extreme weather events (floods, hurricanes, drought) and escalating health risks linked to air pollution.


The Relationship between kWh and CO₂


Publicly available data shows that, on average, 1 kWh of electricity consumed equates to 0.5 kg of CO₂ emissions, though in some global estimates, this figure reaches 1 kg/kWh. For example, according to the UK Government Conversion Factors for Greenhouse Gas Reporting (2023), the carbon factor is 0.207 kg of CO₂ per kWh. The industry in the UK is incentivized to reduce emissions, receiving £64.90 per ton of CO₂ saved - or approximately €78 for every 1,000 kg of CO₂, which equates to a reduction of 2,700 kWh.

It is worth noting that emission conversion data often lags behind industrial developments due to political and regulatory complexities - particularly within the 27-member European Union, where harmonization and updates are slower to implement.


kWh and Cost: A Global Comparison


Electricity prices vary globally, largely based on production methods. For comparison:
 • China: 0.08 €/kWh
 • France: 0.16 €/kWh
 • Germany: 0.23 €/kWh
 • Italy: 0.30 €/kWh
 • United Kingdom: 0.39 €/kWh

Clearly, energy efficiency is not just an ecological imperative - it’s an economic advantage. In a market where Asian manufacturers benefit from lower labor costs, European producers must invest heavily in R&D and engineering quality to stay competitive.


The Time Factor


Few manufacturers are willing to guarantee long-term efficiency - many deem it unfeasible. Yet Pneumofore machines operate continuously (24/7) for decades without efficiency loss. To illustrate: one year equals 8,760 operating hours; over a 10-year period, that’s 87,600 hours. A Pneumofore machine, therefore, runs the equivalent of a car at the speed of 100 km/h traveling 8,760,000 km - equal to 218 laps around Earth’s equator.


Performance and Sustainability


Pneumofore’s machines are designed for high performance with rapid plug-and-play installation, which reduces both downtime and operational costs. Ordinary maintenance, required once or twice annually, involves only replacing refrigerant and three filter cartridges. Easy machine access further streamlines these tasks. Selecting the correct refrigerant viscosity ensures proper cooling and lubrication, thereby preserving energy efficiency. The use of original spare parts is mandatory to maintain the extended guarantee.

While imitation rotary vane pumps and compressors exist, none match the reliability, heritage or engineering quality of Pneumofore. Many are simplified replicas lacking the performance benefit of the authentic design.


Durability, Efficiency and Performance: The Value of Quality


The longevity and energy efficiency of a machine depend on the quality of its components. While some manufacturers focus on mass production using cost-reducing materials, Pneumofore invests in cutting-edge engineering to minimize environmental impact and maximise reliability and service life. For instance, high-quality bearings, robust motors, efficient radiators and fans are essential elements - often under-specified by competitors.


Proven Longevity: Reliability in Action


Several video testimonials of customers using Pneumofore machines for the production of aluminium cans, in Europe and in the Americas, some since decades are available online on the Pneumofore YouTube channel. Thousands more industrial, heavy-duty rotary vane machines are running in disparate climates, mostly air-cooled, also in tropical countries. The video reported installations are no anomaly: many machines perform reliably for 20 to 30 years before needing their first overhaul.

Such longevity plays a key role in sustainability. The production of 1 kg of crude steel emits about 2 kg of CO₂. Durable machines reduce replacement frequency, conserving natural resources and lowering emissions. Pneumofore’s simple geometric design also simplifies overhauls, further extending machine life.


The Most Competitive Rental Rates


More customers are opting to rent rather than purchase equipment. Pneumofore rental contracts include full maintenance - labor and parts - and are performance-based, with penalties for any decline in energy efficiency.

Thanks to its guaranteed long-term energy efficiency, Pneumofore offers 5+ year rental agreements with monthly rates lower than the competition. Although the initial purchase cost is higher, the Total Cost of Ownership (TCO) over 10+ years positions Pneumofore as the most cost-effective solution for both industrial vacuum pumps and compressors.


A Commitment Beyond Profit


Pneumofore’s philosophy is increasingly rare in today's industry, where short-term returns often eclipse long-term value. Here, engineering excellence takes precedence, aimed at minimizing environmental impact. The company’s commitment to maintain stable the energy efficiency over time aligns with international efforts to reduce CO₂ emissions.

By exceeding expectations in both reliability and sustainability, Pneumofore continues to earn the trust of industry professionals worldwide.


About the Author

 Eng. Daniel Hilfiker, President of Pneumofore

Daniel Hilfiker represents the third generation of Swiss engineers managing Pneumofore, the world's oldest rotary vacuum pumps and air compressor manufacturer, celebrating more than 100 years of expertise. Daniel graduated as Mechanical Engineer at the Federal Technical Institute of Zürich, Switzerland, in 1993. He is personally engaged in R&D with strong commitment for lowest environmental impact which corresponds to minimal operational costs. He participates to worldwide conferences on regular basis, as his pneumatic theory and products are applied in many sectors including container glass production, can making, aerospace, medicine, food, petrochemical and more.


About Pneumofore


Founded in 1923, Pneumofore manufactures vacuum pumps and compressors for industrial applications worldwide. Pneumofore compressors and vacuum pumps are found worldwide, whenever customers require extraordinary reliability and constant performance over time. Leader in the Rotary Vane technology, Pneumofore solutions focus on efficiency, durability, minimal Life Cycle Cost, and high environmental respect. For more information, visit www.pneumofore.com.

More videos are available on the YouTube channel www.youtube.com/pneumofore. 

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