How Vacuum Technology is Driving the Energy Revolution in Thermoforming and Plastics Processing
2026/07/16
Thermoforming is one of the most widely used plastic processing methods in the world. From food packaging trays to automotive interior components, from medical device packaging to industrial pallets, thermoforming shapes the plastic products we use every day. But there is a hidden cost that many manufacturers overlook: energy consumption.
Vacuum technology is a critical element for quality and efficiency in plastics processing – in thermoforming, recycling, film extrusion, and plastic degassing and coating. However, traditional vacuum systems in thermoforming operations are often oversized, inefficient, and energy-intensive. Modern vacuum pumps used in plastics production are now designed to consume less power while maintaining high performance. This article explores how advanced vacuum technology – particularly oil-sealed rotary vane pumps like Wordfik's PVX series – is driving an energy revolution in thermoforming and plastics processing.
Thermoforming involves heating plastic sheets to a forming temperature, then using vacuum pressure to draw the softened plastic against a mold surface. The vacuum system must:
- Evacuate air rapidly between the plastic sheet and the mold
- Maintain stable vacuum throughout the forming cycle
- Handle short cycle times in high-speed production lines
Traditional thermoforming operations typically use multiple vacuum pumps per machine – often two pumps per thermoforming machine: one for forming the foil into the mold and another for other functions. This decentralized approach leads to:
| Problem | Impact |
|---|---|
| Oversized pumps running at full capacity | Wasted energy during idle periods |
| Multiple pumps per machine | Higher total energy consumption |
| Heat generation | Increased cooling costs |
| Inefficient pump operation | Higher electricity bills |
Research has shown that Roots pumps traditionally used in thermoforming can waste up to 90% of energy via waste heat from the motor. In one documented case, replacing four oil vane pumps consuming 14.5 kW total with a modern alternative reduced loaded power to just 4.4 kW – an effective 70% energy savings.
Wordfik's PVX series oil-sealed rotary vane vacuum pumps are engineered specifically for demanding industrial applications like thermoforming. Here's how they deliver energy efficiency:
- Optimized Pumping Speed Matching
The PVX series offers a range of pumping speeds from 40 m³/h to 360 m³/h, allowing manufacturers to select exactly the right pump for their application – not oversized, not undersized. This eliminates the energy waste of running a pump that is too large for the actual demand.
- Efficient Motor Design
PVX pumps feature high-efficiency copper-wound motors that deliver maximum output per kilowatt of electricity consumed. The result: more vacuum with less energy.
- Reduced Heat Generation
Efficient operation means less wasted energy as heat. This not only saves electricity but also reduces facility cooling costs – a hidden but significant expense in thermoforming operations.
- Stable Vacuum Performance
PVX pumps maintain stable vacuum levels throughout the forming cycle, ensuring consistent product quality while operating at optimal efficiency. Maintaining stable vacuum levels during sealing, forming, and cooling is critical for both quality and energy efficiency.
One of the most significant advances in vacuum pump energy efficiency is Variable Speed Drive (VSD) technology. The built-in VSD feature adjusts pump speed according to actual demand, ensuring more productivity and less energy consumption throughout the production period.
In thermoforming applications, VSD technology delivers:
- Up to 70% energy savings compared to fixed-speed pumps
- Up to 58% energy savings in typical thermoforming applications
- Reduced power consumption during idle periods
- Extended pump life through softer starts and reduced wear
For facilities with multiple thermoforming machines, central vacuum systems offer even greater energy savings. Instead of each machine having its own pump(s), a central system uses fewer, larger pumps that operate more efficiently.
The benefits are substantial:
- Fewer pumps – one vacuum pump instead of five
- Energy savings of more than 50%
- Significantly reduced maintenance costs
- Pumps only run when vacuum is actually needed in the process
- Reduced heat emission into the production area
Wordfik's PVX series oil-sealed rotary vane vacuum pumps are specifically designed for demanding thermoforming and plastics processing applications.
| Feature | Benefit |
|---|---|
| 0.5 mbar ultimate vacuum | Consistent forming quality |
| 40-360 m³/h pumping speeds | Right-sizing for any application |
| High-efficiency copper motors | Maximum output per kW |
| Gas ballast valve | Handles moisture from heated plastics |
| Heavy-duty cast-iron construction | 24/7 continuous operation |
| Low noise operation | Improved working environment |
| Model | Pumping Speed (50Hz) | Ultimate Vacuum | Best For |
|---|---|---|---|
| PVX40 | 40 m³/h | 0.5 mbar | Small thermoforming machines |
| PVX63 | 63 m³/h | 0.5 mbar | Medium thermoforming machines |
| PVX100 | 100 m³/h | 0.5 mbar | Large thermoforming machines |
| PVX160 | 160 m³/h | 0.5 mbar | High-speed thermoforming |
| PVX202 | 200 m³/h | 0.5 mbar | Multiple machines / central systems |
| PVX250 | 250 m³/h | 0.5 mbar | Large-scale production |
| PVX302 | 300 m³/h | 0.5 mbar | Maximum throughput applications |
A leading thermoforming manufacturer replaced four conventional oil vane pumps with a modern efficient alternative. The results were remarkable:
| Metric | Before | After | Improvement |
|---|---|---|---|
| Total energy consumption | 14.5 kW | 4.4 kW | 70% reduction |
| Number of pumps | 4 | 1 | 75% fewer pumps |
| Maintenance frequency | High | Low | Significant reduction |
In another case, a dairy food packaging facility with five thermoforming machines each having two vacuum pumps switched to a centralized vacuum system:
- Drastically reduced running time of individual pumps
- Massive energy savings through optimized operation
- Two-stage package evacuation improved efficiency further
- 30% more energy savings than comparable models with advanced rotary vane technology
- 26% energy savings during active production, 94% during breaks with Eco-mode
- 40% energy cost reduction reported by manufacturers switching to efficient systems
Consistent vacuum levels mean consistent forming quality. Modern vacuum pumps maintain stable vacuum during sealing, forming, and cooling, resulting in:
- Fewer rejects
- Better detail reproduction
- More consistent wall thickness
Oil-sealed rotary vane pumps with advanced design features require less frequent maintenance, reducing downtime and labor costs.
When you add up energy savings, reduced maintenance, and improved productivity, the total cost of ownership of a modern vacuum system is significantly lower than traditional alternatives.
Lower energy consumption means lower carbon emissions. For manufacturers working toward sustainability goals, upgrading vacuum systems is one of the most effective steps they can take.
Evaluate your current vacuum systems. How many pumps are running? What is their total energy consumption? Are they running continuously even when not needed?
Select pumps with the correct pumping speed for your actual requirements – not oversized "just in case."
For facilities with multiple machines, a central vacuum system can deliver substantial energy savings.
Work with a vacuum pump manufacturer that understands thermoforming applications and can provide the right solution for your specific needs.
The energy revolution in thermoforming and plastics processing is here. Modern oil-sealed rotary vane vacuum pumps – particularly those with efficient motor designs, right-sized for the application, and integrated into central systems – can deliver energy savings of 50-70% compared to traditional approaches.
Wordfik's PVX series offers thermoforming manufacturers:
- Deep vacuum down to 0.5 mbar for consistent forming quality
- Right-sized pumping speeds for any application
- High-efficiency motors for maximum energy savings
- Proven reliability in 24/7 continuous operation
Whether you're operating a single thermoforming machine or a full production facility, Wordfik has the vacuum solution to help you reduce energy costs, improve product quality, and achieve your sustainability goals.
