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Schmalz enables smarter manufacturing with electric vacuum technology
Articles- Sep 28,26
Schmalz’s electric vacuum generators enable flexible automation, reducing energy use while supporting mobile robotics and digital manufacturing
Modular factories, mobile robotics and rising energy costs are reshaping industrial automation. In response, electrical vacuum generation is emerging as an alternative to traditional compressed air systems. It enables self-sufficient gripping solutions, reduces energy losses and integrates seamlessly into digital manufacturing environments.
Production managers today face the challenge of making plants more flexible while improving energy efficiency. To achieve this, companies are adopting modular production cells, autonomous mobile robots (AMRs) and concepts that reduce dependence on compressed air. However, traditional infrastructure remains a challenge, with fixed compressed air networks requiring connectors and modifications whenever production layouts change.
Vacuum technology plays a vital role in this transformation. It enables gripping, holding and movement of workpieces across industries including electronics manufacturing, logistics and automotive. Traditionally, ejectors generate vacuum using compressed air, and this technology continues to support many applications. However, evolving production models require more flexible solutions.
Vacuum moves with mobile automation
Mobile robotics is driving demand for adaptable vacuum solutions. AMRs and automated guided vehicles (AGVs) move freely across factories and cannot depend on fixed media connections. Collaborative robots (cobots) also require flexibility as they frequently change work environments.
Michael Pojtinger, Head of Business Development Process Vacuum Automation (Components), Schmalz, explained, “The factory is becoming modular, but compressed air is made for fixed installations.”
Electrical vacuum generators address these limitations by operating without central compressed air systems. They require only an electrical connection, with an integrated motor driving a pump or blower to generate vacuum directly at the point of use. Power can come from the grid or a robot’s battery, allowing the gripping unit to function independently of stationary connections.
This creates new opportunities for AMR and AGV applications, enabling robots to move through production areas without hose connections or fixed media supplies. Electrical vacuum generators also simplify cobot integration by eliminating the need for external air treatment systems.
Flexible factories without compressed air
More companies are evaluating where compressed air is no longer essential. In specific production areas, and sometimes across entire facilities, manufacturers are exploring concepts that reduce reliance on this medium to improve energy efficiency, lower costs and support sustainability goals.
Electrical vacuum generators play an important role in these applications by producing vacuum directly where it is required, without central compressed air infrastructure. “Handling remains powerful and safe, even without the pipe network,” said Pojtinger.
The technology also supports more flexible factory planning, as production cells can be relocated without reinstalling compressed air pipelines. Since electricity is generally available throughout manufacturing facilities, companies can reduce planning efforts and minimise downtime during modifications.
“Depending on the application and load case, electrical vacuum generators save up to 95 per cent energy compared to compressed air-powered ejectors,” added Pojtinger. The actual savings depend on factors such as cycle frequency, load profile and operating time.
Compressed air systems require energy-intensive generation, processing and distribution, with losses occurring throughout the process. Electrical systems convert electricity directly into vacuum at the point of use, helping reduce operating costs and support lower CO? emissions, depending on the electricity mix.
Digital integration for smart manufacturing
Schmalz develops electrical vacuum generators as part of a modular system architecture. The portfolio includes compact vacuum pumps for cobots and end-of-arm applications, as well as high-performance electric pumps and vacuum blowers for stationary processes.
The company provides components across the complete vacuum chain, from suction cups to sensor technology. These electrical vacuum generators capture process data and integrate into connected production environments through IO-Link.
Users can monitor operations and adjust parameters easily. “The vacuum component becomes a data-providing field device. This creates the basis for condition monitoring and condition-based maintenance,” explained Pojtinger.
Vacuum technology enters a new phase
Modern automation increasingly depends on dynamic, connected and modular structures. Electrical vacuum generation aligns with this shift, and Schmalz continues to develop solutions that address changing industrial requirements.
Infrastructure-independent vacuum components are not intended to replace pneumatic systems universally but provide an additional option where compressed air limits flexibility. “Production managers can use this additional option to consistently orient automation towards mobility, flexibility and digital transparency,” said Pojtinger.
Practical example: Electrical end-of-line handling
Bizerba, a specialist in weighing and packaging systems, implemented a smart picking solution for a Spanish food processor using a fully electrical vacuum generation system mounted directly on the robot arm.
In this application, two cobots equipped with Schmalz grippers pick up foil-wrapped meat packages and place them into transport crates at up to 96 picks per minute. The electrical vacuum supply is provided by the GCPi compact electric pump combined with compact electric valves.
Mounted directly on the gripper, the decentralised solution provides vacuum quickly and efficiently without requiring a central compressed air source. It delivers performance comparable to pneumatic systems while consuming significantly less energy and reducing operating costs.
The digital connection through IO-Link enables monitoring of process parameters and supports predictive maintenance. Electrical vacuum generation improves productivity, reduces manpower requirements and enhances process reliability in automated order-picking operations.
Schmalz
Michael Pojtinger
Vacuum Automation
Industrial Automation
Electric Vacuum Generators
Mobile Robotics
Manufacturing Industry
Germany
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