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Air-Saving Vacuum Ejectors Cut Energy Use by Up to 90% in Automotive Plants
Articles- Feb 05,26
Air-saving vacuum ejectors are helping Indian automotive manufacturers reduce energy costs, cut carbon emissions and achieve rapid ROI while ensuring reliable, zero-defect production, shares Rajesh Salunkhe, Industry Segment Manager, Schmalz India.
It’s always a pleasure to share our expertise and work experience with our esteemed customers on innovative vacuum automation solutions. As someone who has spent 18 years across automotive vacuum automation applications, I’ve seen how small innovations can transform entire industries. Today, one such innovation is reshaping Indian manufacturing: Air-Saving vacuum generators.
Walk into any automotive supplier in India today and you’ll hear the same refrain: “Reduce Carbon footprints.” The industry is under relentless pressure to reduce carbon footprints, and every line must deliver zero-defect quality. Yet behind the scenes, many factories still rely on legacy vacuum systems that quietly waste 70 per cent–90 per cent of compressed air—the second-largest utility cost in manufacturing. This hidden inefficiency drains profits, inflates energy bills, and undermines sustainability goals.
Why Air-Saving Matters
Compressed air is expensive. Every cubic meter wasted is money lost — and emissions added. In fact, energy costs for compressed air have risen nearly 20 per cent in the past three years. From Automotive OEMs to their Tier I and II supplier, that can mean million of rupees in avoidable expenses annually.
Air-saving ejectors directly tackle this challenge. By consuming air only when needed, they cut energy costs by up to 90 per cent. But the benefits go far beyond savings:
- Reliability in harsh Indian conditions—no electronics to fail during voltage dips or monsoon humidity.
- Zero-defect performance—stable vacuum ensures consistent quality, fewer rejects, and lower warranty costs.
- Sustainability impact—each line can reduce CO? emissions by over 4 tons annually, equivalent to planting 700 trees.
This isn’t just about machines. It’s about enabling manufacturers to stay competitive, meet government incentives, and align with global carbon neutrality targets.
Industrial vacuum automation applications are depending on compressed air supply. Schmalz pneumatically and electrically operated air saving ejectors ensure 90 per cent compressed air savings during vacuum automation cycle time.
Result
- Less compressed air usage
- Less electrical consumption
- Reduced carbon footprint
Automotive OEM’s production process—press shop, BIW (Body in White), paint shop and assembly lines—major vacuum automation compressed air usage is at press shop, BIW line and assembly line. Schmalz ensures to provide right products to all the vacuum automation applications, such as our 100 per cent compressed saving ejectors – 100 per cent pneumatically and electrically.
Real-World Transformation
Consider an automotive BIW (Body in White) line that replaced its non-air saving basic ejectors with air saving ejectors. The results were dramatic:
- Energy costs dropped from Rs 35,000 to Rs 13,300 per month—a 62 per cent reduction.
- ROI was achieved in just seven months.
About the author:
Rajesh Salunkhe is the Industry Segment Manager of Schmalz India, where he has spent over a decade shaping strategy and driving growth. He is a seasoned sales and business development professional with extensive experience in industrial automation and vacuum technology. Earlier in his career he held key roles including Area Sales Manager (West Region), Sales Engineer for Pune and Goa territories, and Manager – Marketing and Sales, building a strong foundation in customer engagement, territory management and commercial leadership.
Vaccum automation solutions
compressed air savings
automotive manufacturing India
energy efficiency in factories
carbon footprint reduction
BIW automation
industrial vacuum systems Rajesh Salunkhe
Schmalz India
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