In automation, pneumatic grippers and vacuum cups are considered compact, fast, and proven solutions for handling components. That is precisely why they are often taken for granted. An individual consumer seems small, and their air demand is manageable. However, within the overall system, this can become a significant factor affecting energy consumption and cost-effectiveness.
A single gripper or suction cup has virtually no impact on energy consumption. However, in automated systems with many cycle times, multiple handling points, and continuous operation, energy consumption quickly adds up. Added to this are pressure losses, leaks, poorly designed piping, or unnecessarily high pressure levels, which further increase actual demand.
This effect is often underestimated, especially when it comes to vacuum cleaners.
Vacuum generation using ejectors is often very simple and robust in terms of function, but it is not always the most energy-efficient solution. If vacuum pumps are operated continuously, unnecessarily large safety margins are built in, or leaks occur in the system, compressed air consumption increases significantly. What may seem insignificant in a single process can have a noticeable impact over many cycles.
It’s also worth taking a closer look at pneumatic grippers. Gripper size, stroke, cycle rate, pressure level, and the design of the peripheral equipment directly affect how efficiently the system operates. Not every application requires maximum gripping force, and not every suction cup requires maximum holding force. If the system is designed to be larger or more powerful than necessary, not only do air consumption and energy costs increase, but so do dynamic losses and mechanical stresses in the process.
That is precisely the key point. Compressed air in material handling is not a minor issue, but rather part of the overall technical and economic assessment of a system. Anyone who takes energy efficiency in automation seriously should focus not only on compressors and supply systems, but also on the many small power consumers directly within the process.
