Car audio factory case Puyan Screw Vacuum System - 24/7 Stable
In the field of automotive electronics manufacturing, a stable centralized vacuum system is key infrastructure for ensuring production continuity. In May last year, Shanghai Puyan Machinery Equipment Co., Ltd. (hereinafter referred to as "Puyan Machinery") successfully delivered a standby screw vacuum system to a car audio manufacturer in Suzhou for centralized vacuum supply across the entire plant. This effectively solved the customer's practical problems caused by the previous decentralized air supply method, such as high noise, frequent failures, and difficult maintenance.
Project Background: Extremely High Demands for Vacuum Systems in Car Audio Production
The customer is primarily engaged in the production of automotive audio speakers, amplifiers, and control modules. The production line extensively uses vacuum suction cups for material handling, positioning, and air tightness testing, requiring extremely high stability and continuity of vacuum. Previously, the customer used multiple small rotary vane pumps for decentralized air supply. This not only resulted in sharp noise and noticeable oil mist, but also caused partial production line stoppages if a single unit failed. The equipment department spent a significant amount of time each week on repairs and maintenance.
The customer explicitly requested a screw vacuum system with "standby" automatic switching capability, to ensure 24/7 uninterrupted air supply while reducing operating noise and maintenance intensity.
Puyan Solution: 2 PLG55W Units + 10L Water Vapor Filter + Puyan Vacuum Control System
Based on the actual operating conditions of the customer's plant, the Puyan Machinery technical team conducted an on-site survey and customized the following configuration:
- Core Vacuum Source: 2 Puyan PLG55W Screw Vacuum Pumps
The PLG55W features a non-contact twin-screw rotor design, achieving an ultimate vacuum below 5 Pa and a pumping speed of 198 m³/h (per unit). The pump is characterized by low noise, low vibration, water vapor tolerance, and no easily worn vanes, making it particularly suitable for 24/7 continuous operation. - Inlet Treatment System: 10L Water Vapor Filter (one independently configured for each pump)
Effectively captures trace moisture and dust that may be present in the pipeline, protecting the long-term stable operation of the screw unit and extending the replacement intervals of lubricating oil and the oil separator. - Control System: Puyan Vacuum Control System
Enables standby automatic switching: under normal conditions, one pump runs while the other stands by; if the running pump fails or its pumping speed is insufficient, the standby pump automatically cuts in, ensuring production lines do not stop due to vacuum interruption. Remote monitoring and data logging functions are also optionally available.
The customer provided their own buffer tank. The Puyan team assisted with pipeline connection and the integrated commissioning of the entire system. The complete system adopts a skid-mounted structure, prefabricated at the factory, requiring only connection to the main pipeline and power supply on site.
Project Results: Comprehensive Improvement in Stability, Energy Efficiency, and Maintainability
After one year of operation of this screw vacuum system, the customer reported the following significant improvements:
- Stable Vacuum Level: Under continuous production conditions, the system's vacuum level remained consistently stable, with no suction cup detachment or positioning deviation caused by insufficient vacuum.
- No Oil Contamination: Compared to the original rotary vane pumps, the screw pumps produce no exhaust contamination, and the workshop environment has significantly improved.
- Drastically Reduced Maintenance Workload: Only two routine maintenance sessions (lubricating oil and filter changes) were performed within the year, with no unscheduled downtime due to failures. The equipment department has been freed from "frequent pump repairs".
The customer's equipment manager commented: "Puyan's standby screw vacuum system is so worry-free. Before, we had to deal with rotary vane pumps every week. Now, we hardly need to touch it for a whole year, and the vacuum is extremely stable. For our new line expansion, the first thing we thought of was to ask Puyan for an upgrade."
Deepening Cooperation: Customer's Interest in Adding Variable Frequency Drive
Recently, the customer proactively contacted Puyan Machinery, indicating that due to production capacity expansion, they plan to add two new production lines. At the same time, they wish to upgrade the existing screw vacuum system for energy savings by converting it to a variable frequency control system. On May 14, the Puyan technical team visited the customer's plant again and had in-depth discussions with production and equipment managers regarding the retrofit plan. The preliminary decision is to add variable frequency drives, vacuum sensors, and a PID closed-loop control module to the existing system, allowing both screw vacuum pumps to run at demand-based speeds. This is expected to achieve an overall energy saving rate of over 30%. The customer highly认可 the plan and has clearly expressed a purchase意向, planning to complete the retrofit in the third quarter.
Puyan Machinery specializes in vacuum pumps and custom vacuum systems. Our core strengths lie in on-demand customization (providing non-standard designs based on air volume, vacuum level, media, etc.), our own brand, and rapid response (providing solutions within 24 hours). Besides car audio manufacturing, this screw vacuum system is also widely used in lithium battery vacuum drying, food and pharmaceutical packaging, electronic component handling, rubber vulcanization degassing, printing and paper conveying, and other industries. If your plant faces issues such as insufficient vacuum, system instability, or the need for energy-saving upgrades or retrofits, please contact Puyan Machinery for a customized solution.