If you’re looking to invest in an industrial vacuum system, it’s important to understand the costs involved. From selecting the right type of vacuum pump to determining the appropriate system size, your choices will significantly impact both your initial investment and long-term operating expenses. Industrial vacuum systems, which include pumps, piping, and infrastructure, can vary widely depending on the scale of your facility and the complexity of your needs.
This guide will compare the upfront costs associated with rolling out a new industrial vacuum system versus the ongoing costs of maintaining and operating it. By examining factors like equipment type, system design, and energy consumption, you’ll be better prepared to make an informed investment decision for your business.
UPFRONT COST CONSIDERATIONS
When evaluating the upfront cost of an industrial vacuum system, there are four key categories to consider: system type, pump selection, the number of machines or workstations needed, and any customizations or modifications. Each of these factors plays a crucial role in determining both the overall price and the efficiency of your system.
1. POINT-OF-USE PUMPS VS. CENTRALIZED SYSTEMS
Perhaps the biggest cost differentiator is whether you opt for point-of-use pumps or a centralized system. Let’s look at how this decision affects both upfront and ongoing costs.
INITIAL INVESTMENT
Pricing is simpler with point-of-use systems, which scale linearly as each new workstation requires its own pump. Centralized systems have a higher upfront cost due to the need to install infrastructure like piping and control systems and ventilated or insulated central pump rooms.
That said, for larger facilities, the cost per station will come down as additional work points can “piggyback” on the same service backbone.
SPACE REQUIREMENTS
Centralized systems generally take up a significant amount of floor space and may need to be placed in a climate-controlled utility room, which requires additional construction or reallocation of equipment. A single pump placed at the point of use is typically integrated with the OEM equipment and needs little to no floor space, making it a better option for facilities with limited square footage.
OPERATIONAL FLEXIBILITY
Point-of-use systems enable the vacuum supply to each machine to be customized and tailored to that machine’s specific needs. On the other hand, centralized systems provide the same vacuum supply to all machines connected to the system and would require additional components to provide varying vacuum levels to equipment.
However, they simplify the monitoring and maintenance needs of a facility. While point-of-use systems suit facilities with varying needs, centralized systems excel in at-scale, standardized environments.
ENERGY COSTS
Typically, point-of-use systems consume more energy because each pump operates independently, often at full power. Centralized systems only run pumps as necessary to meet the facility’s demand. Many central systems also have the option to use energy-efficient features like variable frequency drives, which control the pump’s speed to meet demand and operate more efficiently. So, centralized systems are more energy-efficient, especially for facilities with variable or high demand.
MAINTENANCE COSTS
Each pump in a point-of-use system needs individual maintenance, which in large facilities with numerous pumps increases labor and material costs. Centralized systems require less maintenance overall since fewer pumps service the entire facility. This makes larger centralized setups less labor-intensive and more cost-efficient to maintain.
DOWNTIME COSTS
Point-of-use systems isolate downtime to individual pieces of equipment but lack redundancy that would allow that equipment to continue running. Centralized systems often include redundant pumps, ensuring fewer production interruptions for maintenance or unplanned downtime of a single pump. Therefore, centralized systems are more reliable for mission-critical applications where uptime is essential.
2. PUMP TYPES
Another major cost differentiator will be the types of pumps you choose for your application. In many cases, this will be determined entirely by the requirements of your application but may still have significant cost implications.
Commonly used pump types include hook and claw, dry rotary vane, and oil-lubricated pumps. Let’s explore the costs associated with choosing each of these.
INITIAL INVESTMENT
Hook and claw pumps are built with an oil-less, contact-less compression chamber, which requires precise machining to create tight tolerances, resulting in their higher sticker prices. Dry rotary vane systems also tend to cost more upfront due to the use of advanced materials that reduce wear, while oil-lubricated systems are generally the most affordable option because of their simpler design.
ENERGY COSTS
Hook and claw central systems offer efficiency and robust performance for continuous duty operations. Dry rotary vane pumps are efficient for moderate vacuum levels, while oil-lubricated systems are the most cost-effective for achieving deeper vacuum levels.
MAINTENANCE COSTS
Hook and claw pumps require minimal maintenance, with occasional inspections. Major overhauls are infrequent but tend to be costly and time-consuming. Dry rotary vane pumps need regular service to inspect and replace vanes and other parts subject to wear. Oil-lubricated pumps have the most demanding maintenance schedules, requiring frequent oil changes and oil separation element replacements for proper functioning.
RELIABILITY
Hook and claw pumps perform reliably over long periods in clean environments but are vulnerable to contamination in demanding conditions. Dry rotary vane pumps are trusted in the harshest environments, such as in woodworking applications. Oil-lubricated pumps are unique in their ability to perform best at the deepest vacuum levels when other pump types are under maximum load, so they’re optimal for high-load work over extended periods.
3. NUMBER OF MACHINES/WORKSTATIONS
The more machines require vacuum, the higher the system capacity needed to handle simultaneous demands. This increases the size, power, and number of pumps in the system.
For example, a small facility with 10 machines may require a single 15 HP pump, while a larger facility with 50 machines might need a multi-pump system (e.g., three 20 HP pumps).
SYSTEM COMPLEXITY
Extensive systems require more complex piping systems to connect machines to the centralized vacuum source. This increases upfront material and labor costs relative to smaller installations. Systems that require higher flow rates will also require investment in larger-diameter plumbing to reduce pipe losses.
SYSTEM CAPACITY
More complex systems will require higher flow rates to keep up with the demand of numerous machines and equipment, requiring more powerful pumps or multiple units.
For example, a small system (e.g., 10 machines) might need 100-200 SCFM capacity, while a larger system (e.g., 100 machines) might need 500-1,000 SCFM capacity or more.
INSTALLATION COSTS
Elaborate systems require more labor and time for installation, particularly where extensive piping and electrical connections must be installed. Installation costs will scale proportionally with the size and complexity of the infrastructure that must be put in place.
4. CUSTOMIZATIONS AND MODIFICATIONS
Industrial vacuum systems are highly tailored solutions designed to meet specific needs, rather than “out-of-the-box” implementations. For any vacuum system roll-out, expect additional system customizations or infrastructure modifications to add to the price. Common examples include:
ENHANCED FILTRATION SYSTEMS
Upgrading to advanced filtration, such as adding HEPA or ULPA filters, may be required in some applications but calls for specialized materials and precision engineering. Standard systems use basic filters with paper or polyester elements, while upgraded filtration systems are ideal for laboratories or industrial environments that involve liquids and vapors.
EXPLOSION-PROOF DESIGN
Fine powders, sawdust, and explosive vapors can create potentially dangerous operating conditions. These systems need specialized components like conductive hoses, flame suppressors, and spark-resistant motors to meet NFPA codes and standards.
MATERIAL-SPECIFIC CONFIGURATIONS
Systems designed to handle specific materials, such as corrosive chemicals or fine powders, warrant specialized designs. These systems might require chemical-resistant linings or anti-clogging features for challenging applications.
NOISE REDUCTION
Soundproofing with enclosures or mufflers to reduce noise levels helps to improve staff comfort.
AUTOMATION
Many manufacturers and integrators have options such as automatic on/off pump control, IoT connectivity, variable frequency drive-controlled pumps, and more. Each feature adds complexity to the controls, increasing the overall cost of the system.
RETROFITTING
Costs can increase significantly when centralized industrial vacuum systems are retrofitted into existing buildings. Installing piping and electrical components within established walls and ceilings can be more labor-intensive, and coordinating installation so as not to disrupt ongoing operations may necessitate after-hours work, increasing labor costs.
ONGOING COSTS
The ongoing costs of your industrial vacuum system are the total expense of keeping your equipment operating once installed. These include energy costs, maintenance costs, and downtime costs.
ENERGY COSTS
Your pumps will consume more energy when operating at deeper vacuum levels or under heavy demand. You can ensure energy efficiency by matching your pump type to your application and required vacuum depth.
For example, hook and claw pumps deliver high levels of overall efficiency but are not suitable for dusty or contaminated environments. Dry vane pumps, in general, deliver good efficiency across the board but draw more power as demand increases, and oil-filled pumps are most efficient when operating at maximum power, making them ideal for producing deep vacuums.
Balance energy costs against the expense of investing in additional pump volume to determine the best option for you. Consider working with an established supplier like Becker Pumps, with experience across all pump technologies, to help you identify the most efficient mix of pump type and capacity for your unique needs.
MAINTENANCE COSTS
Different types of pumps have varying maintenance needs. For example, oil-lubricated pumps require regular oil changes and replacements of the oil separation elements and inlet filters. Maintenance for dry rotary vane pumps focuses on air filter inspection and replacement, bearings greasing, and vane replacements as required.
Dusty or corrosive processes require more frequent filter replacements and lubrication, resulting in higher overall wear. You can minimize maintenance costs by using the right pump for your application and operating it correctly.
Ongoing maintenance may seem costly but should be seen against the potential savings on more expensive repairs and the increased longevity of your equipment.
Preventative maintenance with regular equipment checks and scheduled oil changes and filter replacements can help to prevent costly downtime and is a more predictable expense than unplanned major repairs. Be sure to include it when comparing the lifetime ownership cost of different types of pumps.
DOWNTIME COSTS
Managing downtime is an important part of ensuring your investment’s success. Unanticipated downtime for routine maintenance or in the case of a pump failure can have significant costs in terms of lost productivity. Make sure to budget for routine maintenance as well as unplanned downtime for repairs.
BECKER: YOUR INDUSTRIAL VACUUM PARTNER
Becker Pumps is one of the leading suppliers of industrial vacuum equipment worldwide. We build powerful, cost-effective systems that deliver value from the start and prove their worth over years of trouble-free service. We also support our equipment throughout its long life with outstanding service, support, and only original Becker parts.
Let Becker advise you on the best combination of equipment for your facility. We’ll work with you to develop the ideal industrial vacuum system that meets your needs today and grows with you so you can achieve your long-term business objectives.
Contact us to learn more or click below to explore our world-class industrial vacuum systems.
