Vacuum systems play a critical role in a variety of industrial operations. These systems remove air or gas from a designated space to create a low-pressure environment, enabling processes such as material transport, packaging, and product drying. Whether used in food processing, woodworking, or other industrial applications, industrial vacuum systems all operate under similar principles. This blog discusses how vacuum systems work and describes their main components and configurations.

Understanding Vacuum Creation

At its core, a vacuum is created when air is removed from a sealed system, reducing the internal pressure relative to atmospheric pressure. This pressure differential generates suction, which can be harnessed for a variety of applications. Industrial vacuum systems are designed to achieve specific vacuum levels depending on the requirements of the application. Some processes require a deep vacuum (near complete air removal), while others operate efficiently with a partial vacuum.

Vacuum levels are generally categorized as follows:

• Low vacuum (above 1 Torr) – Used in general industrial applications such as material handling and packaging.
• Medium vacuum (1 Torr to 10^-3 Torr) – Common in laboratory and manufacturing processes.
• High and ultra-high vacuum (below 10^-3 Torr) – Found in specialized applications like semiconductor manufacturing.

Key Components of an Industrial Vacuum System

An industrial vacuum system consists of several key components that work together to generate and maintain the vacuum:

1. Vacuum Pumps

The heart of any vacuum system, the vacuum pump, removes air or gas from a chamber or pipeline. Different types of pumps are used based on the required vacuum level and application:

• Rotary Vane Pumps – These pumps use rotating blades to create a vacuum and are ideal for packaging, medical, and industrial applications. Becker’s dry and oil-lubricated rotary vane pumps offer reliable performance for continuous operation.
• Claw Pumps – Claw vacuum pumps generate a vacuum using two claw-shaped rotors that move in opposite directions. They are known for their efficiency and oil-free operation, making them ideal for industries like printing and food packaging.
• Screw Pumps – Screw vacuum pumps operate using two counter-rotating rotors to compress and move air. They offer high efficiency, low maintenance, and dry, contact-free operation, making them well-suited for demanding applications in woodworking, secondary packaging, and electronics.

Regenerative Blowers – Available in single-stage and double-stage, these are used for applications that require high airflow at lower vacuum levels, such as pneumatic conveying and environmental air sampling.

2. Filters

Filters protect vacuum pumps and other components by trapping dust, debris, and contaminants before they enter the system. Proper filtration extends the lifespan of the pump and ensures consistent vacuum performance.

• Inlet Filters – Prevent contaminants from entering the pump and damaging internal components.
• Exhaust Filters – Capture oil mist or other emissions to maintain a clean working environment.

3. Piping and Hoses

Piping and hoses connect vacuum pumps to various system components and the application itself. These must be properly sized and sealed to minimize pressure losses and maintain system efficiency.

• Rigid Piping – Often used in centralized vacuum systems for long-term reliability.
• Flexible Hoses – Provide mobility and ease of installation in point-of-use vacuum applications.

4. Valves

Valves regulate airflow, ensuring the correct vacuum level is maintained for different processes. Modern vacuum systems often include automated controls that adjust pump speed and power consumption based on demand.

• Check Valves – Prevent backflow that could damage the pump.
• Solenoid Valves – Allow for automatic system operation based on programmed settings.

5. Controls

Controls are the brains of a vacuum system. They offer electrical protection for the pump and, depending on how complex they are, they can also:

• Control when the system’s pumps turn on and off.
• Monitor the system’s vacuum level.
• Vary the speed of the system’s pumps.

Industrial Vacuum System Configurations

Industrial vacuum systems can be configured in different ways depending on the application and required capacity:

1. Point-of-Use Systems

These systems consist of a vacuum pump installed directly at the location where the vacuum is needed. Common in CNC machining, small packaging operations, and laboratory settings, point-of-use systems provide localized vacuum without extensive piping.

2. Centralized Vacuum Systems

A centralized vacuum system supplies multiple machines or workstations from a single vacuum source. These systems are common in manufacturing plants and large-scale production environments. Benefits include:

• Reduced maintenance – Fewer pumps mean less downtime and easier servicing.
• Improved efficiency – Centralized control optimizes energy use.
• Better working environment – Pumps can be located away from work areas to reduce noise and heat.

Types of Industrial Vacuum Systems

Four common types of vacuum systems are used in various industrial applications:

• Hook and Claw Central Vacuum Systems – Our Advantage-C systems feature our hook and claw technology, with an oil-free and contact-free compression chamber, delivering high efficiency and deep vacuum levels up to 28” Hg. These systems are ideal for industrial and medical applications requiring continuous operation with minimal maintenance.
• Oil-Less Rotary Vane Central Vacuum Systems – The Advantage-D and Advantage-X systems use dry rotary vane pumps to provide clean, oil-free vacuum up to 27” Hg, making them perfect for medical, surgical, and general industrial applications.
• Oil-Lubricated Rotary Vane Central Vacuum Systems – Designed for deeper vacuum applications, our Advantage-L systems achieve up to 29.9” Hg, with the option to upgrade to our Advantage-P style systems, which include auto-purge functionality to enhance longevity and performance in demanding environments.

Dry Screw Vacuum Systems – Our VADS Series systems feature non-contacting screws, direct-drive, and an oil-free working chamber for robust operation. With variable frequency drive and minimal maintenance, you can count on this reliable and cost-effective solution.

Applications of Industrial Vacuum Systems

Industrial vacuum systems are used in a wide range of industries, including:

• Food Packaging – Removing air from packaging to extend product shelf life.
• Woodworking – Providing vacuum hold-down to keep the workpiece in place during the cutting process.
• Printing – Holding paper in place, protecting product from damage, and removing waste during production.

Why Choose Becker for Industrial Vacuum Solutions?

With decades of expertise in vacuum pump technology, our pumps and systems are designed for reliability, efficiency, and performance across a wide range of industrial applications. Use the link below to learn more about our cutting-edge industrial vacuum systems and find the right solution for your unique application.