The need for energy-efficient vacuum pumps
Vacuum pumps are indispensable in many industrial processes, from food packaging and plastic forming to water aeration and material handling. However, these pumps consume energy – often more than people realize. With rising energy costs, stricter legislation (such as the Ecodesign Directive) and a growing focus on sustainability, energy efficiency has become crucial. Companies are actively looking for ways to be smarter about their energy consumption, spurred in part by audits, subsidies(EIA/MIA) and CO₂ reduction targets.
So the key question is: How can you save energy with vacuum pumps without sacrificing performance? Fortunately, there are several smart strategies, ranging from investing in new technology to simple modifications. In this blog, we share five essential insights to reduce your energy consumption.
1. Choose the right pump technology: Efficiency starts at the source
Not every vacuum pump is the same; energy consumption varies significantly among types. Although traditional oil-lubricated pumps are still widely used, modern alternatives often offer higher efficiency and lower maintenance costs.
Examples of energy-efficient vacuum pumps:
- Dry screw pumps: No oil required, ideal for continuous operation, very energy efficient.
- Claw pumps (claw pumps): Robust, efficient and low maintenance.
- Scroll pumps: Compact, quiet and energy efficient, perfect for smaller applications.
- Side channel fans: Optimal for processes that do not require a deep vacuum.
The key is to select a pump that exactly matches the required vacuum level and actual consumption profile. Oversizing inevitably leads to unnecessary energy consumption and higher costs.
Case study: Savings in plastics processing
A customer replaced five older oil-lubricated pumps with three modern dry screw pumps. Result: in addition to lower maintenance costs, energy savings of nearly 40% by better matching pump capacity to process demand and eliminating overcapacity.
2. Frequency regulation (VSD): smartly controlling demand.
Many vacuum pumps run continuously at full power even when the process demand is lower. This is similar to constantly running at full throttle regardless of speed.
What is a VSD (Variable Speed Drive)?
A VSD or frequency control dynamically adjusts the pump motor speed based on the current vacuum demand. At lower demand, the pump runs slower, directly resulting in lower energy consumption.
Although DOVAC does not supply pumps with standard integrated VSD, we do advise on implementation and supply separate VSD systems. Suitability depends very much on the specific application.
Is a VSD always necessary?
Not necessarily. For processes with constant, stable vacuum levels, a VSD offers little added value. However, for applications with significant fluctuations in demand or frequent downtimes, a VSD can provide significant energy savings. Our technical advisors will be happy to help you make the right trade-off.
3. Prevent leakage losses: Seal energy leaks
A vacuum system should ideally be completely sealed. In practice, however, leakages in pipes, fittings or equipment are common. Each leak forces the pump to work harder, leading to unnecessary power consumption.
How to address leakage losses?
- Have your system periodically tested for leaks (e.g., with ultrasonic detection).
- Use high-quality, wear-resistant fittings and piping suitable for vacuum.
- Seal unused machines with check valves.
Beware of invisible wasters
Sometimes there are no obvious leaks, but energy consumption is still too high. Possible causes:
- Clogged filters.
- Incorrectly adjusted valves.
- Unnecessarily long or too narrow pipes.
A thorough inspection by a specialist can uncover these hidden inefficiencies and help save energy.
4. Centralization of vacuum: Efficiency through economies of scale.
Many companies use decentralized pumps at each machine. While this seems convenient, it often leads to higher energy consumption, especially if not all machines are running simultaneously.
Advantages of a centralized vacuum system:
- Smart control based on total demand.
- Fewer pumps needed.
- Optimal utilization of available capacity.
- More efficient maintenance and lower overall energy consumption.
DOVAC designs and implements customized central vacuum systems. Hybrid systems, a combination of central and decentralized, can also be an effective solution to save energy.
5. Maintenance is essential for energy savings
A properly maintained vacuum pump performs more efficiently and uses less energy. Contaminated oil, clogged filters or worn seals increase resistance and load, leading to higher power consumption. Regular, preventive maintenance is crucial for both efficiency and reliability.
Focus points in maintenance:
- Use original, matching parts.
- Change oil, filters and gaskets on time according to schedule.
- Monitor the pump for signals such as overheating or unusual noises.
- Document consumption and performance to quickly detect anomalies.
A preventive maintenance plan not only prevents unexpected downtime, but also helps prevent peak consumption due to inefficiently running pumps and contributes to sustainable energy savings.
Case study: Impact of filter maintenance
At a customer in the packaging industry, highly contaminated filters were causing excessive noise and heat generation. After replacing the filters, the power consumption of the pump decreased by 18% and the noise problems disappeared.
Summary: Five keys to saving energy with vacuum pumps
| Insight | Advantage |
|---|---|
| 1. Proper pump technology | Prevents overcapacity, lower base consumption |
| 2. Consider VSD (if useful). | Dynamic adaptation to process demand |
| 3. Prevent leaks & blockages | Less load pump, direct energy savings |
| 4. Centralize where possible | More efficient system, fewer pumps needed |
| 5. Invest in maintenance | Maintaining efficiency and reliability |
Saving energy without compromise
Saving energy with vacuum pumps need not be a complex task. It requires conscious choices, a well-designed installation and regular maintenance. With these five insights, you can realize significant savings without compromising the performance or reliability of your vacuum system.
DOVAC supports you with technical expertise, honest advice and customized solutions – whether it’s a new energy-efficient vacuum pump, a maintenance plan, VSD control or advice on leak detection.
Do you also want to save energy with your vacuum pumps?
Contact DOVAC for customized advice on energy-efficient vacuum solutions, systems, components and smart applications. We are happy to help.
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