Custom Vacuum System Engineering: Inside Dekker’s Turnkey Design Process
Provided by Industrial Air Services – Your Dekker Vacuum Partner in Nashville, Knoxville & Chattanooga. Call (615) 641-3100 for design, installation, and support.
In industrial environments, vacuum systems are often the invisible backbone of production—quietly supporting everything from product handling and packaging to distillation, drying, and chemical recovery. But no two processes are exactly the same. That’s why off-the-shelf vacuum pumps, while convenient, often fall short when it comes to meeting the complex demands of modern manufacturing.
Dekker Vacuum Technologies has earned a reputation for doing things differently. Through its custom vacuum system engineering services, Dekker delivers fully integrated, performance-optimized solutions tailored to each customer’s unique process. Whether your facility is launching a new line or replacing legacy equipment, a custom-designed system ensures reliability, energy efficiency, and scalability.
As the authorized Dekker representative in Tennessee, Industrial Air Services is proud to provide custom vacuum system consultation, installation, and support across Nashville, Knoxville, and Chattanooga.
Let’s explore what makes Dekker’s custom vacuum engineering process exceptional—and how you can benefit from a solution that’s truly built around you.
Why Custom Engineering Matters
Many industrial facilities struggle with vacuum systems that were never quite right from the start—systems that are too large, too small, too complex, or simply not robust enough to meet process demands. These mismatches lead to:
Energy waste from oversized pumps
Excess maintenance from improper materials or poor filtration
Inconsistent vacuum levels, affecting product quality
System failures that create downtime and lost production
Limited ability to scale as needs change
Custom-engineered vacuum systems solve these problems at the root, using real process data and advanced modeling to design a system that’s right-sized, process-matched, and future-proof.
Step-by-Step: Dekker’s Turnkey Vacuum System Design Process
Here’s how Dekker—and Industrial Air Services—turn your vacuum challenges into streamlined, high-performance solutions:
1. Process Assessment
It all begins with a detailed application review. Industrial Air Services engineers will evaluate:
Gas composition and temperature
Vapor load and moisture content
Required flow rate (CFM) and vacuum pressure
Duty cycle and system run times
Environmental and space constraints
Cleanliness and regulatory requirements
We also conduct vacuum audits and collect real-time system performance data when needed.
2. Sizing and Technology Selection
Next, we match your requirements with the right vacuum technology. Dekker offers:
Liquid ring pumps (including the oil-sealed Vmax line)
Rotary vane systems (DuraVane)
Rotary piston and hybrid designs
Custom multi-pump skids and central vacuum systems
The goal is to select the most efficient and reliable option—not just for today, but for years to come.
3. System Layout and 3D Modeling
Dekker’s engineering team creates detailed 3D renderings of your custom vacuum package, including:
Pump, separator, and reservoir positioning
Electrical panel integration
Frame or skid mount design
Maintenance access zones
Sound enclosures or noise abatement
Custom piping or discharge routing
This step ensures a clean installation with minimal surprises, even in tight plant layouts.
4. Controls and Automation
Custom vacuum systems include control panels with relay logic, PLC, or touchscreen options. Dekker can integrate:
Pressure sensors and alarms
Variable speed drive (VFD) controls
Remote monitoring via GENIUS Instant Insights™
SCADA system compatibility
Redundancy sequencing for multi-pump operation
Industrial Air Services will help you program and test these systems on-site.
5. Factory Testing and Commissioning
Every Dekker custom system is fully assembled and tested at the factory in Michigan prior to shipping. You receive:
Verified performance data
FAT documentation
Maintenance guides
Panel wiring diagrams
Easy startup procedures
Upon arrival, Industrial Air Services installs, commissions, and verifies the system at your facility.
📞 Ready for a custom vacuum system designed around your process? Call Industrial Air Services at (615) 641-3100 today.
Applications That Benefit Most from Custom Vacuum Design
Custom systems are ideal for any process with tight tolerances, unique gas loads, or specialized performance demands, including:
Pharmaceutical and biotech: freeze-drying, sterile transfer, solvent recovery
Food and beverage: MAP packaging, dairy processing, vacuum cooling
Chemical manufacturing: distillation, crystallization, vapor recovery
Pulp and paper: couch rolls, dewatering, press section support
Plastic and rubber: extrusion, thermoforming, degassing
Energy and power plants: condenser evacuation, transformer drying
No matter your industry, Dekker and Industrial Air Services can tailor a vacuum solution to fit your exact needs.
Real-World Case Study: OEM Integration in Memphis
A large OEM in Memphis needed a space-saving, plug-and-play vacuum solution for its new automated packaging equipment line. The customer had limited floor space and strict performance requirements for vacuum drawdown and reliability.
Industrial Air Services and Dekker collaborated to design a compact, skid-mounted central vacuum system using DuraVane rotary vane pumps with pre-filtering, reservoir tank, and custom PLC controls.
Results:
Installed in under one day
Integrated seamlessly with customer’s automation logic
Delivered 30% energy savings vs. legacy pump setup
Reduced unplanned maintenance to near-zero
This turnkey solution allowed the OEM to focus on production—not vacuum troubleshooting.
Advantages of a Dekker Custom Vacuum System
Tailored to your exact process requirements
Single-source responsibility: design, components, controls, and documentation
Engineered for future scalability
Pre-tested and ready to run
Local service and support from Industrial Air Services
Reduced TCO (Total Cost of Ownership) from smarter sizing and lower maintenance
Why Work with Industrial Air Services?
As your Dekker-certified regional partner, Industrial Air Services delivers:
Full project management, from design through installation
Application engineering with real-world field experience
Installation by trained, experienced vacuum technicians
Preventive maintenance programs and emergency service
Stocked replacement parts and factory-trained support
Offices serving Nashville, Knoxville, and Chattanooga
You’re not just buying equipment—you’re gaining a team that will support your system for its full life cycle.
📞 Contact Industrial Air Services at (615) 641-3100 today to schedule a vacuum audit or discuss your next custom-engineered solution.
Conclusion
When performance, efficiency, and reliability matter, an off-the-shelf vacuum pump often isn’t enough. Dekker’s custom vacuum system engineering—delivered locally by Industrial Air Services—ensures that every pump, pipe, panel, and parameter is tuned to your exact needs.
If you’re ready to upgrade your vacuum system the right way, call (615) 641-3100 or connect with Industrial Air Services for a consultation today.
