Custom Vacuum Systems: How Atlas Copco Engineers Tailor Solutions for Every Industry
When it comes to industrial vacuum systems, a one-size-fits-all approach rarely delivers the best results. Every manufacturing process, plant layout, and operational demand is different. That's why custom vacuum systems have become increasingly important for companies that prioritize energy efficiency, reliability, and production quality.
Atlas Copco has long recognized this need for customization. Their Systems + Solutions engineering group works with businesses across industries to design vacuum systems specifically tailored to each customer’s processes, environment, and goals.
In this blog, we'll dive into why custom vacuum solutions are crucial, how Atlas Copco delivers them, and why Industrial Air Services is your best partner for designing and supporting a system that works for you.
📞 Ready to discuss your custom vacuum needs? Call Industrial Air Services at (615) 641-3100 today. We proudly serve Nashville, Knoxville, and Chattanooga.
The Problem with Off-the-Shelf Vacuum Systems
Prepackaged, off-the-shelf vacuum systems are convenient—but they rarely provide optimal performance.
Common problems with cookie-cutter solutions include
Oversized or undersized systems wasting energy
Insufficient redundancy leading to costly downtime
Space conflicts with existing plant layouts
Poor integration with plant controls (SCADA, PLC)
Failure to meet industry-specific standards for cleanliness or safety
Every facility has unique factors such as operating hours, flow requirements, pressure ranges, environmental conditions, available floor space, and long-term production goals. A poorly matched vacuum system can lead to excessive energy bills, equipment failures, and lost production.
What Is a Custom Vacuum System?
A custom vacuum system is an engineered solution designed specifically around your facility’s needs. This might include
Selecting the best pump technology (dry, oil-sealed, liquid ring)
Sizing the pumps accurately for your flow and pressure needs
Designing a centralized or distributed vacuum system layout
Incorporating redundancy for mission-critical applications
Custom control panels, VFDs, and automation integration
Skid-mounted systems for easy installation
Noise reduction strategies through acoustic enclosures or remote installation
Atlas Copco’s Systems + Solutions team specializes in building these engineered vacuum systems for industries like food and beverage, chemical processing, electronics manufacturing, plastics, energy production, and pharmaceuticals.
Why Atlas Copco Leads in Custom Vacuum Systems
Atlas Copco brings major advantages to custom system engineering, including
Industry-Leading Technology
Atlas Copco’s vacuum pumps include innovations like
VSD⁺ (Variable Speed Drive) for massive energy savings
HEX@™ smart control interfaces
GENIUS Instant Insights™ cloud-based monitoring
Energy recovery options to capture heat for reuse
Whether you need oil-sealed rotary screw pumps, dry screw pumps, claw pumps, or liquid ring technology, Atlas Copco offers best-in-class solutions.
Application-Specific Engineering
Atlas Copco’s engineers don’t just sell products—they analyze your entire vacuum demand curve, production schedule, and layout constraints. They model system performance under real-world conditions to maximize efficiency and reliability.
Energy Optimization
Custom systems are designed to minimize energy waste. Variable speed operation, intelligent pump staging, and real-time load adjustment ensure you use only the energy you need—leading to lower operating costs and a faster ROI.
Scalability and Flexibility
Atlas Copco systems are designed to grow with you. Need to expand production next year? No problem. Custom systems allow for additional pumps or automated load sharing without major redesigns.
Integrated Monitoring and Remote Management
Atlas Copco’s GENIUS Instant Insights™ platform enables 24/7 remote monitoring, predictive maintenance alerts, and real-time system performance reporting—keeping your operation ahead of problems.
Real-World Example: Centralized Vacuum System for a Bottling Plant
A regional beverage manufacturer needed to upgrade their vacuum supply for bottling and packaging lines. Their legacy decentralized system featured multiple small pumps scattered across the facility, causing
High energy costs from inefficient operation
Noise problems on the production floor
Frequent pump failures with no backup redundancy
Industrial Air Services worked with Atlas Copco’s Systems + Solutions team to design a centralized vacuum system featuring
Three GHS VSD⁺ rotary screw vacuum pumps with intelligent load sharing
Custom stainless steel piping network with isolation valves
Remote monitoring and alert system through GENIUS platform
Energy recovery system to capture and reuse waste heat
Results included
38% reduction in total system energy consumption
Noise reduction of 12 dB on the production floor
Zero production downtime from vacuum failures
Payback period of less than two years
📞 Want a customized system assessment? Call Industrial Air Services at (615) 641-3100.
Industries That Benefit from Custom Vacuum Systems
Atlas Copco’s tailored vacuum solutions are trusted across industries like
Food and Beverage Processing (bottling, canning, MAP packaging)
Pharmaceutical and Biotech Manufacturing (sterile transfer, freeze drying)
Plastics and Rubber (extrusion, molding, degassing)
Semiconductor Fabrication (wafer processing, chip manufacturing)
Paper and Pulp Production (sheet forming, dewatering)
Energy and Power (transformer drying, turbine manufacturing)
Every sector has unique vacuum demands, and a custom system ensures that your process operates efficiently and reliably.
Key Components of a Custom Vacuum System
A complete Atlas Copco custom system typically includes
Correctly sized vacuum pumps (dry, oil-sealed, or liquid ring)
Centralized or distributed piping networks
Backup redundancy and isolation valves
Customized PLC or HMI controls with HEX@™ interface
Energy-saving VSD⁺ drives and smart sequencing
Remote monitoring and predictive maintenance features
Optional acoustic enclosures and vibration dampening
By engineering the entire system, not just the pumps, Atlas Copco delivers solutions that are greater than the sum of their parts.
How Industrial Air Services Helps Design Your Custom Solution
At Industrial Air Services, we don’t believe in selling products—we believe in delivering solutions that work.
Our custom vacuum system services include
On-site plant walkthroughs and vacuum demand assessments
System modeling and energy savings calculations
Full engineering design with CAD drawings and performance simulations
Installation, commissioning, and startup support
Preventive maintenance programs to protect your investment
24/7 service and emergency support across Tennessee
From design to implementation, we ensure that your Atlas Copco custom vacuum system is perfectly matched to your needs and fully optimized for performance and reliability.
📞 Ready to explore a custom-designed vacuum solution? Call Industrial Air Services at (615) 641-3100 today.
Conclusion
Custom vacuum systems offer unmatched advantages in energy efficiency, process reliability, and long-term operational savings. Atlas Copco’s engineering expertise, paired with Industrial Air Services’ local support, ensures that your facility gets a vacuum system that’s not only effective—but also future-proof.
Industrial Air Services proudly serves the Nashville, Knoxville, and Chattanooga regions as your trusted partner for Atlas Copco vacuum solutions. Contact us today at (615) 641-3100 to schedule a site evaluation or discuss your custom vacuum needs.
