Custom Vacuum Systems: Tailored Solutions for Complex Industrial Needs
No two industrial facilities are exactly alike. Each plant has unique processes, layouts, operating conditions, and production goals. When it comes to vacuum systems, a standard off-the-shelf solution often falls short. That’s why custom vacuum system engineering has become essential for companies seeking maximum reliability, energy efficiency, and process optimization.
Atlas Copco leads the industry in providing fully engineered, customized vacuum solutions designed to meet the specific challenges of your operation. Backed by the expertise of Industrial Air Services, custom vacuum systems are no longer a luxury—they're a competitive advantage.
📞 Need a vacuum system built specifically for your needs? Call Industrial Air Services at (615) 641-3100 for expert consultation in Nashville, Knoxville, and Chattanooga.
Why Custom Vacuum Systems Are Necessary
Every production process demands specific vacuum characteristics. Factors like required flow rates, ultimate pressure, vapor loads, chemical exposure, system redundancy, and control integration all affect the design.
Choosing a standard system without considering these variables often results in
Oversized or undersized vacuum pumps wasting energy or failing to meet demand
Frequent maintenance due to incompatible process conditions
Complex installations requiring expensive retrofits
Limited ability to scale production up or down
Higher operational and repair costs over time
Custom-engineered vacuum systems ensure that every component—from the pumps to the controls—is perfectly matched to your real-world requirements.
Key Components of a Custom Vacuum System
A tailored vacuum solution typically includes
Accurately sized vacuum pumps for flow and pressure needs
Centralized or distributed piping and vacuum headers
Redundancy for critical applications where uptime is essential
Custom control panels, HMI displays, and automation integration
Remote monitoring capabilities through platforms like GENIUS Instant Insights™
Energy recovery systems where applicable
Noise and vibration mitigation strategies for workplace comfort
Space-optimized layouts for easy installation and maintenance
Atlas Copco’s broad vacuum product portfolio, combined with Systems + Solutions engineering expertise, makes it possible to create fully customized solutions for virtually any industrial sector.
Examples of Industries That Benefit from Custom Vacuum Systems
Pharmaceuticals
Critical applications like freeze-drying, sterile product handling, and coating processes demand extremely clean, oil-free vacuum solutions with precise control.
Electronics and Semiconductor Manufacturing
Wafer fabrication, photolithography, and vacuum deposition require ultra-high vacuum levels, cleanroom compatibility, and minimal contamination risk.
Food and Beverage
Modified atmosphere packaging (MAP), bottling, dairy processing, and evaporation systems benefit from centralized, energy-efficient vacuum designs that maximize uptime.
Plastics and Rubber
Extrusion, thermoforming, and degassing processes rely on vacuum consistency to maintain product quality and reduce scrap rates.
Power Generation and Energy
Transformer drying, turbine evacuation, and other processes need robust, moisture-resistant vacuum systems engineered for high uptime.
Printing and Packaging
Printing presses and flexible packaging machines operate more efficiently and consistently with vacuum systems tuned to precise operating pressures and duty cycles.
Atlas Copco’s Approach to Custom Vacuum System Design
Site Assessment and Data Collection
Industrial Air Services and Atlas Copco engineers conduct on-site evaluations, reviewing process requirements, facility layout, load variations, and energy consumption patterns.
System Modeling and Simulation
Using advanced modeling software, engineers simulate different vacuum system configurations to find the most energy-efficient, cost-effective design.
Component Selection
Atlas Copco’s extensive lineup of vacuum pumps—including GHS VSD⁺ rotary screw, DWS VSD⁺ dry screw, LRP VSD⁺ liquid ring, and DZS dry claw pumps—ensures the perfect match for each application.
Control System Design
HEX@™ smart interfaces and GENIUS Instant Insights™ remote monitoring can be integrated for superior operational control and predictive maintenance.
Installation Planning
Custom skids, modular system designs, and optimized piping layouts simplify installation and allow for future scalability.
Training and Ongoing Support
Industrial Air Services provides training for your team and offers preventive maintenance programs to ensure your system delivers peak performance year after year.
Real-World Example: Chemical Plant Vacuum Upgrade in Knoxville
A chemical manufacturing facility needed to upgrade an aging vacuum system supporting solvent recovery and distillation operations. Their legacy setup used multiple small oil-sealed pumps scattered across the plant floor, leading to
High energy costs
Frequent maintenance and inconsistent vacuum levels
Noise issues disrupting production staff
Industrial Air Services worked with Atlas Copco’s Systems + Solutions team to design a centralized vacuum system featuring
Three GHS VSD⁺ rotary screw pumps with automatic load balancing
Custom stainless-steel piping and headers
Integrated GENIUS remote monitoring for early warning alerts
Redundant pump setup for 100% uptime coverage
Results after installation
Energy savings of 42% compared to the old system
Reduced maintenance costs by 35%
Improved product yield through stable vacuum control
📞 Interested in a similar custom solution? Call Industrial Air Services at (615) 641-3100 today.
Advantages of Custom-Engineered Vacuum Systems
Lower Total Cost of Ownership
Correctly sized and configured systems use less energy, require less maintenance, and last longer.
Higher Reliability and Uptime
Built-in redundancy and proactive monitoring minimize downtime risks.
Optimized Process Efficiency
Precise vacuum control improves product quality and reduces scrap.
Scalability
Custom systems are easier to expand or modify as production needs evolve.
Compliance and Safety
Customized designs ensure compatibility with cleanroom standards, explosion-proof requirements, or hazardous material handling regulations.
How Industrial Air Services Supports Custom Systems
Industrial Air Services is your local Atlas Copco expert for customized vacuum system design and support. Our services include
Site evaluations and system sizing
Full CAD and modeling support for custom layouts
Installation and commissioning
Training for operators and maintenance teams
Preventive maintenance contracts and emergency service
Our goal is not just to sell equipment—it’s to deliver vacuum solutions that help our customers grow, optimize costs, and achieve long-term success.
📞 Want to design a custom vacuum solution for your facility? Call Industrial Air Services at (615) 641-3100 today.
Conclusion
Custom vacuum systems are the future of efficient, reliable, and sustainable industrial operations. Whether you need to streamline energy use, improve product quality, or eliminate downtime risks, a properly engineered Atlas Copco system can deliver major performance and financial advantages. With Industrial Air Services as your local partner, you’ll have the expertise needed to design, install, and maintain a custom vacuum system built for your success.
Call Industrial Air Services at (615) 641-3100 to schedule a consultation or site walkthrough in Nashville, Knoxville, or Chattanooga.
