Energy Savings in Vacuum Applications: How Dekker Delivers Sustainable Performance
Provided by Industrial Air Services – Dekker Vacuum experts serving Nashville, Knoxville & Chattanooga. Call (615) 641-3100 for energy-efficient vacuum solutions, audits, and system upgrades.
In today’s industrial environment, energy efficiency is no longer optional—it’s essential. Manufacturers face increasing pressure to reduce operational costs, meet sustainability goals, and comply with energy regulations. Vacuum systems, often overlooked in energy evaluations, can be a major contributor to plant power consumption and a hidden opportunity for savings.
Dekker Vacuum Technologies leads the way in developing high-efficiency vacuum systems that reduce waste, lower energy usage, and maintain exceptional performance across industries. Whether you operate a small CNC shop or a multi-line chemical processing facility, Dekker’s smart vacuum design can help you meet your performance goals while cutting energy bills.
At Industrial Air Services, we specialize in auditing, designing, and servicing Dekker vacuum systems that prioritize both performance and efficiency.
The Energy Cost of Vacuum
Vacuum pumps are heavy-duty equipment that often run 24/7 in support of packaging, drying, forming, conveying, and processing applications. When improperly sized or poorly maintained, vacuum systems can account for up to 20% of a facility’s total energy consumption.
Common energy inefficiencies include: – Oversized pumps running under light load – Pumps running continuously in batch operations – Poor system design with long pipe runs or leakage – Lack of automation or pressure control – Heat and friction losses due to wear or improper sealing – Water waste in open-loop liquid ring systems
These inefficiencies not only drive up energy costs but also shorten the life of vacuum equipment and increase maintenance needs.
How Dekker Designs for Efficiency
Dekker takes a holistic approach to vacuum system design, focusing on total lifecycle efficiency. Key features include:
Closed-loop liquid ring systems Dekker’s Vmax and ChemSeal systems use oil or glycol as a seal fluid in a closed loop. This eliminates the need for continuous fresh water input and prevents energy loss through fluid cooling and discharge.
Right-sizing for true demand Dekker engineers and Industrial Air Services work together to ensure every system matches the actual flow and pressure needed—reducing wasted horsepower and energy draw.
Variable frequency drives (VFDs) When paired with pressure transducers, Dekker pumps can ramp up or down in real time based on demand. This avoids unnecessary full-speed operation and reduces wear.
Smart controls and sequencing In multi-pump systems, Dekker includes automatic lead-lag sequencing, load balancing, and digital controls to rotate pump duty and prevent overuse.
High-efficiency motors All Dekker systems can be supplied with premium-efficiency or inverter-duty motors that meet or exceed DOE energy standards.
Low-slip pump designs Precision machining, durable seals, and smooth fluid paths reduce internal leakage and resistance, allowing for faster evacuation and more consistent vacuum at lower energy input.
Real-World Example: Packaging Plant in Knoxville
A regional food packaging facility operated four legacy rotary vane pumps that ran continuously regardless of demand. After an energy audit by Industrial Air Services, the plant replaced the setup with a Dekker Vmax closed-loop systemwith two pumps and VFD control.
Results: – Energy consumption dropped by 36% – Maintenance intervals extended by 40% – Water usage eliminated (over 200,000 gallons/year saved) – Payback period: 16 months – Improved uptime and pressure stability
This single upgrade brought the facility into compliance with its corporate sustainability initiative and reduced utility spend by tens of thousands annually.
Energy Audit and System Evaluation Services
Industrial Air Services offers onsite energy audits to evaluate vacuum system performance and identify areas of waste or inefficiency. Our audits typically include: – System flow and vacuum level testing – Motor load and power draw monitoring – Seal fluid and piping inspection – Leak detection and system integrity checks – Usage pattern analysis (batch vs. continuous) – ROI projections for upgrade or replacement options
We follow up with a detailed report and recommendations customized to your facility.
Integrating VFD and Smart Controls
One of the simplest and most impactful upgrades to any vacuum system is VFD integration. VFDs allow the pump to modulate speed based on actual demand, which can reduce energy use by 20–50% depending on the process.
Dekker VFD systems can be integrated into: – Vmax liquid ring packages – DuraVane rotary vane systems – Central vacuum stations – Existing systems with compatible motors
Industrial Air Services can retrofit your current system or design a fully automated package with touch panel controls, remote monitoring, and SCADA integration.
Reducing Water Waste with Closed-Loop Systems
Traditional liquid ring pumps often rely on open-loop water systems, where thousands of gallons per day are used for cooling and sealing—and then discharged to waste.
Dekker’s closed-loop designs eliminate this waste entirely by: – Reusing oil or glycol with minimal top-off – Including separators, filters, and heat exchangers to maintain fluid quality – Preventing environmental discharge and permitting issues – Qualifying for water conservation rebates in many municipalities
Sustainability isn’t just good for the environment—it saves real money over time.
Why Industrial Air Services?
As a regional Dekker Vacuum partner, we help facilities design smarter systems that reduce both power and maintenance overhead. Our services include: – Energy audits and performance benchmarking – Equipment upgrades and turnkey system installation – Dekker VFD and automation integration – Preventive maintenance and predictive diagnostics – Service plans to keep systems running at peak efficiency
We serve clients in Nashville, Knoxville, Chattanooga, and surrounding areas, with fast, local support and deep vacuum system expertise.
Conclusion
If your vacuum system is outdated, oversized, or inefficient, you may be spending far more on electricity, water, and maintenance than you realize. Dekker’s energy-efficient designs—especially when paired with expert support from Industrial Air Services—can help your facility meet its performance and sustainability targets while protecting your bottom line.
Call Industrial Air Services at (615) 641-3100 today to schedule an energy audit or explore upgrade options for your vacuum system.
