How Dekker’s ChemSeal Series Tackles Aggressive Chemical and Corrosive Gas Applications

Provided by Industrial Air Services – Serving Nashville, Knoxville & Chattanooga. Call (615) 641-3100 for sales, installation, or technical support.

In chemical manufacturing, vacuum pumps are exposed to some of the most punishing environments imaginable. From acids and solvents to high-temperature vapors and explosive atmospheres, these systems must perform reliably while handling corrosive and potentially hazardous gas streams.

Standard vacuum pumps can’t survive these conditions. That’s why Dekker Vacuum Technologies developed the ChemSeal Series—a line of liquid ring vacuum pumps engineered specifically for chemically aggressive applications. These systems offer rugged construction, corrosion-resistant materials, and FM-approved options to meet the safety and performance needs of today’s chemical and pharmaceutical processors.

At Industrial Air Services, we help chemical plants across Tennessee design and install ChemSeal systems that can stand up to real-world demands—safely, efficiently, and with confidence.

What Makes Chemical Vacuum So Demanding?

Chemical applications present unique challenges to vacuum systems:

– Corrosive gases and vapors (such as chlorine, HCl, SO₂, acetone, or ammonia)
– High temperatures that degrade seals, gaskets, and bearings
– Condensable vapors that turn to liquid inside the pump, causing erosion or slugs
– Process fluctuations in pressure and load
– Explosion risk in volatile or solvent-heavy environments

Any of these issues can cause premature failure in standard pumps, leading to costly downtime, safety risks, and non-compliance with environmental regulations.

The ChemSeal Advantage

Dekker’s ChemSeal liquid ring vacuum pumps are built for the extreme. Using high-grade materials and specialized components, these systems are designed to resist corrosion, control volatile emissions, and operate continuously under harsh conditions.

Core features include:

– Corrosion-resistant construction: Options include 316 stainless steel, Duplex stainless, or other exotic alloys for all wetted components
– FM-approved explosion-proof motors: Ideal for Class I, Division 1 environments
– Seal liquid containment: Closed-loop operation prevents contaminated discharge and protects personnel
– Heavy-duty bearings and shaft seals: Withstand thermal cycling and pressure surges
– Gas scrubber compatibility: Seamlessly integrates with vapor recovery or abatement systems
– Custom system design: Skid-mounted, tested, and ready for turnkey integration into existing infrastructure

These features make ChemSeal the go-to choice for aggressive process environments where uptime and safety are non-negotiable.

Common ChemSeal Applications

Chemical manufacturing includes a wide range of processes where ChemSeal pumps excel:

– Vacuum distillation and evaporation
– Reactor vessel evacuation
– Crystallization and solvent stripping
– Degassing of resins and polymers
– Drying ovens and rotary dryers
– Transfer and filtration under vacuum
– Environmental remediation involving VOCs or HAPs

ChemSeal pumps are also used in pilot plants, lab-scale systems, and hazardous material containment setups where reliability is paramount.

Real-World Case: Solvent Recovery Line in Middle Tennessee

A specialty chemical plant in Middle Tennessee needed a vacuum solution for its solvent recovery system, which processed highly acidic and flammable vapors at elevated temperatures.

Previous systems had failed due to seal degradation and corrosion of the wetted surfaces. Industrial Air Services collaborated with Dekker to deliver a ChemSeal system built with 316 stainless steel, explosion-proof motor, and a closed-loop seal liquid circuit compatible with the plant’s solvent.

Results:

– Zero unplanned downtime in 18 months
– Improved recovery efficiency by 22%
– Eliminated corrosion-related service calls
– Full compliance with local and federal emission regulations

Material Selection Matters

Not all stainless steel is created equal. Industrial Air Services works closely with Dekker’s engineers to select materials that match your specific chemical exposure:

– 316 Stainless Steel: Excellent general chemical resistance
– Duplex Stainless Steel: Higher strength and better chloride resistance
– Hastelloy® or Alloy 20: Used for particularly aggressive acid or oxidizer applications
– Ceramic Coatings: Optional for added abrasion and pH protection

By selecting the right material for impellers, pump casings, and sealing elements, we ensure your system operates safely and reliably under the full range of process conditions.

Explosion-Proof Options for Hazardous Environments

Many chemical and pharmaceutical plants are classified as hazardous areas due to the presence of flammable vapors or solvents. ChemSeal systems are available with:

– FM-approved motors
– Sealed conduit and electrical fittings
– Intrinsically safe sensor circuits
– Anti-static coatings and corrosion-resistant housings
– Motor insulation and thermal protection systems

Industrial Air Services ensures these components are properly selected, installed, and tested for compliance with Class I, Division 1 requirements and NEC/OSHA standards.

Smart Monitoring and Control

ChemSeal vacuum systems can be outfitted with integrated sensors and control panels that monitor:

– Seal liquid level and temperature
– Vacuum pressure
– Pump motor current
– Fluid flow rate
– Safety interlocks for vapor recovery or scrubber operation

These features help maintenance teams anticipate problems, optimize performance, and reduce total cost of ownership.

Custom Skid Packages Available

Industrial Air Services can design ChemSeal systems as modular skid packages that include:

– Vacuum pump and motor
– Liquid separator and filtration system
– Control panel (with optional PLC/SCADA integration)
– Explosion-proof junction boxes and conduit
– Piping manifolds and valves
– Maintenance access zones and drain ports

These systems arrive ready to install and are fully tested at the factory before shipment.

Why Work with Industrial Air Services?

We’re more than a parts supplier—we’re your vacuum system partner. Our team provides:

– Application-specific design support
– Dekker-certified startup and commissioning
– Preventive maintenance programs
– Emergency field service and repairs
– Regional inventory of OEM fluids and parts
– Dekker factory training and technical support

With offices in Nashville, Knoxville, and Chattanooga, we respond quickly to your needs and understand the specific demands of chemical production facilities across the Southeast.

Conclusion

When your vacuum system faces corrosive, volatile, or chemically reactive gases, you need more than a generic pump—you need a solution that’s engineered for survival. Dekker’s ChemSeal series, combined with the hands-on support of Industrial Air Services, delivers the performance, safety, and longevity that chemical manufacturers require.

Call Industrial Air Services at (615) 641-3100 to request a system evaluation, material compatibility review, or custom ChemSeal system proposal today.

The Future of Vacuum Pump Reliability: Preventive Maintenance and Monitoring Strategies from Dekker

Provided by Industrial Air Services – Your regional Dekker Vacuum partner in Nashville, Knoxville & Chattanooga. Call (615) 641-3100 for service, audits, and preventive maintenance programs.

Vacuum pumps play a mission-critical role in manufacturing processes across food production, chemicals, pharmaceuticals, plastics, pulp and paper, and energy. But unlike high-profile machinery, vacuum systems are often neglected—until they fail. When that happens, downtime is costly, maintenance is reactive, and product quality may suffer.

Dekker Vacuum Technologies is changing that with advanced design, long-life components, and built-in monitoring systems that take the guesswork out of maintenance. By shifting from reactive repairs to predictive strategies, you can extend equipment life, reduce service costs, and ensure uninterrupted vacuum performance.

At Industrial Air Services, we specialize in helping facilities move from old-school maintenance toward future-ready, condition-based care. Let’s look at how Dekker’s vacuum systems are built for reliability—and how you can take advantage of smart maintenance to protect your operations.

Understanding the Risks of Poor Maintenance

Vacuum pump failure rarely happens overnight. It builds over time from a combination of overlooked oil changes, worn components, clogged filters, or overheating. These failures can lead to

Production downtime Increased scrap or quality issues Overloaded motors and elevated energy bills Unscheduled emergency service calls Shortened equipment lifespan

In many cases, these outcomes are preventable with routine inspections, fluid analysis, and early-warning diagnostics.

Dekker’s Built-In Reliability Features

Dekker doesn’t just build high-performance pumps—it builds them to last. Whether you’re running a DuraVane rotary vane unit or a Vmax oil-sealed liquid ring system, reliability is engineered into every design.

Key durability features include Hardened stainless-steel components in critical wear areas Precision-machined tolerances for reduced internal friction Closed-loop seal fluid systems that reduce contamination and scaling Heavy-duty bearings and shaft seals Low-maintenance oil filtration and recovery systems

These designs reduce the wear rate over time—but like any machine, they still require care to deliver their full lifespan.

Smart Monitoring Systems

Modern Dekker systems offer smart sensor technology, either integrated at the factory or added through Industrial Air Services. Features include

Temperature sensors for motor and seal protection Vacuum pressure sensors for performance tracking Oil level and oil temperature sensors Motor load feedback Leak detection

With these tools in place, you can receive early alerts when parameters drift out of spec—allowing your team to schedule service before damage occurs.

How Preventive Maintenance Saves Time and Money

Preventive maintenance (PM) programs include scheduled inspections, fluid replacements, filter changes, and performance checks at regular intervals based on hours or usage.

The benefits include Reduced risk of catastrophic failure Predictable maintenance budgeting Less downtime from emergency shutdowns Extended pump service life (often by 2–3x) Improved energy efficiency

For example, a properly maintained Vmax system can operate for over 20,000 hours between major overhauls. That’s years of operation with minimal intervention—if routine tasks are handled correctly.

Oil Analysis and Seal Fluid Monitoring

Dekker and Industrial Air Services offer routine oil analysis as part of PM programs. By testing for wear metals, contamination, and viscosity changes, you can catch early signs of

Bearing failure Seal degradation Overheating or cavitation Fluid breakdown due to process gases

We recommend testing at least once every 2,000–4,000 hours depending on pump type and application. This small investment can prevent thousands in repair or replacement costs.

Custom Maintenance Plans from Industrial Air Services

We offer preventive maintenance programs tailored to your equipment and usage. These plans can include

Quarterly, semi-annual, or annual service intervals Dekker-certified oil, filters, and parts On-site vibration and noise diagnostics GENIUS Instant Insights™ remote monitoring setup Maintenance logs and documentation for audits

These plans are ideal for facilities with limited in-house maintenance resources or teams managing multiple plant systems.

Real-World Example: Pharmaceutical Facility in Knoxville

A pharma production site in Knoxville relied on Dekker rotary vane pumps for vacuum drying and tablet coating. They had no formal maintenance schedule—only reacted when pump pressure dropped or strange noises occurred. Industrial Air Services implemented a PM plan that included

Quarterly oil changes and vane checks Biannual motor and bearing inspections GENIUS monitoring alerts for pressure spikes

The result was a 100% reduction in unplanned vacuum downtime and improved product consistency. The pumps also used 12% less energy due to optimized motor loading and airflow management.

GENIUS Instant Insights™: Remote Monitoring for the Win

Dekker’s GENIUS Instant Insights™ platform gives you a remote dashboard for your vacuum system, delivering

Live operating metrics Maintenance reminders System health reports Access from any web-enabled device

Industrial Air Services can install GENIUS hardware, train your staff, and connect the system to your maintenance platform. This tool transforms your vacuum system from a blind spot into a data-rich asset you can manage in real time.

Why Partner with Industrial Air Services

As a regional Dekker distributor and service partner, we offer

Certified Dekker PM programs for all pump types Emergency repair and diagnostic services System rebuilds and upgrade consultation In-stock filters, fluids, and OEM parts Field service across Nashville, Knoxville, and Chattanooga

When you work with us, you get peace of mind that your vacuum systems are operating efficiently—and backed by experts who know the technology inside and out.

Conclusion

Vacuum pump failure doesn’t have to be part of your operating reality. With smart monitoring and preventive maintenance, you can stay ahead of problems, reduce unplanned downtime, and extend the life of your Dekker system.

Dekker’s rugged engineering, combined with Industrial Air Services’ field support, makes it easy to keep your vacuum systems running at peak reliability for years to come.

Call Industrial Air Services at (615) 641-3100 to enroll in a maintenance plan or schedule a no-cost system review today.

Vacuum in Action: How Dekker Supports Mission-Critical Applications in Pulp & Paper, Plastics, and Chemical Processing

Brought to you by Industrial Air Services – Trusted Dekker Vacuum Partner in Nashville, Knoxville & Chattanooga. Call (615) 641-3100 for expert support and custom solutions.

In industrial manufacturing, vacuum systems don’t just support production—they drive it. From removing water in pulp & paper mills to degassing plastics and recovering solvents in chemical plants, reliable vacuum is the heartbeat of efficiency and uptime. When these systems fail or underperform, the ripple effects can disrupt entire operations.

That’s why more facilities are turning to Dekker Vacuum Technologies—a brand known for rugged reliability, engineering precision, and tailored system design. Through its comprehensive product range and commitment to custom solutions, Dekker plays a critical role in some of the most demanding industries in the world.

As a certified Dekker partner, Industrial Air Services delivers local service and application support across Tennessee. Let’s explore how Dekker vacuum systems support mission-critical operations in pulp & paper, plastics, and chemical processing.

Pulp & Paper: Dewatering, Press Support & Couch Roll Efficiency

In pulp and paper manufacturing, vacuum is essential from sheet formation through drying. Whether in the forming section or press section, vacuum systems remove water, support fiber transfer, and reduce energy load downstream.

Common vacuum applications in pulp & paper include:

Couch roll dewatering

Suction box operation

Felt conditioning

Vacuum press support

Transfer roll and turning suction

Challenges in this environment:

Large flow volumes (often thousands of CFM)

Saturated, dirty gas streams

Continuous duty cycles

System sensitivity to pressure fluctuations

Dekker’s solution: Dekker’s Maxima and Vmax series liquid ring vacuum pumps are ideal for this rugged, 24/7 environment. They are engineered to handle large water vapor loads without overheating or fouling and are available in stainless steel or special alloy options for corrosive pulp liquors.

Industrial Air Services helps paper facilities size and design these systems for multiple paper machine sections—offering energy optimization, noise control, and preventive maintenance programs that maximize uptime.

Plastics: Degassing, Thermoforming & Extrusion Support

The plastics industry relies on vacuum for product quality and process efficiency. Whether you’re extruding PVC pipe, vacuum-forming packaging trays, or removing air bubbles during molding, a consistent vacuum level can mean the difference between scrap and sellable goods.

Common vacuum uses in plastics processing:

Extruder venting and degassing

Sheet and film thermoforming

Injection molding support

Resin drying and conveying

Process challenges include:

Varying vacuum demand throughout production

Dust and vapor contamination

Tight tolerances on vacuum level to prevent part defects

Footprint limitations on OEM machinery

Dekker’s solution: The DuraVane rotary vane series is a go-to choice for plastics OEMs and processors, offering compact size, consistent vacuum levels, and simple maintenance. For higher vapor loads or continuous-duty extrusion lines, Dekker’s Vmax oil-sealed liquid ring systems offer a rugged, closed-loop solution that handles sticky gas streams and minimizes fluid consumption.

Case example: A plastics packaging facility near Chattanooga installed a multi-pump Vmax system sized by Industrial Air Services. The upgrade replaced noisy, failure-prone rotary vane pumps and resulted in:

22% reduction in cycle time

Lower scrap rates

30% maintenance cost reduction

Quieter, safer working conditions

Chemical Processing: Solvent Recovery, Distillation & Reactor Evacuation

In the chemical industry, vacuum is indispensable. It enables low-temperature distillation, improves reaction rates, protects sensitive compounds, and recovers valuable solvents. At the same time, these processes often involve corrosive vapors, pressure fluctuations, and safety-critical operations.

Key vacuum applications in chemical plants:

Vacuum distillation

Reactor vessel evacuation

Solvent stripping and recovery

Drying ovens and tray dryers

Filtration and crystallization

Industry challenges include:

Corrosive gases and solvents (acids, alcohols, aromatics)

Fluctuating load conditions

Strict environmental and safety regulations

The need for explosion-proof and FM-approved equipment

Dekker’s solution: The ChemSeal series of liquid ring pumps is purpose-built for corrosive chemical environments. Featuring duplex stainless steel or other exotic alloys, ChemSeal systems offer FM explosion-proof motors and gas-sealing features to handle the harshest gas streams safely and efficiently.

Industrial Air Services provides system audits and can design custom ChemSeal skid packages with:

Solvent-compatible materials

Closed-loop seal liquid recovery

Corrosion-resistant piping and valves

Integrated controls and safety interlocks

Real-world results: A specialty chemical processor in Nashville switched to a ChemSeal system with PLC control and dual pump redundancy. Benefits included:

24/7 uptime with no operator intervention

40% solvent recovery rate improvement

Immediate ROI in under 14 months

Zero safety or environmental compliance violations

📞 Need a vacuum system that works as hard as your process? Call Industrial Air Services at (615) 641-3100 today to get started.

Why Industrial Air Services and Dekker?

Dekker is one of the few vacuum pump manufacturers that offers both product and process engineering. Every pump is backed by decades of industrial experience, with solutions that span:

Liquid ring (Maxima, Vmax, ChemSeal)

Rotary vane (DuraVane)

Rotary piston and hybrid systems

Custom skids and multi-pump systems

Controls, tanks, reservoirs, and separators

Industrial Air Services enhances this offering with:

Local vacuum audits and sizing

Full installation and startup

SCADA and control panel integration

Maintenance, training, and 24/7 emergency response

OEM parts and Dekker-certified service

Whether you need a single-point replacement or a full vacuum system overhaul, we’ll help you plan, install, and support it every step of the way.

Conclusion

In pulp & paper, plastics, and chemical processing, the right vacuum system is the difference between smooth production and costly delays. Dekker’s proven pump technologies—paired with Industrial Air Services’ expertise—deliver custom-engineered solutions that are built for uptime, efficiency, and process stability.

Don’t settle for a generic vacuum system. Partner with Industrial Air Services and get a vacuum solution designed around your process.

📞 Call (615) 641-3100 to schedule a site visit, application review, or request a system proposal today.

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.

How Dekker’s Vmax Systems Revolutionize Liquid Ring Vacuum Pump Efficiency

Provided by Industrial Air Services – proudly serving Nashville, Knoxville, and Chattanooga. Call (615) 641-3100 for sales, service, or consultation.

In industrial vacuum systems, reliability and performance are non-negotiable. Yet, efficiency and sustainability are becoming just as critical as uptime. Whether you're managing a food packaging line, chemical process, or a power plant condenser, your vacuum equipment needs to do more than just “work”—it needs to save energy, reduce waste, and minimize maintenance. That’s where the Dekker Vmax liquid ring vacuum system stands apart.

Dekker has taken the traditional liquid ring pump design and reengineered it for modern industrial demands. The result is a closed-loop, oil-sealed vacuum solution that offers better performance, lower operational costs, and longer equipment life. As an authorized Dekker partner, Industrial Air Services is proud to bring this powerful system to facilities across Tennessee and the Southeast.

Let’s take a closer look at how the Vmax system works, what makes it unique, and why it may be the smartest upgrade you can make to your vacuum infrastructure.

What Is the Vmax System?

The Vmax is a pre-engineered, turnkey vacuum system built around Dekker’s time-tested liquid ring technology. Unlike traditional water-sealed pumps, the Vmax system uses oil as the sealant fluid—allowing for better lubricity, improved vacuum performance, and a fully closed-loop design.

Each Vmax unit includes:

A liquid ring vacuum pump with robust construction

Oil recovery and filtration components

A recirculation reservoir

Inlet filters, discharge separators, and non-return valves

Controls and sensors for real-time operation and monitoring

Everything is skid-mounted and factory-tested, meaning your installation time is minimized, and your system is up and running faster.

Why Oil Sealing Matters

One of the key innovations in the Vmax system is its use of oil instead of water as the sealing liquid. This change offers several critical benefits:

Oil doesn't evaporate easily, reducing make-up fluid costs and maintenance

It provides superior lubrication, lowering friction and wear inside the pump

It enables tighter tolerances, which allow for deeper vacuum levels

It resists corrosion and contamination, even in demanding chemical or vapor-heavy applications

The result? Better performance, longer pump life, and lower total cost of ownership.

Closed-Loop Efficiency

In traditional open-loop liquid ring systems, water is constantly introduced, consumed, and discharged—wasting both fluid and energy. The Vmax system changes that with its closed-loop design, where the oil is continuously filtered and reused.

This creates several distinct advantages:

Near-zero fluid loss, even during continuous operation

Lower utility costs, as there’s no need for fresh water or wastewater treatment

Minimal environmental impact, making it easier to meet sustainability and compliance goals

Combined with energy-efficient motor options and intelligent system controls, the Vmax is a powerhouse of industrial vacuum performance with an impressively low environmental footprint.

📞 To schedule a system review or request a quote, call Industrial Air Services at (615) 641-3100.

Designed for the Real World

Dekker designed the Vmax for plants that need serious vacuum power under rugged conditions. Whether you’re evacuating large tanks, handling saturated vapors, or supporting a multi-line packaging process, the Vmax delivers steady vacuum levels with minimal operator input.

It’s ideal for:

Food and beverage processing

Pharmaceutical and chemical manufacturing

Power plants and refineries

Pulp and paper

General industrial operations

The system is available in a range of sizes and configurations, with vacuum capacities from 35 to over 2,000 CFM. Industrial Air Services can help size and customize your Vmax system to meet your specific production requirements.

Real-World Example: Chemical Plant in Knoxville, TN

A specialty chemical facility in Knoxville was struggling with high maintenance costs and inconsistent performance from its aging water-sealed vacuum pumps. Excess water usage, pump cavitation, and fouling led to frequent downtime—and rising environmental compliance issues due to wastewater disposal.

They installed a Dekker Vmax system with stainless-steel wetted parts and upgraded oil filtration. The results were immediate:

Energy savings of 28%

Zero unplanned downtime in 12 months

No wastewater generation

Return on investment in under 18 months

The plant also reported smoother process control due to consistent vacuum levels and faster cycle times on batch reactors.

Integrated Controls and Diagnostics

Vmax systems come equipped with a control panel and optional PLC integration that makes operation and monitoring simple. Industrial Air Services can help connect your Vmax system to plant SCADA or building automation platforms, allowing:

Remote monitoring

Trend tracking

Automatic alarms for fluid levels, temperature, and vacuum setpoints

Predictive maintenance alerts

This digital capability ensures that maintenance teams can take proactive action—long before problems cause downtime.

Why Choose Vmax Over Traditional Liquid Ring Systems?

Here’s what sets the Vmax apart:

Oil-sealed design extends pump life and improves performance

Closed-loop operation eliminates fluid loss and wastewater

Pre-engineered skid package reduces installation time and risk

Proven durability, even in vapor-heavy or corrosive applications

Lower operating costs across energy, fluid, and maintenance

Full-service support through Industrial Air Services

If your facility is running outdated, water-sealed liquid ring pumps or operating rotary vane pumps that can’t handle the process vapors, it’s time to consider an upgrade.

What You Get with Industrial Air Services

As a Dekker-authorized distributor, Industrial Air Services provides full-cycle support, including:

Application and sizing assistance

Turnkey installation and commissioning

Integration with existing vacuum headers and control systems

Preventive maintenance programs

OEM spare parts and service kits

24/7 emergency response

We’ve helped companies across Nashville, Knoxville, and Chattanooga modernize their vacuum infrastructure—saving money, reducing downtime, and improving process reliability.

📞 Contact Industrial Air Services at (615) 641-3100 today to schedule a site evaluation or demo of the Vmax system.

Conclusion

In industries where reliability and cleanliness matter, the Dekker Vmax liquid ring vacuum system delivers unmatched efficiency, sustainability, and value. With a rugged oil-sealed design and closed-loop operation, it’s built to handle the toughest applications while reducing total cost of ownership. Backed by the regional expertise and 24/7 support of Industrial Air Services, you can rest assured your vacuum system will work just as hard as you do.

Call (615) 641-3100 or visit us to learn more about Vmax systems or request a custom proposal today.

Liquid Ring vs. Rotary Vane: Choosing the Right Vacuum Technology for Your Industrial Process

In the world of industrial vacuum systems, one size does not fit all. Selecting the wrong type of vacuum pump can result in higher energy bills, more frequent maintenance, and reduced productivity. Two of the most popular—and very different—vacuum pump technologies in use today are liquid ring and rotary vane vacuum pumps. Both have proven track records in a wide range of industries, but each brings its own strengths, limitations, and ideal use cases.

Dekker Vacuum Technologies, a leading manufacturer of engineered vacuum solutions, offers high-performance options in both categories, including the Vmax series of liquid ring pumps and the DuraVane series of rotary vane pumps. As an authorized Dekker partner, Industrial Air Services provides expert consultation, installation, and service across Tennessee and the Southeast to help you make the right choice for your application.

📞 To request a site visit or speak with a vacuum expert, call Industrial Air Services at (615) 641-3100 today.

Understanding Liquid Ring Vacuum Pumps

A liquid ring vacuum pump uses a rotating impeller and a sealing liquid—usually water or oil—to generate vacuum. As the impeller turns inside an offset casing, the liquid forms a ring that traps and compresses air between the blades. These pumps are ideal for saturated gas streams and are known for durability in harsh environments.

Dekker’s Vmax series, available through Industrial Air Services, is a top-tier option for industrial facilities that require continuous duty vacuum and efficient operation in wet or contaminated gas streams. The system includes integrated oil recovery, filtration, and control components to reduce waste and simplify maintenance.

Liquid Ring Pump Highlights:

• Excellent for handling water vapor, solvents, and particulates

• Ideal for food processing, chemical applications, and power generation

• Low-maintenance and long-lasting

• Quiet, vibration-free operation

Understanding Rotary Vane Vacuum Pumps

Rotary vane pumps operate with a rotor mounted off-center inside a chamber. Sliding vanes trap and compress gas in segmented chambers. These oil-lubricated pumps provide high vacuum levels and are ideal for clean, dry applications that require steady mid-to-deep vacuum.

Dekker’s DuraVane series, distributed and serviced by Industrial Air Services, offers precision-machined, compact rotary vane systems that are popular for packaging, printing, woodworking, and medical suction systems.

Rotary Vane Pump Highlights:

• Compact and efficient for intermittent use

• Simple to service with regular oil changes

• Effective for dry, clean gas streams

• Fast startup and deep vacuum levels

Key Differences: Which Is Right for You?

Vacuum level needs: Rotary vane pumps generally offer deeper vacuum than liquid ring systems and are ideal when pressures below 25 Torr are required.

Gas composition: Liquid ring pumps handle vapors, moisture, and contaminants with ease, while rotary vane systems require dry intake gas.

Maintenance and lifecycle costs: Liquid ring pumps require less frequent attention, while rotary vane pumps need routine oil changes and vane inspections but may offer greater energy efficiency for light-duty use.

Continuous operation: For round-the-clock vacuum needs, especially in humid or dirty environments, liquid ring pumps like the Vmax are ideal. Rotary vane pumps excel in batch or cycling processes.

System footprint and complexity: Rotary vane systems are compact and straightforward. Liquid ring systems may require additional fluid handling and separators, but offer superior durability.

Real-World Example: Food Packaging Application

A major Tennessee-based food packaging plant turned to Industrial Air Services when it needed to upgrade its aging vacuum system used for MAP (Modified Atmosphere Packaging). The facility’s process produced moisture and residue that clogged and degraded the performance of its previous rotary systems.

A Dekker Vmax liquid ring system was installed for its ability to handle moisture-laden gas streams with zero performance loss. The new system improved uptime, reduced energy costs by 20%, and eliminated unplanned maintenance events over a 12-month span.

Hybrid Solutions? Dekker Can Do That Too

Sometimes, the best solution is a hybrid approach. Dekker and Industrial Air Services can engineer vacuum systems that combine the energy savings of rotary vane pumps with the moisture tolerance of liquid ring pumps. We provide tailored, turnkey packages that balance cost, performance, and long-term ROI.

Why Choose Industrial Air Services?

As a Dekker-authorized distributor and vacuum system specialist, Industrial Air Services delivers more than equipment—we provide end-to-end vacuum system solutions including:

• On-site application consultation and sizing

• Dekker pump and system selection

• Installation and integration with existing systems

• Preventive maintenance and 24/7 support

• OEM parts, fluids, and training

Whether you're designing a new line or retrofitting an old one, we’ll help you choose and support the right Dekker vacuum pump for years to come.

📞 Call Industrial Air Services at (615) 641-3100 today to schedule a vacuum assessment or request a quote.

Conclusion

Choosing between a rotary vane and a liquid ring vacuum system depends on your specific process, gas composition, and operating conditions. Dekker Vacuum Technologies manufactures high-performance equipment in both categories, and with Industrial Air Services as your regional partner, you get the expertise, support, and service you need to make a smart, cost-effective choice.

Contact us at (615) 641-3100 or visit us in Nashville, Knoxville, or Chattanooga to learn more about how we can help you improve vacuum performance, reduce downtime, and maximize energy efficiency.

Choosing the Right Atlas Copco Vacuum Pump: A Complete Buyer’s Guide

Vacuum systems are critical to countless industrial processes—from food packaging to pharmaceutical manufacturing, plastics extrusion, semiconductor fabrication, and more. Choosing the right vacuum pump isn’t just about picking the most powerful option—it’s about selecting the pump that matches your process demands, energy goals, environmental requirements, and long-term operational strategy.

Atlas Copco offers one of the widest, most innovative selections of industrial vacuum pumps available today. In this guide, we’ll walk you through the key factors to consider when selecting a vacuum pump and explain how Industrial Air Services can help you design a solution optimized for success.

📞 Need expert help selecting the right vacuum system? Call Industrial Air Services at (615) 641-3100 for assistance across Nashville, Knoxville, and Chattanooga.

Why Selecting the Right Vacuum Pump Matters

Installing the wrong vacuum system can lead to

Wasted energy and inflated operating costs

Frequent maintenance and unexpected downtime

Inconsistent process quality and product defects

Overpaying for capacity you don’t need—or under-specifying and falling short

Choosing the right pump ensures

Lower total cost of ownership (TCO)

Stable, reliable process performance

Reduced energy consumption and carbon footprint

Simplified maintenance and better system longevity

Factors to Consider When Choosing a Vacuum Pump

Process Requirements

Start by understanding your process vacuum needs. Key parameters include

Required operating pressure (mbar or Torr)

Gas flow rate (ACFM or m³/h)

Gas type (clean air, vapor-laden, corrosive, or particulate)

Duty cycle (continuous, intermittent, heavy load variations)

Special conditions (explosive atmospheres, cleanroom standards)

Atlas Copco offers solutions that cover rough, medium, and high vacuum applications across all these conditions.

Pump Technology Options

Atlas Copco manufactures several types of vacuum pumps, including

Oil-Sealed Rotary Screw (GHS VSD⁺ Series)

High efficiency for continuous duty applications like bottling, plastics, woodworking, and packaging

Dry Screw (DWS VSD⁺ Series)

Oil-free, contamination-free solution ideal for food, pharma, and semiconductor applications

Dry Claw (DZS Series)

Low maintenance, energy-efficient, compact pumps for plastics, CNC machining, and pneumatic conveying

Liquid Ring (AWL, AWS, AWD Series)

Best suited for wet, vapor-heavy, or corrosive gas processes like chemical production, wastewater treatment, and power generation

Each technology offers specific advantages depending on the process.

Energy Efficiency Goals

Atlas Copco’s VSD⁺ (Variable Speed Drive) technology allows pumps to automatically adjust motor speed based on real-time demand—saving up to 50% on energy costs compared to fixed-speed alternatives.

If energy efficiency is a priority, prioritize pumps like the GHS VSD⁺, DWS VSD⁺, and LRP VSD⁺ Series models.

Maintenance Requirements

Consider how much time and labor you can allocate to system maintenance.

Dry claw and dry screw pumps offer lower maintenance needs compared to oil-sealed pumps, which require regular oil changes and filter replacements.

Smart monitoring options like GENIUS Instant Insights™ can further simplify maintenance by providing predictive alerts and performance dashboards.

Space Constraints and Installation Flexibility

If floor space is tight or if you need mobile, modular setups, choose compact systems like the DZS dry claw series or skid-mounted multi-pump systems.

Custom layouts from Atlas Copco’s Systems + Solutions team can optimize centralized vacuum plant installations for even the most challenging facilities.

Environmental or Safety Compliance

Industries like pharmaceuticals, semiconductors, and food production often require oil-free, clean vacuum systems to comply with ISO, FDA, EHEDG, or GMP standards.

Facilities handling flammable vapors or working in hazardous zones may require explosion-proof pumps, which Atlas Copco can provide across several product lines.

Popular Atlas Copco Vacuum Pump Options

GHS VSD⁺ Series

Oil-sealed rotary screw pumps with VSD⁺ energy-saving technology

Excellent for plastics, packaging, woodworking, and bottling industries

Highly efficient with low lifecycle costs

DWS VSD⁺ Series

Dry screw vacuum pumps with oil-free operation

Ideal for semiconductor, food, and pharmaceutical applications

Handles vapors and condensables with ease

DZS Dry Claw Series

Compact, low-maintenance claw pumps

Perfect for industrial processes like CNC support, conveying, and thermoforming

Simple to maintain and operate

LRP VSD⁺ Series

Liquid ring vacuum pumps built for wet and vapor-heavy conditions

Excellent in chemical, wastewater, and power applications

Built for rugged environments with maximum reliability

AWL, AWS, AWD Liquid Ring Series

Heavy-duty liquid ring solutions for highly corrosive or saturated gas environments

Designed for long life even in aggressive processes

How Industrial Air Services Helps You Select the Right Pump

Industrial Air Services offers a structured approach to vacuum system selection, including

On-site process evaluations and data logging

Vacuum demand profiling and application engineering

Energy savings calculations and lifecycle cost modeling

Custom system design, installation, and commissioning

Preventive maintenance programs and 24/7 emergency support

We combine Atlas Copco’s world-class technology with local, hands-on expertise to ensure you get the perfect vacuum solution—built to meet today’s needs and tomorrow’s growth.

📞 Ready to start your vacuum system evaluation? Call Industrial Air Services at (615) 641-3100 today.

Real-World Example: Medical Device Manufacturer in Chattanooga

A medical device manufacturer needed to replace outdated oil-sealed pumps in a cleanroom environment. Contamination risk was high, and downtime penalties were severe.

They switched to Atlas Copco DWS VSD⁺ dry screw pumps with GENIUS remote monitoring.

Results included

Zero product contamination from oil or particles

Energy savings of 36% compared to legacy equipment

Real-time performance monitoring reduced maintenance needs

Faster ramp-up times and more consistent process control

Today, the facility runs a fully oil-free, efficient vacuum system aligned with ISO 14644-1 cleanroom standards.

Key Tips for a Successful Vacuum System Purchase

Always evaluate actual process needs instead of oversizing "just in case."

Consider lifecycle costs, not just upfront equipment price.

Think long-term about maintenance, serviceability, and scalability.

Leverage digital tools like HEX@™ and GENIUS for smarter, more efficient operations.

Work with a trusted, experienced partner like Industrial Air Services.

Conclusion

Selecting the right vacuum pump is about more than specifications—it’s about understanding your full operational landscape and choosing a solution that improves efficiency, reliability, and profitability. Whether you need oil-free dry vacuum, rugged liquid ring performance, or energy-saving rotary screw technology, Atlas Copco and Industrial Air Services can deliver a vacuum system perfectly matched to your business.

Call Industrial Air Services at (615) 641-3100 today to schedule a site consultation or start designing your ideal vacuum solution across Nashville, Knoxville, and Chattanooga.

Understanding Dry Vacuum Technologies: Benefits of Screw and Claw Pumps

Modern industrial operations demand vacuum solutions that are not only reliable and energy-efficient but also clean, low maintenance, and environmentally sustainable. In industries like pharmaceuticals, food production, electronics, plastics, and research, contamination from oils or liquids is unacceptable. That's where dry vacuum technologies—specifically dry screw pumps and dry claw pumps—shine.

Atlas Copco, a global leader in vacuum solutions, offers some of the most advanced dry vacuum technologies on the market today. In this blog, we’ll explore the fundamentals of dry vacuum pumps, compare screw and claw technologies, and explain how partnering with Industrial Air Services ensures the right solution for your operation.

📞 Need help selecting the right dry vacuum system? Call Industrial Air Services at (615) 641-3100 for expert service across Nashville, Knoxville, and Chattanooga.

What Are Dry Vacuum Pumps?

Unlike oil-sealed rotary vane or liquid ring vacuum pumps, dry vacuum pumps achieve compression without using any liquid or oil inside the pumping chamber. This eliminates the risk of oil contamination and minimizes maintenance requirements.

Dry pumps operate by trapping gas and reducing its volume through the mechanical action of rotors, claws, or screws—without any internal lubrication.

Benefits of dry vacuum pumps include

Oil-free, contamination-free operation

Lower maintenance and cleaning requirements

Greater suitability for cleanroom and high-purity environments

Better energy efficiency for many industrial processes

Reduced waste and environmental impact

Atlas Copco’s dry vacuum lineup includes the DWS VSD⁺ dry screw pumps and the DZS Series dry claw pumps, both designed for maximum reliability and efficiency.

Understanding Dry Screw Vacuum Pumps

Dry screw vacuum pumps operate by using two intermeshing helical screws rotating in opposite directions. As the screws rotate, gas is trapped between the screw threads and moved toward the discharge port while being compressed.

Key features of dry screw pumps

High pumping speeds across a wide pressure range

Ability to handle condensable vapors and light particulate loads

Smooth, pulse-free gas flow for sensitive processes

Robust design suited for harsh, corrosive, or dirty gas streams

Atlas Copco’s DWS VSD⁺ models feature Variable Speed Drive (VSD⁺) technology, allowing motor speed to automatically adjust to real-time process demands—saving energy and extending equipment life.

Ideal applications for dry screw pumps

Pharmaceutical freeze drying (lyophilization)

Chemical vapor deposition (CVD) in semiconductor production

Food packaging and vacuum drying

Vacuum distillation and solvent recovery

Plastic extrusion and degassing

Understanding Dry Claw Vacuum Pumps

Dry claw vacuum pumps use two rotors with claw-shaped profiles rotating in opposite directions. Gas enters the compression chamber, is trapped between the claws, and is compressed as the claws rotate and approach the discharge port.

Key features of dry claw pumps

Extremely low maintenance (very few wearing parts)

Efficient design requiring minimal power input

Ability to handle humid or dusty gases

Highly compact and modular construction

Atlas Copco’s DZS Series claw pumps are known for rugged durability, compact footprint, and cost-effective operation in a variety of industrial settings.

Ideal applications for dry claw pumps

Pneumatic conveying systems

Plastics thermoforming and molding

Woodworking CNC machine support

Food processing (conveying, pick-and-place)

Environmental remediation (soil vapor extraction)

Real-World Example: Semiconductor Cleanroom in Nashville

A semiconductor fabrication facility required ultra-clean, oil-free vacuum for their etching and wafer processing operations. Contamination from traditional oil-sealed pumps was unacceptable.

They installed Atlas Copco DWS VSD⁺ dry screw pumps with HEX@™ smart controls and GENIUS Instant Insights™ remote monitoring.

Results included

Maintained ISO 6 cleanroom standards without risk of contamination

Energy savings of 30% through VSD⁺ dynamic control

Zero vacuum pump-related downtime in 18 months

Improved product yields and reduced defect rates

📞 Need similar clean vacuum solutions? Call Industrial Air Services at (615) 641-3100 today.

Advantages of Atlas Copco’s Dry Vacuum Technologies

VSD⁺ Standardization

All Atlas Copco dry screw and claw pumps with VSD⁺ technology automatically adjust motor speed to real-time demand, drastically reducing energy use.

Compact, Modular Design

Atlas Copco’s DWS and DZS pumps are designed for easy installation, small footprints, and flexible system integration.

Smart Monitoring

With GENIUS Instant Insights™ remote monitoring and HEX@™ touchscreen controls, you can manage your vacuum system more efficiently and proactively.

Low Noise and Vibration

Dry claw and screw technologies operate quietly, improving workplace environments and reducing the need for costly acoustic enclosures.

Environmentally Friendly

No oil contamination, reduced emissions, and lower energy consumption help facilities meet stringent environmental regulations and corporate ESG goals.

Maintenance Best Practices for Dry Vacuum Pumps

Follow recommended service intervals for inspections and preventive maintenance

Replace shaft seals and check rotor clearances as needed (especially for dry screw pumps)

Keep cooling fins and air filters clean to maintain optimal temperatures

Use Atlas Copco OEM parts and fluids for any maintenance to preserve warranty and performance

Set up remote monitoring through GENIUS to catch small issues before they escalate

How Industrial Air Services Supports Your Dry Vacuum System

Industrial Air Services provides full support for Atlas Copco dry vacuum systems, including

Site audits and application consulting

System design, installation, and commissioning

Preventive maintenance contracts

24/7 emergency service and rapid response

GENIUS system setup and remote monitoring training

With local service teams in Nashville, Knoxville, and Chattanooga, we ensure your vacuum systems stay optimized and operational at all times.

📞 Ready to upgrade to oil-free dry vacuum technology? Call Industrial Air Services at (615) 641-3100 today.

Conclusion

Dry vacuum technologies, including screw and claw pumps, are revolutionizing industrial operations by offering contamination-free, energy-efficient, and low-maintenance vacuum solutions. Whether you need high pumping speed for pharmaceutical manufacturing or rugged reliability for plastics extrusion, Atlas Copco’s dry vacuum systems provide the performance and peace of mind modern industries demand. With Industrial Air Services as your trusted partner, you’ll have the local support and engineering expertise needed to design, install, and maintain your ideal vacuum solution.

Contact Industrial Air Services at (615) 641-3100 to get started with a site evaluation or discuss upgrading your vacuum systems across Nashville, Knoxville, and Chattanooga.

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.

Best Practices for Vacuum Pump Maintenance: How to Extend Equipment Life and Maximize ROI

Industrial vacuum pumps are critical assets in manufacturing, food production, pharmaceutical operations, electronics fabrication, and countless other sectors. Yet despite their importance, vacuum pumps are often overlooked when it comes to proactive maintenance. Unfortunately, neglecting these vital machines leads to unnecessary downtime, costly repairs, and reduced equipment lifespan.

Proper vacuum pump maintenance isn't just about preventing failures—it’s about maximizing return on investment (ROI), optimizing energy efficiency, and ensuring process reliability. In this blog, we’ll break down proven maintenance best practices and explain how Industrial Air Services and Atlas Copco can help you protect your vacuum systems and your bottom line.

📞 Need help with a preventive maintenance program? Call Industrial Air Services at (615) 641-3100 for service across Nashville, Knoxville, and Chattanooga.

The High Cost of Neglecting Vacuum Pump Maintenance

Vacuum pumps operate in demanding conditions—handling vapors, contaminants, fluctuating loads, and continuous-duty cycles. Without routine care, small issues snowball into major problems.

Costs of poor maintenance include

Unplanned downtime and production losses

Emergency repair expenses and expedited parts orders

Reduced pump efficiency leading to higher energy bills

Contamination of process materials (critical in pharma, food, and electronics)

Premature equipment replacement costing tens of thousands of dollars

The good news is that implementing a structured maintenance strategy can dramatically reduce these risks.

Best Practices for Vacuum Pump Maintenance

Follow Manufacturer Service Schedules

Every vacuum pump comes with a recommended maintenance schedule based on operating hours, duty cycle, and environmental conditions. Key intervals typically include

Oil changes (for oil-sealed pumps) every 2,000 to 4,000 hours

Filter inspections or replacements every 3 to 6 months

Seal inspections and lubrication checks every 6 to 12 months

Major overhauls every 20,000 to 40,000 hours depending on pump type

Following these schedules prevents unexpected failures and extends pump life.

Monitor Performance Indicators

Pay close attention to key indicators like

Increasing operating temperature

Rising motor current draw

Fluctuations in vacuum pressure levels

Unusual vibrations or noises

Oil condition and contamination levels

Using smart monitoring platforms like Atlas Copco’s GENIUS Instant Insights™ provides real-time data to detect early signs of wear or failure.

Keep the Pump Clean

Dirt, dust, and debris can clog cooling fins, filters, and valves—causing overheating and reduced efficiency. Regular cleaning of external surfaces and filter elements is a simple but essential maintenance task.

Inspect Seals and Gaskets

Leaks compromise vacuum performance and introduce contaminants into the system. Check mechanical seals, shaft seals, and gasket joints during routine inspections and replace worn components promptly.

Use OEM Parts and Fluids

Using non-OEM parts or off-brand fluids may seem like a cost-saving move but often leads to accelerated wear, compatibility issues, and warranty voidance. Always use Atlas Copco-approved oil, filters, seals, and spare parts to maintain optimal performance and protect your investment.

Implement a Preventive Maintenance Plan

Rather than waiting for a problem to arise, implement a structured preventive maintenance (PM) plan that includes

Regular oil analysis

Performance trend monitoring

Scheduled filter changes

Annual or semi-annual full system inspections

Component wear measurements (bearings, vanes, rotors)

Industrial Air Services offers preventive maintenance contracts tailored to your equipment and production schedule, ensuring consistent care without overburdening your internal maintenance team.

Benefits of a Strong Vacuum Pump Maintenance Program

Longer Equipment Life

Well-maintained vacuum pumps often operate reliably for 10 to 15 years or more—delivering an outstanding return on your initial investment.

Reduced Downtime

Preventive maintenance minimizes unexpected breakdowns and emergency outages, keeping production lines running smoothly.

Lower Energy Costs

Clean, properly lubricated, and leak-free vacuum pumps operate more efficiently—reducing electrical consumption and cutting operating expenses.

Improved Process Quality

Stable, consistent vacuum levels ensure high product quality, especially in sensitive applications like food packaging, electronics manufacturing, and pharmaceutical production.

Faster ROI

By extending equipment life, reducing repair costs, and improving efficiency, preventive maintenance delivers measurable financial returns.

Real-World Example: Food Packaging Plant in Tennessee

A regional food processor was experiencing frequent vacuum pump failures on their MAP (Modified Atmosphere Packaging) lines. Each downtime event cost the plant thousands of dollars in lost production and emergency service calls.

Industrial Air Services implemented a comprehensive preventive maintenance program for their Atlas Copco GHS VSD⁺ rotary screw pumps, including

Quarterly system inspections

Oil analysis every 2,000 hours

Annual seal replacement program

Remote monitoring through GENIUS Instant Insights™

Results after 12 months

Zero unplanned vacuum pump downtime

Energy savings of 18% through setpoint optimization

Increased pump lifespan projections by 6–8 years

📞 Want similar results? Call Industrial Air Services at (615) 641-3100 today.

Common Maintenance Mistakes to Avoid

Skipping Routine Inspections

Small leaks, clogged filters, and oil contamination are easy to fix if caught early but become costly if ignored.

Using the Wrong Fluids

Not all oils are the same. Atlas Copco vacuum pumps are engineered to operate with specific fluids that resist oxidation, foaming, and vapor carryover.

Ignoring Minor Changes

Changes in sound, vibration, or vacuum pressure are early warnings. Investigating small issues prevents big repairs.

Delaying Preventive Maintenance

Trying to "stretch" service intervals may seem economical but often leads to higher costs over time due to accelerated wear and unplanned failures.

Why Partner with Industrial Air Services

Industrial Air Services is your local Atlas Copco vacuum expert. We offer

Certified preventive maintenance and repair services

Customized PM programs based on your process needs

GENIUS Instant Insights™ setup and remote monitoring support

OEM parts and fluids stocked locally for faster service

24/7 emergency support across Nashville, Knoxville, and Chattanooga

We don't just maintain equipment—we build long-term partnerships focused on maximizing your uptime and operational success.

📞 Ready to protect your vacuum systems and maximize ROI? Call Industrial Air Services at (615) 641-3100 today.

Conclusion

Vacuum pumps are vital to your operations, and protecting them with a strong preventive maintenance program is one of the smartest investments you can make. From extending equipment life to cutting energy costs and preventing downtime, the benefits are clear. With Industrial Air Services and Atlas Copco’s industry-leading vacuum technologies, you can ensure that your systems stay reliable, efficient, and ready to support your business goals for years to come.

Contact Industrial Air Services at (615) 641-3100 today to schedule a maintenance consultation or learn more about how we can help optimize your vacuum operations across Nashville, Knoxville, and Chattanooga.

GENIUS Instant Insights™: How Remote Monitoring is Revolutionizing Vacuum Pump Management

Industrial facilities depend on vacuum systems for critical operations across manufacturing, packaging, chemical processing, food production, and electronics. But when a vacuum pump fails without warning, the result is costly downtime, product losses, and emergency repairs. Today, thanks to advancements in digital technology, predictive maintenance and remote system management are transforming how facilities manage their vacuum equipment.

Atlas Copco’s GENIUS Instant Insights™ platform is at the forefront of this shift. By providing real-time remote monitoring, performance data, and predictive alerts, GENIUS helps businesses avoid costly downtime, improve energy efficiency, and make smarter maintenance decisions.

In this blog, we'll explore how GENIUS Instant Insights™ works, the benefits it delivers, and why partnering with Industrial Air Services ensures your facility gets the most from your Atlas Copco vacuum systems.

📞 Want to learn how GENIUS can protect your operations? Call Industrial Air Services at (615) 641-3100 for support in Nashville, Knoxville, and Chattanooga.

The High Cost of Unplanned Downtime

Vacuum pump failures can happen for many reasons, including seal wear, overheating, bearing failure, or contamination. Without early warning, these failures often cause

Unexpected production stoppages

Expensive emergency repair costs

Product scrap or quality issues

Increased energy waste as pumps struggle

Higher maintenance labor costs

Studies show that the average unplanned downtime event costs between $2,500 and $25,000 per hour depending on the industry. Proactively monitoring equipment health is the most effective way to prevent these disasters—and GENIUS Instant Insights™ is specifically designed to do just that.

What Is GENIUS Instant Insights™?

GENIUS Instant Insights™ is Atlas Copco’s cloud-based platform for vacuum pump monitoring and diagnostics. Installed sensors gather data from your vacuum equipment, which is then transmitted securely to the cloud where it is analyzed in real time.

Key capabilities include

Live performance dashboards accessible from anywhere

Early warning notifications for maintenance needs or abnormal conditions

Energy consumption and system efficiency tracking

Automated maintenance scheduling and reminders

Historical data and trend analysis for smarter decision-making

With GENIUS, facilities gain visibility into their vacuum systems like never before—without the need for manual inspections or local data loggers.

How GENIUS Works

Connected Sensors

Atlas Copco vacuum pumps like the GHS VSD⁺, DWS VSD⁺, and DHS series are factory-equipped or easily retrofitted with GENIUS-compatible sensors that monitor parameters such as pressure, temperature, motor load, vibration, and oil condition.

Secure Cloud Transmission

Collected data is securely transmitted to the Atlas Copco cloud using encrypted communications, ensuring your information is safe.

Real-Time Analysis

Advanced algorithms analyze data patterns to detect anomalies, performance degradation, and early signs of component wear.

Actionable Alerts

When issues are detected, GENIUS sends instant notifications to maintenance teams via email, text, or through the dashboard—allowing fast, informed action.

Benefits of Using GENIUS Instant Insights™

Prevent Unplanned Downtime

By identifying early warning signs of potential failures, GENIUS enables planned maintenance instead of reactive repairs. This can reduce emergency breakdowns by up to 60%.

Optimize Energy Usage

Monitoring motor loads, system leaks, and pressure setpoints helps optimize energy consumption—leading to measurable reductions in operating costs.

Extend Equipment Life

Proactive maintenance and smoother system operation mean pumps last longer, reducing capital equipment replacement costs.

Simplify Maintenance Management

Automated scheduling and clear maintenance timelines take the guesswork out of servicing vacuum pumps, freeing up your maintenance staff for other priorities.

Gain 24/7 Access Anywhere

Access system dashboards from any web-enabled device, whether you’re on the plant floor, in the office, or working remotely.

Support ESG and Sustainability Goals

By minimizing wasted energy and material losses, GENIUS contributes to lower carbon footprints and improved corporate sustainability reporting.

Real-World Example: Semiconductor Manufacturer in Tennessee

A semiconductor production facility operating multiple cleanrooms needed continuous uptime and strict control over vacuum performance. Manual inspections were labor-intensive and often missed early warning signs of trouble.

They upgraded their new Atlas Copco DHS VSD⁺ dry screw pumps with GENIUS Instant Insights™ monitoring.

Results in the first year

Zero unplanned vacuum outages

20% reduction in energy consumption through setpoint optimization

Improved preventive maintenance scheduling and parts forecasting

Immediate alerts that prevented two potential pump failures

📞 Interested in GENIUS for your facility? Call Industrial Air Services at (615) 641-3100 to schedule a consultation.

How GENIUS Pairs with Atlas Copco Smart Vacuum Technologies

Atlas Copco’s GENIUS platform seamlessly integrates with their other intelligent features like

HEX@™ touchscreen control interface for on-site system management

VSD⁺ technology for dynamic energy savings based on real-time demand

Central controller options for managing multi-pump systems automatically

This ecosystem of smart technologies ensures your vacuum system isn’t just efficient—it's self-optimizing.

Industries That Benefit Most from GENIUS

Pharmaceutical and biotech manufacturing

Semiconductor and electronics production

Food and beverage packaging

Plastics extrusion and thermoforming

Automotive component manufacturing

Research laboratories and R&D facilities

Any facility relying on critical vacuum processes can benefit from the real-time visibility, predictive power, and energy optimization GENIUS provides.

Why Choose Industrial Air Services for Your Vacuum Monitoring Needs

Industrial Air Services is your local expert for Atlas Copco vacuum solutions, including GENIUS system setup, training, and support.

Our services include

On-site system audits and GENIUS readiness assessments

Installation of monitoring hardware and system setup

Training your staff to use and interpret GENIUS dashboards

Proactive maintenance and service support based on real-time insights

24/7 emergency response when urgent issues arise

With offices serving Nashville, Knoxville, and Chattanooga, we ensure your vacuum systems are always connected, protected, and optimized.

📞 Want to upgrade your vacuum systems with GENIUS monitoring? Call Industrial Air Services at (615) 641-3100 today.

Conclusion

In today’s fast-paced industrial world, waiting for equipment to fail is not an option. GENIUS Instant Insights™ from Atlas Copco delivers the real-time monitoring, predictive maintenance alerts, and operational visibility needed to protect your critical vacuum systems, reduce energy costs, and maximize uptime. With Industrial Air Services as your trusted partner, you can harness the full power of smart vacuum technology for greater efficiency and reliability.

Contact Industrial Air Services at (615) 641-3100 today to learn more about integrating GENIUS into your vacuum systems across Nashville, Knoxville, and Chattanooga.

Understanding Liquid Ring Vacuum Pumps: When and Why to Choose Them

Vacuum technology powers countless industrial processes, from food production to chemical manufacturing to energy generation. Among the many vacuum technologies available, liquid ring vacuum pumps have carved out a special niche for applications that require reliable, durable, and low-maintenance solutions—especially when handling vapor-heavy, wet, or corrosive gases.

Atlas Copco, a global leader in vacuum solutions, offers a full range of liquid ring pumps designed to meet these tough industrial demands. In this blog, we’ll explore what liquid ring pumps are, how they work, when they’re the best choice, and why Atlas Copco’s designs outperform the competition.

📞 Need help choosing the right vacuum technology? Call Industrial Air Services at (615) 641-3100 for expert advice and service across Nashville, Knoxville, and Chattanooga.

How Liquid Ring Vacuum Pumps Work

Liquid ring pumps use a rotating impeller housed eccentrically inside a casing. A sealant liquid—usually water—enters the pump along with the gas to be compressed. As the impeller rotates, centrifugal force throws the liquid outward, creating a rotating liquid ring.

This liquid ring traps pockets of gas between the impeller blades and the casing. As the impeller continues rotating, these pockets are compressed and pushed toward the discharge port.

Key characteristics of liquid ring operation include

Handling large volumes of vapor without contamination

Ability to compress saturated gases without condensation issues

Resilience to liquid carryover without damage

Simple, robust design with very few moving parts

Because of these properties, liquid ring pumps thrive in wet, dirty, and corrosive environments where other vacuum technologies might struggle.

When to Choose a Liquid Ring Vacuum Pump

Liquid ring pumps are not ideal for every application, but in the right environment, they offer unbeatable advantages.

Choose a liquid ring pump when

The process gas contains significant moisture or vapor

Corrosive or chemically reactive gases are present

High reliability is critical in challenging conditions

Oil-free operation is important (when water is used as the sealing fluid)

Low noise and smooth operation are desired

They are especially useful in industries like

Chemical processing (vapor recovery, distillation)

Pulp and paper (dewatering, vacuum forming)

Power generation (steam turbine evacuation)

Food and beverage (de-aeration, vacuum packaging)

Oil and gas (flare gas recovery, refining)

Atlas Copco’s Liquid Ring Vacuum Pump Series

Atlas Copco’s range of liquid ring pumps includes

AWL Series: Compact, single-stage liquid ring pumps designed for wet processes and moderate vacuum levels

AWS Series: Standard two-stage pumps optimized for deeper vacuum levels and higher gas throughput

AWD Series: Heavy-duty two-stage pumps for demanding, corrosive, or high-temperature applications

AWC Series: Custom-configured systems combining pumps, separators, and control panels for turnkey installation

Each series is engineered for maximum uptime, efficiency, and flexibility. Pumps are available with a range of materials of construction including stainless steel, bronze, and cast iron to handle corrosive or abrasive gases.

Advantages of Atlas Copco Liquid Ring Pumps

Robust Construction

Atlas Copco designs their liquid ring pumps with heavy-duty components, including corrosion-resistant casings and impellers, to extend service life even in the harshest environments.

High Efficiency

Modern design optimizations such as improved impeller profiles and optimized fluid flow channels increase volumetric efficiency and reduce energy consumption.

Quiet Operation

Liquid ring pumps operate with smooth, continuous compression, resulting in much quieter noise profiles than other types of vacuum pumps.

Minimal Maintenance Requirements

With fewer moving parts, no internal metal-to-metal contact, and simple mechanical seals, Atlas Copco liquid ring pumps require very little preventive maintenance compared to dry screw or oil-sealed rotary vane pumps.

Flexible Fluid Options

While water is the most common sealing liquid, Atlas Copco pumps can be configured to operate with specialized fluids such as glycol, solvents, or oils depending on the application.

Real-World Example: Chemical Recovery Plant in Alabama

A specialty chemical manufacturer in Alabama needed a vacuum system for recovering solvent vapors from a batch distillation process. The gas stream contained high moisture content and traces of corrosive acids.

Industrial Air Services evaluated the process and installed two Atlas Copco AWD Series liquid ring vacuum pumps, constructed with stainless steel wetted parts for corrosion resistance.

Results after 18 months

Zero unscheduled maintenance events

Consistent vacuum levels even with fluctuating load

Reduced energy consumption compared to legacy pumps

Solvent recovery rates increased by 12% due to stable vacuum

📞 Considering a liquid ring system for your process? Call Industrial Air Services at (615) 641-3100 for a consultation.

While dry screw pumps are more energy-efficient in dry gas applications, liquid ring pumps dominate when moisture, wet vapors, and dirty gases are involved.

Maintenance Tips for Liquid Ring Pumps

To maximize the life and efficiency of a liquid ring pump

Use clean sealant liquid (filtered water or treated fluid)

Monitor sealant temperature to prevent overheating

Inspect and maintain mechanical seals periodically

Flush the pump when handling sticky or corrosive media

Follow Atlas Copco’s recommended service intervals and use OEM parts

Industrial Air Services offers preventive maintenance contracts to keep your vacuum system operating at peak performance.

Why Choose Industrial Air Services for Liquid Ring Vacuum Solutions

Industrial Air Services is your trusted source for Atlas Copco liquid ring pumps across Tennessee. Our services include

On-site vacuum audits and system design

Pump sizing and materials consultation

Installation and commissioning

Preventive maintenance and emergency service

OEM parts, rebuild kits, and fast repair turnaround

Our experienced team ensures your system is designed right, installed correctly, and maintained for long-term success.

📞 Need a quote or system evaluation? Call Industrial Air Services at (615) 641-3100 today.

Conclusion

Liquid ring vacuum pumps offer unbeatable performance in applications with vapor, moisture, and corrosive gases. Atlas Copco’s AWL, AWS, AWD, and AWC series pumps deliver rugged reliability, low maintenance, and efficient operation. Whether you're upgrading a system or installing new equipment, Industrial Air Services has the expertise to design and support a liquid ring vacuum solution perfectly matched to your needs.

Contact Industrial Air Services at (615) 641-3100 today to schedule a site evaluation or discuss how liquid ring technology can improve your operations in Nashville, Knoxville, or Chattanooga.

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.

Energy-Efficient Vacuum Solutions: How Variable Speed Drive (VSD⁺) Pumps Save You Money

Energy costs are one of the largest operational expenses for industrial facilities, especially for systems that run continuously—like vacuum pumps. In the past, vacuum pumps operated at a constant speed regardless of process demand, wasting tremendous amounts of energy. But modern facilities can no longer afford inefficiency.

That’s why Variable Speed Drive (VSD⁺) vacuum technology, pioneered by companies like Atlas Copco, has become a game-changer across manufacturing, food processing, plastics, packaging, and energy production.

In this blog, we’ll explore how energy-efficient VSD⁺ vacuum pumps work, why they save facilities tens of thousands of dollars annually, and how partnering with Industrial Air Services ensures you get the right energy-saving solution.

📞 Ready to cut your energy bills? Call Industrial Air Services at (615) 641-3100 for sales and service across Nashville, Knoxville, and Chattanooga.

The Problem with Traditional Fixed-Speed Vacuum Pumps

Traditional vacuum pumps are designed to run at full speed whenever they are operating—whether maximum vacuum is required or not. This leads to:

Constant energy consumption

Frequent cycling (on/off), causing wear

Unnecessary maintenance

High peak electrical loads

Overheating and shortened lifespan

Even processes with variable demand—such as fluctuating production lines or multiple shift schedules—still ran pumps at full tilt. This wastes enormous amounts of electricity and reduces equipment reliability.

How VSD⁺ Vacuum Technology Works

Variable Speed Drive (VSD⁺) technology allows the motor speed of the vacuum pump to automatically adjust based on real-time process demand.

If less vacuum is needed, the motor slows down, consuming only the energy required to maintain set pressure. When more vacuum is needed, the pump speeds up to match.

Atlas Copco’s vacuum products, including the GHS VSD⁺ oil-sealed rotary screw pumps and the DWS VSD⁺ dry screw pumps, integrate VSD⁺ as standard—offering unmatched flexibility and energy savings.

Key features include:

Fully automated motor speed adjustments

Precise setpoint control (target pressure maintenance)

Soft start and stop, reducing mechanical stress

Integrated smart monitoring with HEX@™ and GENIUS Instant Insights™

How Much Energy Can You Save?

The energy savings from switching to VSD⁺ vacuum pumps are dramatic.

Industry studies and real-world Atlas Copco case studies show:

Up to 50% reduction in energy costs versus traditional fixed-speed pumps

35% longer service intervals due to reduced mechanical wear

Up to 70% reduction in peak electrical demand charges

For a mid-sized manufacturing facility running multiple vacuum pumps, these savings could amount to $15,000 to $100,000 per year depending on usage.

Plus, reduced energy consumption supports corporate sustainability goals and carbon footprint reduction.

Real-World Example: Plastics Extrusion Plant in Tennessee

A plastics manufacturer operating three legacy oil-sealed vacuum pumps was facing high energy bills and costly maintenance cycles.

They upgraded to three Atlas Copco GHS 585 VSD⁺ rotary screw vacuum pumps.

Results after 12 months:

47% reduction in vacuum system energy usage

Payback period of just under 18 months

32% reduction in unplanned maintenance events

Carbon footprint cut by 60 metric tons per year

📞 Interested in an energy savings audit? Call Industrial Air Services at (615) 641-3100 to schedule one.

VSD⁺ Pumps Improve More Than Just Energy Efficiency

1. Improved Product Quality

Constant vacuum levels mean better consistency in processes like packaging, degassing, freeze-drying, and semiconductor manufacturing.

VSD⁺ pumps deliver steady pressure without fluctuations that can damage products or processes.

2. Reduced Mechanical Stress

Soft starts and optimized speeds mean bearings, seals, and rotors last longer. There’s less vibration, less heat, and far fewer emergency shutdowns.

3. Flexible Operation

If your production volume changes seasonally, daily, or shift-to-shift, VSD⁺ pumps automatically adjust—no manual intervention needed.

This flexibility is essential for industries like food packaging, bottling, plastics, textiles, and electronics.

4. Quieter Work Environments

Atlas Copco’s VSD⁺ vacuum pumps operate with significantly lower noise levels, improving conditions for plant workers and reducing the need for costly acoustic enclosures.

Which Atlas Copco VSD⁺ Vacuum Pumps Are Available?

Atlas Copco offers a full range of VSD⁺ equipped vacuum pumps to fit every industry:

GHS VSD⁺ Series: Oil-sealed rotary screw pumps for packaging, plastics, woodworking, and general industry

DWS VSD⁺ Series: Dry screw pumps for food, pharmaceutical, and semiconductor applications

LRP VSD⁺ Series: Liquid ring pumps for wet and vapor-heavy processes like power generation and chemical manufacturing

DHS 065-200 VSD⁺: Dry screw pumps for clean manufacturing, R&D, and battery production

Each pump is engineered with Atlas Copco’s signature smart control systems (HEX@™) and remote monitoring (GENIUS Instant Insights™) to further optimize performance.

VSD⁺ and Sustainability: A Win-Win

VSD⁺ technology directly supports environmental goals by:

Reducing energy waste

Lowering carbon emissions

Extending equipment lifespan

Reducing the environmental impact of oil and filter disposal

Facilities investing in Atlas Copco VSD⁺ vacuum systems often qualify for energy efficiency incentives, rebates, and carbon reduction credits—providing an additional financial benefit.

How Industrial Air Services Supports Your VSD⁺ Upgrade

Choosing the right vacuum pump isn't just about the brand—it’s about having the right partner.

Industrial Air Services offers:

On-site vacuum audits to assess potential savings

System sizing and application engineering

Turnkey installation and commissioning

Preventive maintenance programs to protect your investment

24/7 emergency support and fast access to OEM parts

Whether you’re replacing a single unit or upgrading an entire facility, our team ensures your VSD⁺ investment delivers maximum returns.

📞 Ready to start saving energy and money? Call Industrial Air Services at (615) 641-3100 today.

Conclusion

Atlas Copco’s VSD⁺ vacuum technology represents a major leap forward in energy efficiency, reliability, and sustainability. By matching vacuum output to real-time demand, these smart systems deliver massive energy savings, reduced maintenance, and better process control.

Industrial Air Services proudly supplies and supports Atlas Copco’s full range of VSD⁺ vacuum pumps across Nashville, Knoxville, and Chattanooga. If you're ready to lower your energy bills and future-proof your vacuum systems, our experts are ready to help.

📞 Call Industrial Air Services today at (615) 641-3100 to learn more or schedule your energy savings audit.

Oil-Sealed vs. Dry Vacuum Pumps: Choosing the Right Technology for Your Application

Industrial vacuum pumps are essential across manufacturing, pharmaceuticals, electronics, food packaging, and energy production. However, not all vacuum pumps are created equal—and choosing the wrong type can mean higher energy costs, more frequent maintenance, and even process contamination.

Two of the most common categories are oil-sealed vacuum pumps and dry vacuum pumps. Each has unique strengths and ideal applications. In this blog, we’ll break down the differences between these two technologies, help you understand which is best for your operation, and highlight how Atlas Copco’s innovative vacuum solutions offer unmatched performance.

📞 Need expert advice on vacuum pump selection? Call Industrial Air Services at (615) 641-3100 for service across Nashville, Knoxville, and Chattanooga.

What Are Oil-Sealed Vacuum Pumps?

Oil-sealed vacuum pumps (such as rotary vane and rotary screw designs) use a thin film of oil to seal, lubricate, and cool internal components. The oil also helps maintain a consistent vacuum level and reduces internal leakage.

Atlas Copco’s GHS VSD⁺ series is a prime example of modern oil-sealed rotary screw vacuum pumps.

Key Features:

High ultimate vacuum levels (down to a few millibar absolute)

Efficient cooling and sealing properties from oil

Excellent for processes with demanding vacuum stability requirements

Long service intervals when properly maintained

Oil-sealed pumps have traditionally been the workhorses of industrial vacuum, offering robust performance in applications where contamination risks are low or manageable.

What Are Dry Vacuum Pumps?

Dry vacuum pumps achieve vacuum without any oil or liquid in the compression chamber. Designs include dry screw, dry claw, scroll, and multistage roots pumps.

Atlas Copco’s DWS VSD⁺ and DZS Claw Series pumps are leading examples of dry vacuum solutions.

Key Features:

No risk of process contamination by oil

Lower maintenance and operating costs

Environmentally friendly operation (no oil disposal required)

Excellent for cleanroom and sensitive manufacturing environments

Dry vacuum pumps have surged in popularity due to stricter contamination controls, sustainability goals, and lower total cost of ownership.

When to Choose Oil-Sealed Vacuum Pumps

Oil-sealed technology remains the best choice for certain applications where:

High vacuum levels are critical (below 1 mbar)

Fluctuating loads are minimal

Moderate contamination risk is acceptable

Cost-conscious operations are important

Common industries and applications:

Plastics extrusion

Vacuum packaging

CNC woodworking

Bottle filling

Automotive vacuum impregnation

Atlas Copco’s GHS VSD⁺ series delivers energy-efficient, oil-sealed performance with integrated VSD technology—optimizing performance while cutting energy use up to 50%.

When to Choose Dry Vacuum Pumps

Dry pumps are the clear winner when:

Oil contamination cannot be tolerated (pharma, semiconductor)

Clean environments like ISO Class cleanrooms are required

Energy savings and sustainability are top priorities

Frequent cycling and load variation are common

Common industries and applications:

Pharmaceutical manufacturing (coating, freeze drying)

Semiconductor and electronics (wafer fabrication)

Food packaging (MAP packaging, dairy filling)

Battery production (lithium-ion cells)

Research labs and biotechnology

Atlas Copco’s DWS VSD⁺ dry screw pumps and DZS dry claw pumps offer rugged, oil-free performance ideal for sensitive processes.

Why Variable Speed Drive (VSD⁺) Changes the Game for Both Types

Whether you choose oil-sealed or dry, Atlas Copco’s VSD⁺ technology delivers major benefits:

Energy savings up to 50%

Quieter operation

Lower heat output

Extended equipment life

Built-in smart control and remote monitoring

By automatically adjusting the motor speed based on demand, VSD⁺ minimizes waste and protects your investment.

Real-World Example: Choosing the Right Pump in Food Processing

A meat processing plant needed vacuum pumps for two very different parts of its facility:

Packaging area: Required moderate vacuum for modified atmosphere packaging (MAP) with frequent cycling.

Brine injection station: Required strong, steady vacuum for marination and injection.

Solution:
 They installed DZS dry claw pumps for the packaging line to eliminate oil contamination and maximize cycling efficiency. For the brine injection system, they installed GHS VSD⁺ oil-sealed rotary screw pumps to ensure strong, stable vacuum at maximum energy efficiency.

Result:

38% energy savings across the vacuum system

Zero contamination issues

Reduced maintenance frequency by 40%

📞 Need a custom recommendation like this? Call Industrial Air Services at (615) 641-3100.

How Atlas Copco Supports Both Technologies

Atlas Copco’s vacuum solutions include:

Oil-Sealed Systems: GHS VSD⁺ rotary screw, LRP VSD⁺ liquid ring pumps

Dry Systems: DWS VSD⁺ dry screw, DZS dry claw pumps, DHS 065-200 VSD⁺ dry screw pumps

Connectivity: GENIUS Instant Insights™ and HEX@™ smart control

Custom Systems: Engineered Systems + Solutions for complex applications

By offering both oil-sealed and dry options—with VSD⁺ as standard—Atlas Copco ensures customers get the best match for their needs.

Final Tips for Choosing the Right Vacuum Pump

Analyze your process requirements carefully: Is ultimate vacuum, contamination control, or energy savings the top priority?

Consider total cost of ownership, not just upfront purchase price.

Factor in maintenance schedules, spare parts, and service availability.

Look for systems with built-in monitoring to protect your investment.

Partner with an expert distributor who can size and configure your system properly.

Conclusion

Choosing between oil-sealed and dry vacuum technology is one of the most important decisions you’ll make for your industrial process. With Atlas Copco’s broad portfolio of GHS, DWS, and DZS pumps—and expert support from Industrial Air Services—you can be confident you’re selecting a vacuum solution that maximizes reliability, minimizes costs, and supports your future growth.

This blog is proudly provided by Industrial Air Services, your trusted source for Atlas Copco vacuum systems in Nashville, Knoxville, and Chattanooga.

📞 For help sizing and selecting your next vacuum pump, call (615) 641-3100 today.

The Evolution of Industrial Vacuum Technology: How Atlas Copco Is Leading the Future

Industrial vacuum technology has come a long way from the early days of bulky, inefficient pumps. Today, vacuum systems are the backbone of critical industries like pharmaceuticals, electronics manufacturing, food processing, energy production, and plastics. Modern industrial processes demand vacuum solutions that are energy-efficient, smart, customizable, and sustainable.

At the forefront of this evolution stands Atlas Copco, a global leader known for pioneering innovations that continue to shape the vacuum landscape. In this article, we'll take a closer look at how industrial vacuum technology has evolved—and how Atlas Copco is driving the future with cutting-edge systems like HEX@™, GENIUS Instant Insights™, and Variable Speed Drive (VSD⁺) vacuum pumps.

📞 Need help selecting the right vacuum system for your operation? Call Industrial Air Services at (615) 641-3100 for expert assistance across Nashville, Knoxville, and Chattanooga.

A Brief History of Industrial Vacuum Pumps

Vacuum technology dates back centuries, but industrial applications began in earnest in the 20th century with the rise of mass manufacturing. Early vacuum pumps were primarily oil-sealed rotary vane designs, delivering reliable performance but often requiring significant maintenance and energy.

Key milestones include:

1950s: Introduction of oil-sealed rotary vane pumps for manufacturing.

1970s: Development of dry screw and claw pumps, offering oil-free operation.

1990s: Variable Speed Drive (VSD) technology emerges, improving efficiency in air compressors—and eventually vacuum pumps.

2010s: Connectivity, smart monitoring, and predictive maintenance become available for vacuum systems.

Today, leading manufacturers like Atlas Copco offer sophisticated, application-specific vacuum solutions that maximize efficiency, sustainability, and uptime.

Atlas Copco’s Role in Transforming Vacuum Technology

Atlas Copco’s commitment to innovation has redefined industrial vacuum systems. Let’s explore some key ways they are advancing the industry:

1. Variable Speed Drive (VSD⁺) Vacuum Pumps

Traditionally, vacuum pumps operated at a fixed speed, regardless of the actual demand. This meant wasted energy, frequent cycling, and premature wear.

Atlas Copco’s VSD⁺ technology changed that by allowing the pump’s motor speed to adjust automatically to the process demand. This results in:

Energy savings up to 50%

Reduced maintenance intervals

Lower operating temperatures

Longer equipment life

The GHS VSD⁺ Series of rotary screw vacuum pumps and DWS VSD⁺ Dry Screw Pumps are excellent examples of how variable speed vacuum pumps have revolutionized industries like plastics extrusion, woodworking, bottling, and food packaging.

2. HEX@™: Smart Vacuum Control at Your Fingertips

Efficiency isn’t just about hardware—it’s also about control. Atlas Copco’s HEX@™ platform provides a new generation of human-machine interface for vacuum pumps.

Features include:

Easy access to pump status, performance trends, and diagnostics

Remote monitoring capabilities

Customized control over operating parameters

Integration with plant automation and MES/SCADA systems

With HEX@™, operators can fine-tune vacuum performance to match exact process needs—saving energy and reducing the risk of failure.

3. GENIUS Instant Insights™

Predictive maintenance is the future of industrial reliability, and Atlas Copco leads the way with GENIUS Instant Insights™.

GENIUS is a cloud-based monitoring platform that connects to Atlas Copco vacuum pumps, providing:

Real-time system status

Maintenance reminders and alerts

Energy consumption reports

Early warnings of potential problems

This proactive approach allows facilities to fix small issues before they become big failures, dramatically improving uptime and reducing emergency repair costs.

4. Tailor-Made Systems: Systems + Solutions

Not all facilities have the same vacuum needs. That’s why Atlas Copco offers custom engineering through its Systems + Solutions service.

Custom solutions may include:

Centralized vacuum systems

Redundancy for critical applications

Skid-mounted units for space-constrained environments

Custom PLC integration

These tailored solutions ensure that customers get exactly the performance they need—without over- or under-sizing equipment.

How Vacuum Technology Is Supporting Sustainability Goals

Sustainability is no longer optional—it's a mandate. Modern vacuum systems must align with global efforts to cut carbon emissions and reduce environmental impact.

Atlas Copco’s innovations help companies achieve:

Lower energy consumption: VSD⁺ and intelligent control mean less wasted energy.

Reduced oil and water usage: Dry vacuum pumps eliminate oil contamination and water sealing needs.

Minimized downtime: Predictive maintenance reduces the environmental impact of emergency production shutdowns.

Smaller carbon footprints: More efficient vacuum systems contribute to corporate ESG goals.

By investing in smart, energy-saving vacuum technology, companies can not only save money but also meet growing environmental regulations.

Industry Applications Where Atlas Copco Excels

Atlas Copco’s vacuum solutions serve a wide range of industries, including:

Pharmaceuticals: Cleanroom-compatible dry pumps for sterile production.

Electronics and Semiconductor Manufacturing: Ultra-clean, oil-free vacuum systems critical for chip fabrication.

Food and Beverage: Hygienic vacuum for packaging, filling, and preserving freshness.

Plastics and Rubber: Vacuum forming and extrusion applications.

Power and Energy: Degassing and insulation production for turbines and transformers.

Printing and Packaging: Consistent vacuum for printing presses and flexible packaging machines.

Across each sector, Atlas Copco’s vacuum innovations offer measurable improvements in energy efficiency, reliability, and process quality.

A Look at Key Product Lines

Here are just a few highlights of Atlas Copco’s broad vacuum portfolio:

GHS VSD⁺ Series: Energy-efficient oil-sealed rotary screw vacuum pumps.

DWS VSD⁺ Series: High-performance dry screw vacuum pumps.

LRP VSD⁺ Series: Liquid ring pumps designed for vapor-heavy and wet applications.

DZS Series: Compact dry claw pumps with low noise and high durability.

AWC/AWS/AWL Series: Robust liquid ring vacuum pumps for harsh environments.

No matter the process or environmental conditions, there’s an Atlas Copco vacuum solution to fit.

📞 Need help determining which system is right for your operation? Call Industrial Air Services at (615) 641-3100.

Future Trends in Industrial Vacuum Technology

Looking ahead, several trends will shape the vacuum industry:

Increased IoT Integration: More facilities will connect their vacuum systems to centralized monitoring and analytics platforms.

Higher Efficiency Standards: Expect even stricter energy regulations and certifications.

Greater Customization: Modular systems designed for plug-and-play integration with smart factories.

Focus on Oil-Free Technology: Particularly in pharmaceuticals, food, and semiconductor production.

Predictive Maintenance as Standard: Maintenance scheduling based on real-time performance data.

Atlas Copco continues to lead the charge, investing heavily in R&D to ensure their vacuum solutions are not just ready for the future—but helping to create it.

Conclusion

Industrial vacuum technology has evolved from basic mechanical pumps to highly intelligent, energy-efficient systems capable of transforming manufacturing processes. With innovations like VSD⁺, HEX@™, and GENIUS Instant Insights™, Atlas Copco is at the forefront of this transformation, offering solutions that maximize uptime, reduce operating costs, and support sustainability goals.

This content is proudly provided by Industrial Air Services, your trusted source for Atlas Copco vacuum solutions in Nashville, Knoxville, and Chattanooga. Whether you need a new system, a retrofit, or expert advice, our team is here to help.

📞 Call Industrial Air Services at (615) 641-3100 today for sales, service, or consultation.

A Guide to Griswold's 811 ANSI Series: Features, Benefits, and Applications

In the world of industrial fluid handling, reliability, efficiency, and ease of maintenance are non-negotiable. When choosing a centrifugal pump, especially one designed to meet ANSI B73.1 standards, operators need a solution that can perform under pressure, simplify system design, and minimize long-term costs. That’s where the Griswold 811 ANSI Series shines.

Engineered for tough operating environments and known for its broad range of sizes and materials, the Griswold 811 is a direct competitor to legacy pumps like the Goulds 3196—but with unique advantages in performance, lead time, and serviceability. Whether you’re upgrading your facility, replacing a legacy pump, or building a new system from scratch, the Griswold 811 offers a flexible and economical solution.

In this post, we’ll take a detailed look at the 811 ANSI Series—what sets it apart, how it performs, and why Industrial Air Services, with offices in Nashville, Knoxville, and Chattanooga, recommends it to industrial clients across the Southeast.

📞 To get a quote or discuss your pump application, call Industrial Air Services at (615) 641-3100 today.

What Is the Griswold 811 ANSI Series?

The Griswold 811 ANSI Series is a line of horizontal, single-stage, end-suction centrifugal pumps designed to meet ANSI B73.1 dimensional standards. This means they are fully compatible with other ANSI-standard pumps, making them ideal for retrofits and replacements.

The 811 Series is designed to deliver reliable, efficient performance in applications that involve:

• Chemical processing

• Pulp and paper manufacturing

• Wastewater treatment

• Food and beverage production

• Oil and gas transfer

• Water purification and boiler feed systems

Each model is engineered for back pull-out service, which allows maintenance teams to service internal components without disturbing piping—a key time-saver for high-usage facilities.

Key Features of the Griswold 811 ANSI Series

The 811 Series is built with durability, flexibility, and total cost of ownership in mind. Here’s what makes it stand out:

• 28 casing sizes for high-performance hydraulic coverage

• Flow rates up to 7,000 GPM

• Heads to 730 feet

• Wide range of material options: ductile iron, 316 stainless, Alloy 20, CD4MCu

• Open or enclosed impellers based on application

• Back pull-out design for easy maintenance

• Interchangeable with other ANSI-compliant pump lines

• Multiple seal chamber configurations including standard, enlarged, and ISO

Its ability to meet a broad spectrum of flow and pressure requirements makes it a true workhorse in industrial pumping systems.

Advantages Over Competing Pumps

When compared to other ANSI-standard pumps such as the Goulds 3196, the Griswold 811 offers several performance and value-driven benefits.

• Simplified hydraulic coverage: Griswold’s 28-size system provides the same flexibility with fewer models to stock

• Superior lead times: Faster manufacturing and delivery versus traditional OEMs

• Cost efficiency: Lower purchase and replacement part costs

• Versatility: Compatible with existing pipe and base configurations

• Reduced vibration and increased reliability with properly selected bearing frames and impellers

Additionally, Griswold’s pumps are fully supported by a comprehensive parts and service network, ensuring long-term success for maintenance teams and operators.

Common Applications by Industry

The Griswold 811 ANSI Series is not a one-size-fits-all pump—it’s a customizable system with configurations suitable for some of the toughest industrial settings.

Chemical Processing:

• Acid and base transfer

• Solvent pumping

• Blending and batching operations

• Handling corrosive or abrasive media with proper material selection

Pulp and Paper:

• White water circulation

• Bleach and chemical pumping

• Headbox feed

• Black liquor handling

Food and Beverage:

• CIP (Clean-in-Place) system pumps

• Ingredient transfer

• Hot water circulation

• Sanitary material options available upon request

Water and Wastewater:

• Filter backwash

• Lift station and digester feed

• Clarifier and settling tank return

• Sludge and slurry handling

Oil & Gas:

• Produced water transfer

• Condensate and cooling loops

• Petrochemical process support

• Explosion-proof motor compatibility

With the right material and configuration, the 811 Series can thrive in nearly any environment requiring dependable, ANSI-compliant centrifugal pumping.

Maintenance Benefits

The Griswold 811 is designed to make maintenance as efficient and straightforward as possible. That includes:

• Back pull-out design allows removal of the rotating assembly without disturbing the suction and discharge piping

• Interchangeable components simplify inventory and reduce training needs

• ANSI dimensions mean easier swap-outs and compatibility with competitor mounting systems

• Wear rings and seal options allow for extended service life

• Enhanced bearing frames for higher load capacity and longer life expectancy

With minimal special tools required and easily accessible internals, facilities can cut down on both downtime and labor costs.

Real-World Example: Industrial Plant Retrofit in Little Rock

A regional manufacturing plant in Little Rock, Arkansas, needed to replace five legacy centrifugal pumps used in a process water system. The old units required frequent service, parts were no longer stocked, and downtime was affecting throughput.

Industrial Air Services proposed the Griswold 811 ANSI Series with ductile iron casings and 316SS impellers to handle light abrasives and temperature fluctuations. The results:

• Full installation completed with zero piping modifications

• Efficiency improved by 11% across the system

• Maintenance frequency dropped by 40%

• All five pumps now share the same spare parts inventory

📞 Want results like this? Call Industrial Air Services at (615) 641-3100 and request a free pump system review.

Integration with the Griswold Interchangeability Tool

Griswold’s free online Interchangeability Tool allows users to match competitor pump models—such as the Goulds 3196—to a Griswold 811 equivalent. This makes it incredibly easy to:

• Retrofit existing systems

• Replace failing units

• Cross-reference parts for quick ordering

• Standardize your facility under one pump platform

Industrial Air Services helps maintenance teams use this tool to save time, reduce costs, and avoid compatibility issues.

Why Industrial Air Services Recommends Griswold

As an authorized Griswold distributor and service partner, Industrial Air Services has firsthand experience with the reliability and performance of the 811 ANSI Series. We support customers across Tennessee with:

• Pump sizing and selection

• Site evaluations and maintenance planning

• Parts stocking and emergency service

• Turnkey retrofits and installations

• Local, knowledgeable support for long-term pump reliability

With offices in Nashville, Knoxville, and Chattanooga, we’re always within reach for fast, expert service.

📞 To speak with a pump expert near you, call Industrial Air Services at (615) 641-3100 today.

Conclusion

If you’re searching for a powerful, flexible, and ANSI-compliant centrifugal pump, the Griswold 811 ANSI Series delivers everything you need and more. With a proven design, strong material options, excellent part availability, and support from Industrial Air Services, it’s the clear choice for long-term operational success.

This blog is proudly provided by Industrial Air Services, with offices in Nashville, Knoxville, and Chattanooga. To request a quote, schedule a walkthrough, or get help selecting the right pump, call (615) 641-3100.

Reducing Downtime: The Role of Griswold's Interchangeability Tool in Industrial Operations

In industrial settings, uptime isn’t just a goal—it’s a necessity. From chemical plants and paper mills to water treatment facilities and food processing plants, a single hour of unexpected downtime can cost thousands in lost production, emergency repairs, and labor. One of the most overlooked contributors to unplanned downtime is slow or inaccurate part replacement during pump maintenance. That’s why Griswold’s Interchangeability Tool has become a critical asset for plant managers and maintenance teams aiming to keep their operations running smoothly.

Griswold, a trusted name in ANSI centrifugal pumps, created this easy-to-use tool to help users instantly identify equivalent replacement parts for a wide range of pumps—including those from other major manufacturers. When paired with reliable product support from Industrial Air Services, with offices in Nashville, Knoxville, and Chattanooga, the result is a streamlined maintenance process that reduces delays, eliminates guesswork, and boosts operational efficiency.

📞 Need help preventing downtime? Call Industrial Air Services at (615) 641-3100 for expert support and fast access to Griswold parts and pumps.

Downtime: The Hidden Drain on Profitability

The cost of downtime extends beyond lost output. It also includes labor, energy waste, unfulfilled contracts, and reputational damage. According to recent studies:

• 82% of companies have experienced unplanned downtime over the last three years

• The average cost of downtime across all industries is $260,000 per hour

• Maintenance delays account for up to 30% of total downtime in many facilities

What often turns a minor issue into a major outage is the inability to quickly source or identify the correct replacement part. That’s where Griswold’s Interchangeability Tool comes into play.

What Is the Griswold Interchangeability Tool?

The Griswold Interchangeability Part Number Lookup Tool is an online resource that allows users to enter pump model numbers or part descriptions from competing brands and instantly retrieve Griswold equivalent part numbers.

It supports:

• Goulds 3196

• Summit ANSI Series

• Peerless and other legacy pump models

• ANSI-standard configurations

The tool helps maintenance teams:

• Cross-reference competitor models

• Reduce time spent searching catalogs or outdated manuals

• Confirm compatibility for quick part ordering

• Consolidate inventory under the Griswold 811 ANSI Series umbrella

How the Tool Helps Prevent Downtime

1. Speeds Up Emergency Repairs

Instead of waiting on hold with OEM support or flipping through parts catalogs, maintenance teams can quickly find the replacement parts they need and call Industrial Air Services for same-day or next-day delivery.

2. Reduces Inventory Complexity

Facilities often stock hundreds of individual pump parts from multiple OEMs. The Griswold Interchangeability Tool allows them to consolidate those parts under a single platform—simplifying stocking, reordering, and training.

3. Enables Predictive Maintenance

The ability to proactively source parts for upcoming shutdowns or overhauls means fewer surprises and a smoother maintenance schedule. Teams can pre-order replacement kits based on historical wear data and reduce the chance of extended outages.

4. Avoids Costly Ordering Mistakes

Incorrect part orders delay repairs and inflate maintenance costs. Griswold’s tool ensures users get the exact match they need the first time, reducing costly returns and miscommunications.

Real-World Example: Wastewater Treatment Plant in Arkansas

A municipal wastewater facility in Arkansas faced repeated pump seal failures in an aging fleet of Goulds 3196 units. While the pumps were still functional, sourcing OEM parts had become unreliable due to extended lead times and discontinued components. The maintenance team turned to Industrial Air Services for help.

Using the Griswold Interchangeability Tool, Industrial Air Services:

• Cross-referenced legacy seal and impeller part numbers

• Supplied Griswold 811 ANSI replacement components that dropped in without system changes

• Trained plant personnel on using the tool for future part lookups

• Established a local parts stocking program based on usage data

Within six months, the facility reported a 60% reduction in unplanned pump-related downtime and a 22% drop in annual maintenance spending.

📞 Want to build a similar program? Call Industrial Air Services at (615) 641-3100 to get started.

Additional Benefits of the Tool

• Completely free and available online 24/7

• Covers all major ANSI-compliant pump manufacturers

• Helps plant engineers evaluate upgrades, not just replacements

• Ideal for MRO teams managing multiple facilities

• Built to support standardization initiatives across corporate sites

Why Griswold 811 ANSI Pumps?

The Griswold 811 ANSI Series is the most common replacement for Goulds 3196 and similar models. Designed for compatibility and long service life, it features:

• Interchangeable dimensions and parts

• High-efficiency impeller designs

• Corrosion- and wear-resistant material options

• Available in 28 casing sizes for maximum coverage

• Easily serviceable with standard tools and back pull-out design

When paired with the Interchangeability Tool, the 811 ANSI Series gives users full control over their pumping systems—without being locked into high-cost OEMs or slow service channels.

Why Partner with Industrial Air Services?

Industrial Air Services is more than a distributor—we’re your pump systems partner. Our team works directly with maintenance managers, engineers, and procurement professionals to ensure you have the right equipment and support when you need it most.

We provide:

• On-site pump system assessments

• Assistance using Griswold’s Interchangeability Tool

• Emergency response and fast parts delivery

• Local inventory programs

• Installation, training, and repair services

With decades of pump experience across multiple industries, we know how to reduce downtime and extend the life of your equipment.

📞 Call (615) 641-3100 to speak with a Griswold expert today.

Conclusion

Downtime is the enemy of efficiency, but with Griswold’s Interchangeability Tool, your maintenance team can fight back. Whether you’re cross-referencing pump components, building a preventive maintenance kit, or converting from legacy equipment to Griswold’s 811 ANSI Series, this tool saves time, reduces errors, and puts your operation back in control.

This blog is proudly provided by Industrial Air Services, with offices in Nashville, Knoxville, and Chattanooga. To learn more about how we support industrial facilities with Griswold pumps and parts, call us at (615) 641-3100 today.

The Competitive Edge: Griswold 811 ANSI Series vs. Goulds 3196 – A Comparative Analysis

When it comes to industrial centrifugal pumps, few names are as widely recognized as the Goulds 3196 and the Griswold 811 ANSI Series. Both pump lines are staples in industries such as chemical processing, pulp and paper, food and beverage, and water treatment. However, despite their shared ANSI B73.1 compliance, these pumps differ significantly in cost, ease of maintenance, lead time, and long-term ownership value.

In this blog, we’ll explore a detailed side-by-side comparison between the Goulds 3196 and Griswold 811 ANSI Series. We’ll analyze design, performance, parts availability, and more—so plant managers, engineers, and maintenance professionals can make the most informed decision when it comes to pump replacement or fleet standardization.

This guide is proudly provided by Industrial Air Services, a trusted distributor and service partner for Griswold products, with offices in Nashville, Knoxville, and Chattanooga.

📞 Ready for a side-by-side quote? Call (615) 641-3100 to speak with a pump specialist today.

ANSI Pump Basics: A Quick Refresher

Both the Goulds 3196 and the Griswold 811 ANSI Series conform to ANSI B73.1 dimensional standards. That means they share identical flange-to-flange dimensions and are interchangeable in terms of installation footprint.

ANSI pumps are known for:

• Back pull-out design for easy maintenance

• Interchangeable dimensions for multi-vendor sourcing

• High corrosion resistance options

• Applications ranging from aggressive chemical handling to clean water transfer

Because they share these standards, the decision between pump brands often comes down to performance, cost of ownership, and aftermarket support.

Performance and Hydraulic Range

Both the Goulds 3196 and Griswold 811 offer broad hydraulic coverage for medium to high-flow applications.

Goulds 3196:

• Flow: Up to 7,000 GPM

• Head: Up to 730 ft

• 41 size selections

• Wide range of impeller trim options

• Known for application-specific materials (CD4MCu, Alloy 20, etc.)

Griswold 811 ANSI Series:

• Flow: Up to 7,000 GPM

• Head: Up to 730 ft

• 28 casing sizes

• Optimized hydraulic coverage with high-efficiency options

• Broad range of metallurgy including ductile iron, stainless steel, and more

Verdict: In terms of hydraulic range, both pumps perform nearly identically, with the Griswold line offering a simplified range that reduces inventory requirements.

Parts Interchangeability and Maintenance

One of the strongest advantages of the Griswold 811 is its interchangeability with the Goulds 3196. Griswold offers parts and assemblies that directly drop into the 3196 footprint. This simplifies spare parts management and provides more competitive pricing on:

• Impellers

• Shafts and sleeves

• Casings

• Bearing housings

• Mechanical seal chambers

Griswold also offers a free Interchangeability Tool to help maintenance teams cross-reference existing Goulds models to Griswold equivalents—making the switch fast and seamless.

Lead Time and Availability

In today’s supply chain environment, lead time can be a deal-breaker.

Goulds 3196:

• Extended lead times depending on model and materials

• Parts may be limited for older models or less common alloys

• OEM-only pricing structure

Griswold 811:

• Known for faster lead times and factory-assembled kits

• Strong domestic manufacturing base

• Widespread availability of common parts through Industrial Air Services

Many Industrial Air Services clients have reduced their pump procurement lead time by more than 50% after switching to Griswold.

Pricing and Cost of Ownership

Initial purchase price often favors Griswold, but where it really shines is in total cost of ownership (TCO).

Griswold customers report:

• Lower upfront costs by 10–25% compared to Goulds

• More affordable replacement parts

• Reduced unplanned downtime due to stronger regional support

• Simplified inventory through part consolidation

When budgets are tight but uptime is critical, Griswold’s pricing structure gives plants more flexibility without sacrificing performance.

Materials and Application Fit

Both pump lines offer a wide range of material options for chemical resistance and wear resistance.

Goulds 3196: Extensive metallurgy options for custom applications, particularly known for use in corrosive environments.

Griswold 811 ANSI Series: Offers comparable metallurgy including 316 stainless, Alloy 20, and CD4MCu equivalents. In most industrial environments, Griswold’s offerings match or exceed performance expectations at a more accessible price point.

Real-World Example: Food Processing Facility in Mississippi

A food manufacturing facility in Mississippi operated a dozen Goulds 3196 pumps for CIP (clean-in-place) systems and process water transfer. When the time came for major overhauls, costs for OEM parts and labor began to skyrocket.

Industrial Air Services introduced the Griswold 811 ANSI Series as a drop-in replacement. After testing two pumps side-by-side for 90 days, the facility reported:

• Lower vibration and noise with Griswold pumps

• Identical flow characteristics

• 17% reduction in total maintenance costs

• Full replacement of remaining pumps within 6 months

Today, the facility is fully converted and relies on Industrial Air Services for rapid part delivery, stocking programs, and on-site service.

📞 Want to compare for yourself? Call (615) 641-3100 and ask for a Griswold-to-Goulds crossover report.

Why Choose Griswold 811 ANSI Series?

• ANSI dimensional compliance for easy retrofit

• Interchangeable with Goulds 3196

• Lower cost of ownership

• Fewer sizes = simplified inventory

• Proven in chemical, municipal, and industrial markets

• Supported by Industrial Air Services for service, startup, and parts

Whether you’re maintaining a single pump or managing a fleet of 50+, Griswold offers the flexibility, reliability, and value that industrial operations demand.

Why Industrial Air Services?

As an authorized Griswold distributor, Industrial Air Services offers:

• Engineering support and site evaluations

• Pump selection and application consulting

• Turnkey installation and retrofits

• Local inventory and same-day shipping on common parts

• 24/7 emergency repair and troubleshooting

Our offices in Nashville, Knoxville, and Chattanooga are ready to support your next maintenance or expansion project with industry-leading knowledge and equipment.

📞 For immediate assistance, call (615) 641-3100 today.

Conclusion

The Goulds 3196 has a long-standing reputation, but the Griswold 811 ANSI Series proves that performance, reliability, and value can come in a more cost-effective, readily available package. With full ANSI compliance, unmatched part interchangeability, and strong regional support from Industrial Air Services, the Griswold 811 is the smart alternative for today’s maintenance teams and plant managers.

This blog is proudly provided by Industrial Air Services, with offices in Nashville, Knoxville, and Chattanooga. Contact our team at (615) 641-3100 to request a quote or schedule a pump system review.

Mastering Pump Maintenance: How Griswold's Interchangeability Tool Streamlines Part Replacement

Industrial pumps are the lifeblood of manufacturing, chemical processing, water treatment, and countless other critical systems. But like any mechanical component, pumps are subject to wear—and downtime from pump failure can be costly. The key to maximizing uptime and performance lies in proactive pump maintenance and having access to replacement parts when and where you need them.

That’s where Griswold’s Interchangeability Tool comes in. Designed to simplify the pump maintenance process, this online resource allows users to quickly identify compatible replacement parts across a wide range of ANSI pumps—including Griswold’s 811 Series and legacy competitor models like the Goulds 3196.

In this blog, we’ll explore how Griswold’s Interchangeability Tool can revolutionize the way maintenance teams handle pump servicing and replacement. We’ll also highlight how Industrial Air Services, with offices in Nashville, Knoxville, and Chattanooga, supports industries in keeping their systems running smoothly with access to Griswold products and expert technical support.

📞 Need help sourcing replacement pump parts? Call Industrial Air Services at (615) 641-3100 today.

The Cost of Poor Pump Maintenance

When pumps go down, operations suffer. A single failure in a chemical plant, paper mill, or food production line can lead to:

• Production delays

• Equipment damage

• Safety hazards

• Regulatory violations

• Tens of thousands in downtime losses

According to industry studies, the average cost of unplanned equipment downtime ranges from $2,500 to $25,000 per hour depending on the process. And pumps, while rugged, are often a hidden point of failure due to:

• Impeller wear

• Seal leakage

• Bearing failure

• Corrosion and erosion

• Improper alignment

Regular maintenance is critical—but even the best maintenance team can’t do their job without fast access to accurate part replacements.

Enter the Griswold Interchangeability Tool

Griswold, a PSG Dover brand and manufacturer of ANSI centrifugal pumps, developed an online Interchangeability Part Number Lookup Tool to solve one of the industry’s most persistent headaches: identifying the correct replacement parts for competitor pump models.

✅ Matches competitor pump models to equivalent Griswold 811 ANSI components
✅ Offers part numbers for casings, impellers, sleeves, shafts, seals, and more
✅ Helps identify upgrades or more efficient configurations
✅ Reduces guesswork and time spent searching through catalogs or old manuals

This tool is especially valuable for facilities that operate a mixed fleet of legacy ANSI pumps from various manufacturers.

A Game-Changer for Maintenance Teams

1. Rapid Identification of Replacement Parts

Maintenance technicians can enter a competitor’s pump model and quickly receive a Griswold equivalent—saving hours of cross-referencing part lists or contacting multiple suppliers.

2. Simplified Inventory Management

By consolidating parts under the Griswold 811 ANSI footprint, facilities can reduce their spare parts inventory while improving part availability and compatibility.

3. Increased Maintenance Efficiency

When a pump goes down, there's no time to wait. The tool streamlines the part lookup process so that downtime is minimized and your system gets back online faster.

4. Supports Predictive and Preventive Maintenance

With easy access to part numbers, managers can build preventive maintenance kits or schedule replacements during planned shutdowns—no surprises, no scrambling.

What Is the Griswold 811 ANSI Series?

Griswold’s flagship product—the 811 ANSI Series—is a line of centrifugal pumps designed to be interchangeable with other ANSI-standard pumps like the Goulds 3196. This makes it a favorite for facilities looking to replace outdated or underperforming pumps without overhauling their piping systems.

• Flow rates up to 7,000 GPM

• Heads to 730 feet

• 28 different casing sizes

• Cast iron, ductile iron, stainless steel, and special alloys available

• Open and enclosed impeller designs

• Seal chamber options: standard, enlarged, and ISO

Whether you’re dealing with corrosive chemicals, abrasive slurries, or temperature-sensitive fluids, there’s a Griswold pump and part to match.

Case Study: Pulp & Paper Facility in Arkansas

A pulp processing facility in Arkansas was experiencing repeated failures in a fleet of aging Goulds 3196 pumps. Sourcing parts had become difficult due to long lead times and discontinued SKUs. The facility turned to Industrial Air Services for help.

Using the Griswold Interchangeability Tool, Industrial Air Services:

• Identified Griswold 811 replacements for the failing pumps

• Provided drop-in-compatible impellers and mechanical seals

• Delivered parts and installation support within 48 hours

• Helped the facility consolidate spares for future use

Result: Downtime was cut by 90%, and the facility has since standardized new installations on the 811 ANSI line.

📞 Want results like this? Call Industrial Air Services at (615) 641-3100.

How to Use the Interchangeability Tool

1. Visit the Griswold website and navigate to the Interchangeability Part Number Lookup Tool

2. Enter your existing pump model or part number

3. Review the Griswold part recommendations

4. Contact Industrial Air Services for availability, quotes, or technical assistance

It’s a simple 3-minute process that can save your team hours—or even days—of downtime.

Why Choose Industrial Air Services?

At Industrial Air Services, we’re more than just a distributor—we’re your pump system partner. As a proud provider of Griswold pumps and parts, we bring decades of experience to help you streamline operations and keep your facility running at peak performance.

• Application support and product selection

• On-site evaluations and walk-throughs

• Emergency parts delivery

• Pump system audits and upgrades

• 24/7 support for critical systems

📞 Get expert help today by calling (615) 641-3100.

Conclusion

Griswold’s Interchangeability Tool isn’t just convenient—it’s a maintenance game-changer. With fast, accurate access to equivalent ANSI parts, maintenance teams can reduce downtime, improve efficiency, and gain control over pump inventory. When paired with the rugged, reliable performance of the 811 ANSI Series, your operation has the tools it needs to stay ahead.

This blog is proudly provided by Industrial Air Services, with offices in Nashville, Knoxville, and Chattanooga. For help cross-referencing parts or upgrading your pumps, call (615) 641-3100 or reach out to our team today.