Designing for Success: How Dekker Helps OEMs Integrate Vacuum Pumps Seamlessly into Their Equipment

Provided by Industrial Air Services – Dekker OEM integration specialists in Nashville, Knoxville & Chattanooga. Call (615) 641-3100 to collaborate on custom vacuum solutions for your equipment builds.

For original equipment manufacturers (OEMs), every component must deliver on performance, reliability, and footprint efficiency. In systems ranging from automated packaging machines to medical processing units and industrial skids, vacuum functionality is often essential—but challenging to design around. That’s where Dekker Vacuum Technologiesstands out as an ideal partner for OEMs who demand custom-fit, dependable vacuum integration.

Through compact, quiet, and efficient vacuum pump systems—like the DuraVane, Vmax, and Maxima series—Dekker works closely with OEMs to ensure seamless integration into production machinery, modular systems, or self-contained units. Combined with local application support from Industrial Air Services, this partnership delivers vacuum performance that’s engineered, not improvised.

Let’s take a closer look at how Dekker supports OEM success and why Industrial Air Services is the preferred resource for OEMs across Tennessee and the Southeast.

Why OEMs Choose Dekker Vacuum Systems

OEMs in fields like food packaging, CNC machining, medical devices, electronics, pharmaceuticals, and plastics require vacuum systems that offer:

– Compact design and flexible mounting
– Quiet, low-vibration operation
– Energy-efficient motors
– Repeatable vacuum performance under load
– Low maintenance for end-users
– Simple integration with electrical controls and automation

Dekker excels in all these areas—offering high-performance, application-specific vacuum systems with factory-level engineering support.

Dekker’s OEM-Friendly Pump Series

DuraVane Rotary Vane Pumps
These oil-lubricated rotary vane pumps are ideal for light-to-medium duty applications requiring steady vacuum and minimal service. Quiet, compact, and available in multiple mounting configurations, DuraVane units are used in:

– Medical suction and evacuation
– Thermoforming machines
– Pick-and-place and robotics
– Dental and veterinary systems
– Lab and cleanroom filtration setups

Vmax Oil-Sealed Liquid Ring Systems
For systems handling moisture-laden or dirty gases, Dekker’s closed-loop Vmax systems offer unmatched durability and cleanliness. OEMs use these in:

– Food processing equipment
– Chemical pilot plants
– Degassing and drying skids
– Waste gas extraction and filtration

Maxima Liquid Ring Pumps
For high-volume OEM builds, such as central vacuum stations or environmental remediation skids, Maxima series pumps are available with modular components, flange compatibility, and custom baseplate sizing.

Design Flexibility: Mounting and Customization Options

Dekker offers a wide variety of configurations to help OEMs adapt vacuum components to tight spaces or unique layouts, including:

– Horizontal and vertical motor arrangements
– Base-mounted, tank-mounted, or skid-mounted formats
– Low-profile and noise-reduced enclosures
– Custom discharge or inlet locations
– Multiple motor voltages and NEMA frame options
– Panel-ready or open-lead motor configurations

Industrial Air Services assists with CAD modeling, clearance checks, and field-fitting components to ensure a perfect mechanical and electrical fit.

Case Study: OEM Packaging Integrator in Chattanooga

A Chattanooga-based packaging equipment OEM needed a reliable vacuum source for its automated bag-sealing lines. The requirements included a small footprint, quick start-up time, and consistent vacuum levels for clean seal integrity.

Industrial Air Services worked with Dekker to supply DuraVane rotary vane systems custom-mounted on the OEM’s stainless control frame, pre-wired for PLC control and fitted with inline filters and mist eliminators.

Results: – Reduced integration time by 60%
– 20% energy savings vs. previous OEM vacuum brand
– Simplified shipping and installation at the end-user site
– Zero field failures after two years in operation

Control System Integration

Dekker pumps can be built with electrical packages that integrate into OEM control systems using:

– Dry contact relays
– VFD-ready inputs
– PLC communication protocols (Modbus, Ethernet/IP)
– Pressure and temperature sensors
– Remote on/off, emergency stop, and status signals

For multi-machine platforms or high-volume production lines, Industrial Air Services can help design vacuum modules that plug into broader automation systems for complete operational visibility.

Engineering Collaboration and Lead Time Support

OEM timelines can be tight. That’s why Dekker and Industrial Air Services offer:

– Rapid prototyping and sample units
– Component drawings and 3D models
– Fast-turnaround build schedules for repeat orders
– Dedicated application support during design and fielding
– Logistics coordination for batch production shipments

Our goal is to become an extension of your engineering team—not just a parts supplier.

Benefits for End-Users (Your Customers)

OEMs that choose Dekker vacuum systems provide their customers with:

– Reliable, consistent vacuum performance
– Quieter equipment operation
– Easier servicing with long intervals between maintenance
– Access to local Dekker-certified support through Industrial Air Services
– Replacement parts, fluids, and documentation easily available
– Systems that are energy-conscious and environmentally efficient

This improves your equipment’s reputation and reduces the need for service callbacks or warranty issues.

Why Partner with Industrial Air Services?

Industrial Air Services is a full-service Dekker distributor with dedicated support for OEMs, integrators, and equipment builders. We provide:

– Product sizing and application matching
– Mounting and control system guidance
– Pre-assembly or integration support
– Service manuals and user documentation tailored to your platform
– Ongoing inventory and logistics coordination
– Field support for your customer base

We serve OEMs across Nashville, Knoxville, and Chattanooga, helping you deliver equipment that’s smarter, cleaner, and easier to maintain.

Conclusion

When your equipment relies on vacuum, make sure your vacuum partner understands your build process, timeline, and performance goals. With Dekker’s OEM-ready vacuum systems and expert local support from Industrial Air Services, your team can integrate reliable, efficient vacuum into any design—without the guesswork.

Call Industrial Air Services at (615) 641-3100 today to request OEM pricing, engineering consultation, or sample system evaluation.

Energy Savings in Vacuum Applications: How Dekker Delivers Sustainable Performance

Provided by Industrial Air Services – Dekker Vacuum experts serving Nashville, Knoxville & Chattanooga. Call (615) 641-3100 for energy-efficient vacuum solutions, audits, and system upgrades.

In today’s industrial environment, energy efficiency is no longer optional—it’s essential. Manufacturers face increasing pressure to reduce operational costs, meet sustainability goals, and comply with energy regulations. Vacuum systems, often overlooked in energy evaluations, can be a major contributor to plant power consumption and a hidden opportunity for savings.

Dekker Vacuum Technologies leads the way in developing high-efficiency vacuum systems that reduce waste, lower energy usage, and maintain exceptional performance across industries. Whether you operate a small CNC shop or a multi-line chemical processing facility, Dekker’s smart vacuum design can help you meet your performance goals while cutting energy bills.

At Industrial Air Services, we specialize in auditing, designing, and servicing Dekker vacuum systems that prioritize both performance and efficiency.

The Energy Cost of Vacuum

Vacuum pumps are heavy-duty equipment that often run 24/7 in support of packaging, drying, forming, conveying, and processing applications. When improperly sized or poorly maintained, vacuum systems can account for up to 20% of a facility’s total energy consumption.

Common energy inefficiencies include: – Oversized pumps running under light load
– Pumps running continuously in batch operations
– Poor system design with long pipe runs or leakage
– Lack of automation or pressure control
– Heat and friction losses due to wear or improper sealing
– Water waste in open-loop liquid ring systems

These inefficiencies not only drive up energy costs but also shorten the life of vacuum equipment and increase maintenance needs.

How Dekker Designs for Efficiency

Dekker takes a holistic approach to vacuum system design, focusing on total lifecycle efficiency. Key features include:

Closed-loop liquid ring systems
Dekker’s Vmax and ChemSeal systems use oil or glycol as a seal fluid in a closed loop. This eliminates the need for continuous fresh water input and prevents energy loss through fluid cooling and discharge.

Right-sizing for true demand
Dekker engineers and Industrial Air Services work together to ensure every system matches the actual flow and pressure needed—reducing wasted horsepower and energy draw.

Variable frequency drives (VFDs)
When paired with pressure transducers, Dekker pumps can ramp up or down in real time based on demand. This avoids unnecessary full-speed operation and reduces wear.

Smart controls and sequencing
In multi-pump systems, Dekker includes automatic lead-lag sequencing, load balancing, and digital controls to rotate pump duty and prevent overuse.

High-efficiency motors
All Dekker systems can be supplied with premium-efficiency or inverter-duty motors that meet or exceed DOE energy standards.

Low-slip pump designs
Precision machining, durable seals, and smooth fluid paths reduce internal leakage and resistance, allowing for faster evacuation and more consistent vacuum at lower energy input.

Real-World Example: Packaging Plant in Knoxville

A regional food packaging facility operated four legacy rotary vane pumps that ran continuously regardless of demand. After an energy audit by Industrial Air Services, the plant replaced the setup with a Dekker Vmax closed-loop systemwith two pumps and VFD control.

Results: – Energy consumption dropped by 36%
– Maintenance intervals extended by 40%
– Water usage eliminated (over 200,000 gallons/year saved)
– Payback period: 16 months
– Improved uptime and pressure stability

This single upgrade brought the facility into compliance with its corporate sustainability initiative and reduced utility spend by tens of thousands annually.

Energy Audit and System Evaluation Services

Industrial Air Services offers onsite energy audits to evaluate vacuum system performance and identify areas of waste or inefficiency. Our audits typically include: – System flow and vacuum level testing
– Motor load and power draw monitoring
– Seal fluid and piping inspection
– Leak detection and system integrity checks
– Usage pattern analysis (batch vs. continuous)
– ROI projections for upgrade or replacement options

We follow up with a detailed report and recommendations customized to your facility.

Integrating VFD and Smart Controls

One of the simplest and most impactful upgrades to any vacuum system is VFD integration. VFDs allow the pump to modulate speed based on actual demand, which can reduce energy use by 20–50% depending on the process.

Dekker VFD systems can be integrated into: – Vmax liquid ring packages
– DuraVane rotary vane systems
– Central vacuum stations
– Existing systems with compatible motors

Industrial Air Services can retrofit your current system or design a fully automated package with touch panel controls, remote monitoring, and SCADA integration.

Reducing Water Waste with Closed-Loop Systems

Traditional liquid ring pumps often rely on open-loop water systems, where thousands of gallons per day are used for cooling and sealing—and then discharged to waste.

Dekker’s closed-loop designs eliminate this waste entirely by: – Reusing oil or glycol with minimal top-off
– Including separators, filters, and heat exchangers to maintain fluid quality
– Preventing environmental discharge and permitting issues
– Qualifying for water conservation rebates in many municipalities

Sustainability isn’t just good for the environment—it saves real money over time.

Why Industrial Air Services?

As a regional Dekker Vacuum partner, we help facilities design smarter systems that reduce both power and maintenance overhead. Our services include: – Energy audits and performance benchmarking
– Equipment upgrades and turnkey system installation
– Dekker VFD and automation integration
– Preventive maintenance and predictive diagnostics
– Service plans to keep systems running at peak efficiency

We serve clients in Nashville, Knoxville, Chattanooga, and surrounding areas, with fast, local support and deep vacuum system expertise.

Conclusion

If your vacuum system is outdated, oversized, or inefficient, you may be spending far more on electricity, water, and maintenance than you realize. Dekker’s energy-efficient designs—especially when paired with expert support from Industrial Air Services—can help your facility meet its performance and sustainability targets while protecting your bottom line.

Call Industrial Air Services at (615) 641-3100 today to schedule an energy audit or explore upgrade options for your vacuum system.

Achieving Cleanroom-Grade Vacuum with Dekker’s DuraVane Pumps

Provided by Industrial Air Services – Your Dekker Vacuum expert in Nashville, Knoxville & Chattanooga. Call (615) 641-3100 for product selection, service, or system design.

Clean environments demand clean solutions. In industries like pharmaceuticals, medical device manufacturing, electronics, and R&D labs, vacuum systems must operate quietly, efficiently, and without contaminating sensitive processes. That’s where Dekker’s DuraVane rotary vane vacuum pumps stand out.

Compact, oil-lubricated, and precision-engineered for performance and reliability, the DuraVane series offers a dependable vacuum source for cleanroom-grade and light industrial applications. These pumps are ideal for facilities that need tight process control, low noise levels, and minimal maintenance—all without compromising on vacuum performance.

At Industrial Air Services, we help facilities across Tennessee source, install, and maintain DuraVane pumps as part of high-performance cleanroom and lab environments.

What Makes DuraVane the Right Fit for Clean Applications?

DuraVane rotary vane pumps are single-stage, oil-lubricated units designed to create consistent vacuum at mid- to deep-range pressures. They use an off-center rotor and spring-loaded vanes to compress air as it moves through the pump chamber. A small amount of oil provides lubrication, sealing, and cooling—ensuring high performance and quiet operation.

Key advantages include: – Quiet operation, ideal for cleanrooms and labs
– Compact footprint and minimal vibration
– Consistent vacuum performance (down to ~1 Torr)
– Easy maintenance with long-life vanes and filters
– Oil mist separator for clean exhaust
– Configurable as standalone or integrated into OEM equipment

These features make DuraVane pumps suitable for a wide range of clean, dry gas applications where space and precision are essential.

Industries That Rely on DuraVane Pumps

DuraVane systems are used in industries where cleanliness, efficiency, and dependability are critical:

– Pharmaceutical production: capsule filling, vacuum drying, packaging
– Medical device assembly: sterile product handling, leak testing
– Electronics manufacturing: board handling, degassing, vacuum ovens
– Laboratory environments: filtration, aspiration, glove boxes
– Printing and packaging: die-cutting, skin packaging, thermoforming
– Dental and veterinary offices: suction and evacuation systems

Because they offer steady performance with very low noise and vibration, DuraVane pumps are especially popular in environments where personnel work in close proximity to the vacuum system.

Compact Design for OEM and Modular Use

DuraVane pumps are available in a wide range of sizes—from small, bench-top units to 10 HP+ industrial systems. Industrial Air Services frequently works with OEMs and integrators to build DuraVane pumps into:

– Cleanroom air handling equipment
– Medical gas delivery systems
– Automated production cells
– Lab-grade filtration systems
– Small-scale vacuum packaging machines

These pumps are available in base-mounted or tank-mounted designs and are often combined with inlet filters, check valves, and exhaust filters for plug-and-play use.

Cleanroom Compliance and Air Quality

One of the main concerns in controlled environments is air contamination from pump exhaust. DuraVane pumps solve this with:

– High-efficiency oil mist eliminators
– Optional HEPA or carbon filtration on discharge
– Fully sealed casings to prevent oil vapor leakage
– Smooth, low-pulse operation to minimize airborne particles

Dekker’s oil-lubricated design, when properly filtered and maintained, meets the cleanliness standards for many ISO 14644-classified cleanroom applications.

Case Study: Biotech Lab in Chattanooga

A biotech lab in Chattanooga needed a vacuum source for its cleanroom-grade tablet testing lab. The system required <5 Torr vacuum levels, low noise, and zero oil mist. Industrial Air Services installed two DuraVane 4 HP pumps with mist separators, inline inlet filtration, and quick-disconnect service ports.

Results: – Measured vacuum held steady at 3.5 Torr under load
– Sound levels remained below 68 dBA at 3 feet
– No detectable oil vapor in exhaust or ambient air
– Maintenance intervals extended to 12+ months between service

This installation allowed the lab to meet both internal air quality standards and process performance benchmarks—without costly infrastructure upgrades.

Simple Maintenance and Long Operating Life

DuraVane pumps are known for low maintenance requirements and long vane life. With proper oil changes and occasional filter replacement, most pumps run for thousands of hours without issue.

Industrial Air Services recommends: – Changing oil every 1,500 to 3,000 hours
– Replacing vanes and seals every 10,000 to 15,000 hours (depending on duty cycle)
– Cleaning or replacing inlet filters regularly to prevent restriction
– Monitoring for pressure loss or noise changes as early signs of wear

We stock DuraVane oils, vanes, filters, and gaskets for fast turnaround and offer preventive maintenance programs for multi-pump installations.

Why Choose Dekker’s DuraVane Series?

DuraVane rotary vane pumps stand out in their category due to: – Precision-machined tolerances for long-term efficiency
– Smooth, quiet operation ideal for sensitive environments
– Versatility in lab, OEM, and light industrial settings
– Reliable vacuum levels in clean, dry gas applications
– Trusted performance backed by Dekker’s engineering and quality control

When paired with local service and support from Industrial Air Services, DuraVane pumps offer a turnkey solution for cleanroom and controlled-environment vacuum needs.

Working with Industrial Air Services

As a Dekker-certified partner, we offer: – Sizing and application consultation
– System design and integration for OEMs
– On-site installation and commissioning
– Maintenance training and PM plans
– Factory-authorized parts and service
– Responsive support across Nashville, Knoxville, and Chattanooga

Whether you need a single tabletop pump or a multi-station cleanroom vacuum system, we’ll help you get it right the first time.

Conclusion

If your vacuum system plays a role in quality control, product integrity, or regulatory compliance, you can’t afford unpredictable performance. With Dekker’s DuraVane rotary vane pumps, you get quiet, consistent, and contamination-free vacuum—perfect for cleanrooms, labs, and precision environments.

Call Industrial Air Services at (615) 641-3100 today to request a quote, schedule a site consultation, or build a custom DuraVane package for your application.

Inside the Maxima Series: Dekker’s Answer to Rugged, High-Capacity Liquid Ring Vacuum Systems

Provided by Industrial Air Services – Your authorized Dekker Vacuum partner serving Nashville, Knoxville & Chattanooga. Call (615) 641-3100 for system design, installation, and support.

When industrial operations demand high-capacity vacuum performance under constant load, reliability becomes more than a benefit—it becomes a necessity. From pulp and paper processing to mining, food production, and large-scale environmental systems, the need for continuous-duty, rugged vacuum equipment is universal.

That’s exactly why Dekker developed the Maxima Series—a heavy-duty line of liquid ring vacuum pumps built to deliver unmatched performance in high-demand, industrial environments. With a combination of durable construction, excellent vapor-handling capability, and straightforward maintenance, the Maxima Series is engineered to run long hours with minimal intervention.

At Industrial Air Services, we help facilities across Tennessee choose, install, and maintain Maxima systems that perform day after day—often for decades.

What Is the Maxima Series?

The Maxima Series from Dekker is a line of single-stage and two-stage liquid ring vacuum pumps designed to handle high volumes of gas and vapor, typically ranging from 40 to over 15,000 CFM. These pumps are water-sealed (though oil sealing is optional) and use centrifugal force and an offset rotor to form a liquid ring, compress gas, and generate vacuum.

With models available in a variety of configurations—including monoblock, bare pump, and complete systems—the Maxima series offers flexibility for both OEM integration and standalone use in central vacuum plants.

Key Features of the Maxima Series

– Capacities from 40 CFM to over 15,000 CFM
– Vacuum levels down to 25 Torr on single-stage units
– Two-stage options for deep vacuum (to 3 Torr)
– Cast iron, stainless steel, or special alloy construction
– Heavy-duty shaft and bearing systems
– Optional seal liquid recovery and recirculation
– Can operate with water, glycol, or oil sealants
– Ideal for saturated vapor and contaminated gas streams

Why Choose Maxima for Heavy-Duty Applications?

The Maxima series excels in demanding environments that require high flow, high uptime, and the ability to handle saturated or dirty gas streams. Its wide operating range and customizable options make it a favorite in industries where a smaller pump simply won’t hold up over time.

Typical applications include:

– Pulp and paper: suction couch rolls, dewatering, press section
– Power generation: condenser evacuation, transformer drying
– Food processing: vacuum cooling, packaging, bulk transfer
– Chemical and petrochemical: vapor recovery, reactor evacuation
– Mining: filtration, slurry dewatering, gas extraction
– Environmental: soil remediation, vapor extraction

With its robust build and simple operation, the Maxima series is designed to run 24/7 under tough conditions—often in remote or difficult-to-service areas.

System Design and Custom Packages

Industrial Air Services works closely with Dekker to build Maxima systems into custom-engineered vacuum packagesthat include:

– Pump and motor mounted on a structural steel base
– Seal liquid reservoir and filtration system
– Inlet separators, check valves, and discharge silencers
– Temperature and pressure gauges
– Control panels with VFD and remote monitoring capability
– Optional PLC or SCADA integration

These systems arrive factory-tested and ready to install, reducing your installation time and risk.

Case Study: Pulp & Paper Facility in Eastern Tennessee

A regional paper mill was operating four 25-year-old vacuum pumps that required constant repair and couldn’t handle the mill’s new production speed. They installed a pair of Dekker Maxima 1500 CFM single-stage pumps with a custom fluid recovery system.

Results:

– Increased press section vacuum stability by 30%
– Reduced downtime by 85%
– Improved sheet moisture control and paper quality
– ROI in just 14 months due to reduced maintenance and scrap rates

This upgrade helped the mill meet production goals while preparing for future capacity expansion.

Why Liquid Ring?

For many high-volume industrial applications, liquid ring vacuum pumps remain the best option due to:

– Ability to handle wet and vapor-laden gases
– Simple internal design with few moving parts
– Minimal sensitivity to particulate carryover
– Built-in cooling from seal fluid
– Stable operation under variable load conditions

The Maxima Series takes these advantages and scales them up—making them ideal for centralized vacuum systems or heavy-duty processing lines.

Maintenance and Longevity

One of the biggest benefits of the Maxima Series is how easy it is to maintain. With proper seal fluid care and routine inspections, these pumps often operate for decades without rebuild.

Industrial Air Services provides preventive maintenance services including:

– Seal liquid analysis
– Impeller clearance checks
– Shaft seal inspection
– Reservoir flushing and filter changes
– Rebuilds and upgrades with OEM parts

When paired with scheduled service and fluid monitoring, Maxima pumps can deliver 20+ years of reliable operation.

FM Approval and Explosion-Proof Configurations

For hazardous or classified areas, Maxima pumps are available with:

– FM-approved motors
– Intrinsically safe sensor circuits
– Explosion-proof junction boxes and wiring
– Corrosion-resistant coatings and materials

These configurations ensure safety and compliance in environments with volatile organic compounds, solvents, or dust risks.

Why Choose Industrial Air Services?

As a Dekker-authorized distributor and service provider, we offer:

– Application review and vacuum audits
– Custom Maxima system design and sizing
– Turnkey installation and startup
– 24/7 field service and troubleshooting
– In-stock fluids, filters, and wear parts
– Preventive maintenance programs to extend pump life

With offices serving Nashville, Knoxville, and Chattanooga, we provide fast, local support backed by factory-trained technicians.

Conclusion

When you need vacuum that works hard—day after day, year after year—the Dekker Maxima Series delivers. Designed for high-flow, heavy-duty applications and built with materials that withstand the harshest conditions, it’s the vacuum pump series trusted by plants that can’t afford downtime.

Call Industrial Air Services at (615) 641-3100 today to request a Maxima system quote, on-site evaluation, or design consultation tailored to your facility’s unique demands.

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.