How smarter vacuum technology can support automation, efficiency and productivity?
Manufacturing environments rarely stay the same for long. Production volumes change, machinery is upgraded, automation increases and processes become more demanding.
Those changes can have a direct impact on vacuum requirements.
A vacuum system that was correctly specified when a production line was installed may not necessarily remain the most appropriate solution as the operation evolves. Changes in duty cycles, airflow requirements, production speed and the number of vacuum points can all affect system performance.
The question is not simply whether the vacuum pumps are still operating.
The more important question is whether the vacuum system is still matched to the production process.
Vacuum demand is rarely constant
Many industrial applications do not require a fixed level of vacuum throughout the production cycle.
Demand can increase and decrease depending on the number of machines operating, the stage of the process or the requirements of individual applications. In automated production, these changes can happen frequently. A fixed-speed pump running continuously at a predetermined output may therefore be supplying more capacity than the process requires at certain points.
This is where system control becomes important. Rather than designing around maximum demand alone, a properly configured system can respond to the actual requirements of the process.
Matching vacuum output to production demand
Variable speed technology provides one way of achieving this.
Becker’s VARIAIR technology uses frequency-controlled motors to adjust pump output according to the requirements of the application. Its control system continuously compares set and actual values and adjusts operation accordingly. For applications with fluctuating demand, this can provide a more precise approach than regulating a fixed-speed pump through throttling or bypass methods. The principle is straightforward: supply the vacuum required by the process, rather than continuously generating more capacity than the application needs.
This can also be particularly relevant where production processes are automated and vacuum requirements form part of a wider machine control system. Becker’s VARIAIR technology is designed to integrate with production controls and automatically adapt air supply to changing process requirements.
When a centralised system makes sense
The way vacuum is distributed throughout a facility also deserves consideration.
As operations expand, it is common to find multiple individual pumps supporting different machines or production areas. While this can work effectively for individual applications, it may not always be the most efficient way to manage vacuum across a larger operation. A centralised vacuum system allows multiple requirements to be supplied from a coordinated pump system.
Becker central systems can incorporate multiple pumps, reserve capacity, lead/lag control and variable speed drives. Modular configurations can also allow capacity to be expanded as production requirements change.
For some facilities, centralisation can also move pumps away from production areas, reducing the noise and heat generated around machinery. The important consideration is not whether centralisation is inherently better than individual pumps. It is whether the system architecture suits the way the facility operates.
Getting the capacity right
There is also a difference between having sufficient vacuum capacity and having the right amount of capacity. An undersized system may struggle to maintain the required vacuum when demand increases. An oversized system, meanwhile, may provide substantially more capacity than the application normally requires. Correct system sizing starts with understanding the process.
That includes the required vacuum level, airflow, duty cycle, number of vacuum points, production schedule and expected changes in demand. Future expansion should also be considered where appropriate.
This is why vacuum system design cannot always be reduced to selecting a pump from a catalogue. The pump technology, controls, system configuration and application all need to work together.
Becker’s engineering approach covers individual pumps and compressors through to complete pneumatic and centralised systems, with solutions selected around the requirements of the application. Becker states that its equipment is used across more than 2,000 applications worldwide.
Where smarter vacuum technology can add value
The benefits of getting the system design right extend beyond the vacuum pump itself. In automated packaging, for example, vacuum can be integral to pick-and-place systems, cartoning, stamping and conveying, where short cycle times and consistent operation are important. Becker supplies vacuum pumps, compressors and intelligent control solutions for these applications.
In woodworking and CNC applications, vacuum can be used for clamping and material handling. In printing and paper processing, variable airflow can support high-speed production and short changeover times. The application determines the requirement. That is why the right vacuum solution is not necessarily the largest pump, the newest technology or the most complex system.
It is the system that delivers the required vacuum performance, at the required point of use, with the right level of control for the production process.
Is your existing system still the right fit?
If your production has changed since your vacuum system was originally installed, it may be worth reassessing the system against today’s requirements.
Consider:
- Has production volume or operating hours increased?
- Have new machines or vacuum points been added?
- Does vacuum demand fluctuate significantly during production?
- Are individual pumps operating independently across the facility?
- Is there a requirement for greater control or integration with production equipment?
- Is future expansion likely to change the system requirements?
These questions can reveal whether the existing configuration is still appropriate or whether there is an opportunity to improve the way vacuum is generated and controlled.
A vacuum system should support production, not constrain it
Vacuum is often one component within a much larger manufacturing process, but its performance can have a direct impact on how that process operates.
As production becomes more automated and requirements become more variable, vacuum systems need to be considered in the same way as other critical production equipment: according to the actual demands of the process.
That may mean variable speed control. It may mean centralisation. It may simply mean reviewing whether the current pump technology and capacity remain appropriate. The starting point is understanding the application.
Becker Pumps Australia works with manufacturers across Australia to develop vacuum and compressed air solutions for a wide range of industrial applications.
If your production requirements have changed, it may be time to review whether your vacuum system has changed with them.
