How to Choose a Vacuum Pump
Selecting the right vacuum pump for your operation is critical to efficiency, cost savings, and minimizing downtime. Whether you're in secondary packaging, thermoforming, CNC routing, printing, composites, or another vacuum-reliant industry, choosing the right pump reduces maintenance costs and energy consumption while maximizing performance.
With so many vacuum pump technologies available, how do you make the best choice? Here’s a comprehensive guide to help you find the right vacuum solution for your needs.
Understanding Your Application’s Vacuum Needs
The first step in selecting a vacuum pump is understanding how and why you need vacuum in your process. The key factors include:
✅ Constant vs. Intermittent Vacuum – Does your process require a continuous vacuum, or does it need periodic suction with cycling on and off?
✅ Process Residues & Contaminants – Are there dust, particulates, or moisture that could enter the pump?
✅ Temperature Sensitivity – Does your operation require handling hot, cold, or fluctuating temperatures?
✅ Material Properties – Are there gases or substances that change state when vacuum is applied?
Each of these factors will determine which vacuum technology is best suited to your application.
Choosing the Right Vacuum Pump Technology
Vacuum pumps come in several different types, each with unique strengths depending on the application’s demands.
1. Dry Rotary Vane Vacuum Pumps
✅ Best for: CNC Routing, Printing, and Packaging
✅ Why Choose This Pump?
✔ Oil-free operation reduces contamination risks
✔ Low maintenance requirements
✔ Consistent vacuum levels for continuous processes
💡 Ideal for applications where clean, dry air is essential and maintenance should be minimal.
2. Oil-Lubricated Rotary Vane Vacuum Pumps
✅ Best for: Thermoforming, Secondary Packaging, and Heavy-Duty Industrial Use
✅ Why Choose This Pump?
✔ Handles high vacuum levels efficiently
✔ More durable in demanding applications
✔ Works well in moisture-prone environments
⚠️ Considerations: Requires oil changes and exhaust filter replacements to prevent contamination.
💡 Great for operations that need high vacuum performance but can accommodate regular maintenance.
3. Hook & Claw Vacuum Pumps
✅ Best for: High-Efficiency Industrial Applications & Heavy Lifting
✅ Why Choose This Pump?
✔ Energy-efficient design reduces operational costs
✔ Maintenance-free for up to 20,000 hours
✔ Operates at all pressure levels between atmospheric and maximum vacuum
💡 Ideal for businesses that need powerful, reliable vacuum solutions with minimal maintenance.
4. Regenerative Blowers
✅ Best for: Cardboard Handling, Large Suction Cup Applications, and Light Materials
✅ Why Choose This Pump?
✔ High flow rates with low-to-medium vacuum
✔ Compact and lightweight design
✔ Oil-free operation for clean air handling
💡 Perfect for high-speed applications requiring airflow rather than deep vacuum levels.
Factors That Affect Vacuum Pump Selection
Aside from the technology type, several other factors will influence your choice:
🔹 Operating Environment: Will the pump be exposed to high humidity, chemicals, or extreme temperatures?
🔹 Energy Efficiency: Does your facility need a low-power-consumption solution?
🔹 Noise Levels: Some pumps are quieter than others, which may be crucial in noise-sensitive environments.
🔹 Maintenance Schedule: Consider the time and cost associated with routine maintenance.
🔹 Space Constraints: Does your production line require a compact, integrated vacuum pump?
Why Choose Bobcat Industrial Air Services for Your Vacuum Pump Needs?
At Bobcat Industrial Air Services, we help businesses select, install, and maintain vacuum solutions to ensure optimal performance for your specific industry.
🔹 Expert Consultation – We assess your vacuum needs and recommend the best pump for efficiency and cost savings.
🔹 Reliable Equipment – We provide industry-leading vacuum pump solutions designed for durability and performance.
🔹 Comprehensive Support – From installation and servicing to replacement parts, we help keep your operations running smoothly.
📞 Need help choosing the right vacuum pump? Contact us today for a consultation!
Once these application parameters are nailed down, the main factors that will determine the specific make and model vacuum pump to choose are:
Required vacuum level
Volume flow (cfm)
Piping/setup
Lastly, take into account your willingness to provide maintenance/service at the recommended intervals. The amount of time and investment required for these activities depends on the make and model of the pump.
Generally speaking, filtration and the right ambient conditions keep the pump healthy.
CONSEQUENCES OF CHOOSING THE WRONG VACUUM PUMP
When choosing the best vacuum pump for a specific application it’s crucial to apply the right amount of vacuum. For instance, a food product could start boiling if the vacuum level is too high. This can lead to a damaged product and additionally, the vapor may damage the pump.
In other instances, e.g. vacuum fixing or pick and place operations, too low a vacuum level can result in a risk for machine operators and machines due to a lack of clamping force.
The wrong pump choice may influence the process outcome, energy efficiency, service intervals, and many other aspects critical to your operation. Because of these factors, anything could happen – from an explosion or fire, to not working properly or the product/process being affected negatively.
VACUUM LEVELS
Vacuum pressure levels are generally classified as rough, medium, or high vacuum. Different companies and experts talk about vacuum levels differently and use different measurement units, so it’s important to clarify. Vacuum pressure can be measured in units of Torr, millibar, microns, or inches of mercury, Pascals (Pa), psi, etc.
So, for instance, a rough vacuum theoretically goes up to 1 millibar or roughly 29.8 inches of mercury. At Becker, we don’t use these terms scientifically, so when we say rough vacuum, we’re typically referring to about 15-20” of mercury or less.
There is a caveat to this. Most vacuum pump manufacturers, ourselves included, say we offer “full vacuum” pumps or to 29.99” of mercury. However, it’s rare for most industrial applications to require that level of vacuum. Most customers who say “I need full vacuum” don’t actually need it, and most companies like Becker will use the term “full vacuum” to mean something above 29” and then further qualify on a per-application basis.
VACUUM VS. FLOW
A vacuum occurs in any place where the gas pressure is lower than the Earth’s atmospheric pressure, which is approximately 14.7 psi (pounds per square inch). To create a vacuum, there must be a flow of gas or liquid from one location to another. Molecules of gas are constantly moving, putting pressure on the surrounding surfaces. As molecules are pumped away from an area, the pressure drops, and a vacuum is created.
Sometimes customers need a high flow but only a low vacuum level. For instance, a fan moves air at a high rate of flow but doesn’t create a vacuum (or only a very nominal vacuum). Other times a customer may need a really high vacuum level. The higher the vacuum, the lower the flow.
In “real” terms this makes sense. A vacuum has to pull molecules from somewhere which causes a corresponding reaction. To get high levels of vacuum, eventually, the flow will have to decrease as you’re pulling from less available volume.
GENERAL RECOMMENDATIONS FOR BECKER PUMPS
Rough vacuum – less than 15” of mercury. With less than 15” customers will also typically need higher flows. We’d recommend a regenerative blower.
Medium vacuum – 15” to 26” of mercury. We recommend dry rotary vane lines.
High vacuum – 26” to 29.92” of mercury. We recommend lubricated vane or claw pumps.
Fine or ultra vacuum – 29.92” of mercury and up. Screw pumps, and other lubricated pumps.
FINAL ADVICE ON CHOOSING A VACUUM PUMP
Finally, specific features or technologies can enhance the functionality and versatility of the vacuum pump you select. These may include filtration, the correct oil (in lubricated pumps), and gas ballast valves.
Remember, in the case of vacuum pumps, bigger is not always better! An oversized pump is only sometimes beneficial. Focusing on the volume flow and pressure level is more important than the installed motor – a larger motor is often a waste of money.
Becker Pumps is a leading manufacturer of vacuum pumps for a wide range of industries and applications. We have the knowledge and expertise to help you make the right pump selection for your specific needs.
