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Vacuum Generators Controlled by Compressed Air May Be Wasting Tens of Thousands of Dollars in Energy Costs per Year!

October 5, 2006 09:34 AM

Michigan City, IN, October 5, 2006 - If you are currently using compressed air to generate vacuum, then consider a more efficient and cost-effective alternative such as a dedicated mechanical vacuum pump system from DEKKER Vacuum Technologies, Inc. 

The problem in a typical compressed air/vacuum generator installation is that the generator regulates 100 psig compressed air from a central compressor system down to anywhere from 30 to 90 psig.  This regulation is a major source of inefficiency.

In most cases, compressed air flows through the system even when no vacuum is needed. For example, during an average evacuation/hold/release cycle, compressed air may only be needed for one-third of the cycle.  During the other two-thirds of the cycle, compressed air continues flowing needlessly wasting energy.

While the entire system is under pressure, losses through ancillary equipment, headers, and the partial loading of compressors reduce overall system efficiency.  Although built-in shut off valves are supposed to help avoid this problem, they are often bypassed, leaky or ineffective. 

The bottom line is that compressed-air vacuum generators are inefficient and expensive to run.

In a cost comparison study a 75HP compressor/vacuum generator system with 20 ejectors/hook-up points running 2000 hours per year (@ $.10 per kW/Hr), tallies up an annual operating cost of $18,675. 

The alternative is a central mechanical vacuum system.  Like a compressed air system, vacuum can be generated from a central location (avoiding noise at the point of use) and distributed through a network of headers and drops.  However, unlike compressed air, vacuum piping can be made of less expensive materials such as PVC.

A central mechanical vacuum pump system, with careful attention to pipe diameter and isolation valve placement, will provide the same service in the same amount of space as an air compressor/vacuum generator system, but use only a fraction of the energy.

Switching to a 10HP dedicated central mechanical vacuum pump system with 20 vacuum usage points will reduce the annual operating cost from $18,675 to $1,840, saving $16,835 per year.  This would be more than enough to pay for the $8,600 DEKKER mechanical vacuum pump system.  The price for this 10HP vacuum system with 20 vacuum usage points represents a $30,400 initial capital investment savings over the $39,000 price tag of a 75HP compressor system with 20 vacuum generators. 

With an optional Variable Frequency Drive upgrade, vacuum supply will adjust according to demand for even tighter control of energy consumption and greater savings.

Conversion to a DEKKER mechanical vacuum pump system may qualify for additional savings from your local utility provider. DEKKER can help handling this process.

For more information about DEKKER Vacuum Systems please contact: 1-888-925-5444 and ask for an application engineer

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