In the industrial sector, vacuum pumps are often the “forgotten” workhorses, until they fail. For over 40 years, Girovac has assisted businesses across the UK in maintaining, repairing, and optimising their vacuum systems. Since 1983, we have observed a recurring pattern: most operational inefficiencies and premature pump failures are not caused by the equipment itself, but by common maintenance and operational errors.
In an era of rising energy prices and stringent production deadlines, these mistakes do more than just shorten the lifespan of your rotary vane vacuum pump; they directly impact your bottom line. Below are seven of the most frequent mistakes we encounter and, more importantly, how you can rectify them to improve energy efficiency and system reliability.
1. Incorrect Sizing: The “Bigger is Better” Fallacy
One of the most significant contributors to wasted energy is over-specification. We frequently see systems equipped with pumps that are far larger than the application requires. While a larger pump might reach the desired vacuum level faster, it consumes significantly more power and operates less efficiently during the sustained “hold” phase of your process.
Conversely, an undersized pump will struggle to maintain the required vacuum, leading to extended cycle times and overheating.
The Solution: Proper system design is essential. Before purchasing new equipment, ensure you have calculated the required flow rate and ultimate vacuum precisely for your application. As we discussed in our previous post on over-specifying vacuum pumps, getting the sizing right is the first step toward a cost-effective operation.
2. Neglecting Oil Quality and Regular Changes
For an oil-lubricated rotary vane vacuum pump, the oil is its lifeblood. It provides lubrication, cooling, and the critical seal between the vanes and the pump chamber. Over time, this oil becomes contaminated with process vapours, dust, and chemical residues.
Operating a pump with degraded or contaminated oil increases internal friction and forces the motor to draw more current to overcome the resistance. In extreme cases, contaminated oil can lead to “sludging,” which can permanently damage internal components.
The Solution:
- Implement a strict oil-change schedule based on operating hours or oil colour.
- Use the correct grade of vacuum oil (generic equivalents can offer significant cost savings if specified correctly).
- Monitor for “milky” oil, which indicates water contamination, and use gas ballast valves where appropriate to purge vapours.
3. Ignoring System Leaks
A vacuum system is only as efficient as its tightest seal. Even a microscopic leak in your piping or at a flange joint forces the pump to work harder to maintain the target pressure. If your pump is running at 100% capacity just to compensate for atmospheric air leaking into the system, you are essentially throwing energy away.
Leaks often develop over time due to vibration, thermal expansion, or the degradation of old O-rings and gaskets.
The Solution: Regular leak detection is vital. Utilise ultrasonic leak detectors or pressure decay tests to identify weak points in your system. Replacing a £10 O-ring could save you hundreds of pounds in annual energy costs.
4. Using the Wrong Filtration or Spares
To protect your pump from process contaminants, high-quality filtration is non-negotiable. However, using the wrong filter, or neglecting to change an existing one, creates a restriction in the inlet line. This restriction forces the pump to work against higher resistance, leading to increased energy consumption and reduced pumping speed.
Furthermore, many operators believe they must always purchase expensive branded spares.
The Solution: While we are proud UK distributors for MIL’S French-engineered systems, Girovac also maintains an extensive stock of high-quality generic spares for major brands like Leybold, Edwards, and Busch. Our generic spares provide the same technical reliability as OEM parts but at a more competitive price point, allowing you to maintain your equipment without compromising your maintenance budget.
5. Lack of Professional Servicing
While daily checks can be performed in-house, there is no substitute for a professional teardown and inspection. Many businesses wait until a pump has seized before seeking help. By this stage, the repair costs are often triple what a preventative service would have been.
A professional service identifies “hidden” issues, such as worn vanes that have not yet shattered, or cooling fans that are partially obstructed by workshop debris.
The Solution: Our North Walsham workshop is equipped to handle everything from minor repairs to full reconditioning of complex vacuum systems. By sending your pump to our engineers, you ensure that every clearance and tolerance is checked against the manufacturer’s specifications. (Note: Repair lead times may vary based on the availability of specific internal components for older models).
6. Environmental Factors: Heat and Dust
Vacuum pumps are sensitive to their surroundings. In many facilities, pumps are tucked away in corners or small enclosures where heat can build up. Since a pump’s efficiency drops as its temperature rises, poor ventilation is a silent energy killer.
Similarly, dust and airborne particles can clog the cooling fins on the motor or the pump body, leading to overheating and premature bearing failure.
The Solution: Ensure your pumps are located in a well-ventilated area with at least 30cm of clearance on all sides. Regular cleaning of the external surfaces and cooling fans with compressed air can significantly extend the life of the motor and internal seals.
7. Skipping Preventative Maintenance (PM)
The “if it isn’t broken, don’t fix it” mentality is the most expensive strategy in the vacuum industry. Preventative maintenance is about identifying the gradual decline in performance before it reaches a failure point.
A pump that is slowly losing its ultimate vacuum capability is a pump that is becoming more expensive to run every day.
The Solution: Develop a PM checklist that includes:
- Inlet filter inspection and cleaning.
- Exhaust filter (oil mist separator) checks to prevent back-pressure.
- Checking belt tension (for belt-driven models).
- Logging operating temperatures and ultimate vacuum levels weekly to spot trends.
The Girovac Approach: 40 Years of Expertise
At Girovac, we take a “total solution” approach to industrial vacuum. Whether you are looking for a brand-new MIL’S vacuum equipment or need a reliable reconditioned unit to get your production line back up and running, we have the technical expertise to assist.
Our partnership with MIL’S, a company with over a century of French engineering history, allows us to provide industry-leading pumps that are designed with energy efficiency and “eco-design” at their core. However, we also recognise the value of legacy equipment. Our workshop regularly services and supplies reconditioned models from brands like Edwards, PFEIFFER, and BUSCH, often providing 6-month warranties on our reconditioned stock (subject to correct installation and use).
Ready to Optimise Your System?
Don’t let maintenance mistakes drain your budget. If you are unsure whether your current vacuum system is operating at peak efficiency, or if you need expert advice on the best spares for your rotary vane pump, our team is here to help.
For technical enquiries or to book a service at our workshop, please email us at [email protected]. With over four decades of experience, no task is too small or too large for the Girovac team.