Views: 0 Author: Wordfik Vacuum Publish Time: 2025-10-25 Origin: Wordfik Vacuum
In the industrial drying sector, manufacturing efficiency and product quality heavily depend on the reliability and performance of vacuum systems. For years, companies have struggled with systems that fail to maintain consistent vacuum levels, consume excessive energy, or require frequent maintenance—issues that directly impact production timelines and operational costs. At Wordfik, with our 18 years of specialized experience in vacuum technology, we understand these challenges intimately and engineer solutions that address them at their core.
Our recent collaboration with a leading industrial drying equipment manufacturer exemplifies our commitment to pushing the boundaries of vacuum technology. Confronted with the need for a high-performance vacuum solution for their 2000L drying systems, they turned to Wordfik for a customized approach that would deliver unmatched vacuum performance while ensuring energy efficiency and operational reliability. This case study explores how our integrated approach—from initial concept to final delivery—provided a vacuum solution that not only met but exceeded our client's expectations.
The client, a manufacturer of high-capacity drying systems for food processing applications, faced several operational challenges that were affecting their production efficiency and end-product quality:
Inconsistent Vacuum Levels: Their existing vacuum systems struggled to maintain stable pressure levels throughout the drying cycle, resulting in uneven moisture removal and compromised product quality in their 2000L drying chambers.
Excessive Energy Consumption: The previous configuration required multiple pumps operating continuously at full capacity, leading to unsustainable energy costs that impacted their competitive positioning.
Frequent Maintenance Downtime: With production schedules demanding maximum operational availability, the client needed a solution that would reduce unplanned downtime and extend service intervals.
Space Constraints: The physical footprint of their existing vacuum system limited their options for production line expansion and required a more compact, integrated solution.
These challenges highlighted the need for a vacuum solution specifically engineered for the demanding requirements of industrial drying applications—one that could maintain deep vacuum levels consistently while offering greater efficiency and reliability.
After thoroughly analyzing the client's specific requirements and operational parameters, our engineering team recommended a custom-configured vacuum system centered around an oil-lubricated rotary vane pump and Roots vacuum pump combination—a configuration particularly well-suited for industrial drying applications requiring rapid pump-down and consistent deep vacuum levels.
The heart of our solution featured a strategically engineered combination of vacuum technologies:
Oil-Lubricated Rotary Vane Pump (300 m³/h): Serving as the backing pump for the system, this component provides reliable base pressure and handles the larger gas loads during initial pump-down phases. The oil-sealed design ensures consistent performance and longevity, even in demanding operating conditions .
Roots Vacuum Pump (1000 m³/h): Positioned between the rotary vane pump and the drying chamber, this vacuum pump significantly increases pumping speed in the rough vacuum range, enabling faster cycle times and improved overall efficiency for the 2000L drying system.
Intelligent PLC Control System: The complete system operates under the supervision of a sophisticated control system that continuously monitors performance parameters, adjusts operational settings in real-time, and provides comprehensive system diagnostics to prevent unscheduled downtime.
The integrated system delivered remarkable performance metrics that directly addressed the client's operational challenges:
Ultimate Vacuum: 1 Pa, ensuring optimal drying conditions for even the most moisture-sensitive products .
Pumping Speed: Optimized for the 2000L chamber volume to achieve rapid pump-down from atmospheric pressure to target vacuum levels.
Energy Efficiency: The strategic combination of pump technologies reduced energy consumption by approximately 35% compared to conventional systems.
The project began with an immersive design process that leveraged the latest in 3D modeling technology to create a virtual prototype of the complete vacuum system:
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With the design finalized and approved, we moved to the manufacturing phase, implementing our stringent quality control protocols throughout:
Precision Machining: Critical components were manufactured to exacting tolerances, ensuring optimal clearances between rotating elements and housing surfaces for maximum efficiency and longevity.
Sub-Assembly Validation: Each major subsystem was individually tested before integration into the complete system, verifying performance against design specifications at every stage.
Cleanroom Assembly: The final assembly took place in a controlled environment to prevent contamination of critical surfaces and ensure the system's internal cleanliness.
Prior to delivery, the complete system underwent rigorous testing under simulated operational conditions:
Performance Verification: We conducted extended run-in tests to verify the system's ability to achieve and maintain the specified 1 Pa ultimate vacuum under various load conditions.
Endurance Testing: The system operated continuously for 72 hours under simulated production conditions to validate long-term reliability and identify any potential issues before shipment.
Safety System Validation: All safety interlocks, pressure sensors, and emergency shutdown procedures were methodically tested to ensure complete operational safety.
The final phase involved careful logistics planning and video technical support:
Protected Packaging & Shipping: The system was packaged using custom-designed crating to ensure complete protection during transit to the client's facility.
Video Technical Support: Our engineers will produce a comprehensive video documenting the equipment's entire operation, from startup to stable performance. The video will also include a detailed walk-through of every PLC controller warning to ensure full operational clarity.
While the oil-lubricated rotary vane and Roots combination proved ideal for this specific drying application, Wordfik engineers a diverse range of Roots vacuum system configurations to address varying industrial requirements:
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| Oil-Sealed Rotary Vane & Roots Vacuum Systems | Two-Stage Oil-Sealed Rotary Vane & Roots Vacuum Systems | Claw & Roots Vacuum Systems | Screw & Roots Vacuum Systems | Water Ring & Roots Vacuum Systems | |
| Backing Pump | Wordfik PVX Series Oil-Sealed Rotary Vane Vacuum Pumps | Wordfik PSV Series Two-Satge Oil-Sealed Rotary Vane Vacuum Pumps | Wordfik ZSV Series Claw Vacuum Pumps | Wordfik DVX DVE Series Screw Vacuum Pumps | Wordfik 2BV 2BE Series Water Ring Vacuum Pumps |
| Pumping Speed of the Backing Pump | 10-750 m³/h | 4-90 m³/h | 100-900 m³/h | 20-1800 m³/h | 60-1800 m³/h |
| Ultimate Pressure of the Backing Pump | 0.1-0.5 mbar | 0.04Pa | 60-200 mbar | 0.1-5 Pa | 33 mbar |
| Booster Pump | Wordfik RTOW Series Roots Vacuum Pumps | ||||
| Optimal Vacuum Range | 1 Pa - 100 Pa | 10⁻⁴ Pa - 1 Pa | 10 Pa - 1000 Pa | 0.1 Pa - 10 Pa | 100 Pa - 5000 Pa |
| Key Advantages | Cost-effective, reliable, proven technology | Higher ultimate vacuum, enhanced moisture handling | Tolerance to liquids and particulates, dry operation | Oil-free operation, low maintenance, energy efficient | Explosion-proof, handles saturated vapors |
| Ideal Applications | Pharmaceutical drying, food drying, chemical processing | Freeze drying, sensitive material dehydration | Food processing, slurry drying, wastewater treatment | Pharmaceutical API drying, electronic material processing, semiconductor industry | Solvent recovery, hazardous chemical processing |
The successful implementation of this customized vacuum system for 2000L drying applications demonstrates Wordfik's commitment to engineering excellence and customer-focused solutions. By leveraging our 18 years of specialized experience in vacuum technology, we deliver systems that not only meet technical specifications but also enhance our clients' operational efficiency and competitive advantage.
At Wordfik, we understand that each industrial application presents unique challenges and specific requirements. Our approach combines technical expertise with practical operational experience to develop vacuum solutions that perform reliably in real-world conditions. From initial concept through to final commissioning, we partner with our clients every step of the way to ensure complete satisfaction and optimal system performance.
Ready to transform your industrial processes with customized vacuum solutions?
Contact Wordfik today to schedule a consultation with our engineering team:
+86 15918352704
info@wordfik.com
Let us demonstrate how our tailored vacuum systems can enhance your operational efficiency, improve product quality, and reduce your total cost of ownership.
