Industrial Vacuum Loading Systems

Industrial Central Vacuum Loader System Overview

Vacuum loading systems are designed to move huge volumes of material.  This type of central vacuum supports one operator and always uses a positive displacement (PD) type of vacuum producer.

Positive displacement machines maintain an equal volume of air while the level of vacuum changes, with horsepower increasing with vacuum.  To the operator, this means the system pulls harder as material flow in the system increases.

This characteristic is the reason PD type machines are used in pneumatic conveying systems.  In fact, given the same horsepower, PD powered vacuums will move three times more material per minute than  vacuum systems with dynamic type vacuum producers. 

Central loading systems may be designed to move hundreds of tons per hour, with hose sizes up to 8" ID and piping systems up to 1000 feet long.  However, as a practical matter, any hose over 4 or 5" ID gets pretty heavy for the operator!

The Vacuum Producer

For applications less than 100 Hp, we prefer the  German engineered KAESER Omega Series. These packages feature an incredible sound enclosure, and run forever with almost no maintenance. 

For applications above 100 Hp. and under 16" Hg, we specify the SUTORBILT Q8000 Series.  These are rugged machines that use a special design to lower their noise level without sacrificing mechanical efficiency.

Other PD type vacuum pumps are used for special applications.

For example, we'll use a HIBON SIAV Series vacuum pump for high flow applications that require 28" Hg.  These awesome machines have revolutionized the vacuum truck industry, and are now being used for industrial central vacuum systems.

Finally, liquid ring pumps as useful for moving very hot materials, super-fine abrasives, or slurries.  There is no heat of compression, but there is a requirement for water.

The Filtration System

Most dry powder systems will incorporate our TLP pulse jet filter, because these separators are designed to handle abrasive and explosive materials.  The cylindrical design offers the benefit of cyclonic separation with the ability to easily withstand 28" Hg.

Most loading systems benefit from being continuously discharged, usually back to process, since vacuum pick-up is continuous.  

If material is to be stored within the system, for batch discharge with the system shut down, remember that these machines will fill up storage requirements fast.

Note that while it is possible to use cartridge type dust collectors, we have found bag type filtration systems to require less maintenance. The filters do not blind nearly as easily, they can be used reliably with super-fine particulate, and they're (usually) cheaper to replace.

The Discharge Device

For most loading system applications, the valve of choice is a flapgate, as shown on the left.  These valves are more robust than rotary air locks, which wear out quickly in high volume systems.

For batch discharge systems, we will always specify an oversized valve.  Vacuum loaders are strong enough to pick-up weld rod, nuts and bolts, and other material that isn't "specified".  No other component in the system has the potential to waste more maintenance time!  We make our valve recommendations based on long term reliable performance, NOT price. 

The Piping Network

Schedule 40 and 80 piping is most commonly specified for loading systems.  Bends are usually 24" CL radius or greater.  Laterals are normally fabricated at 15 to 30 degrees.

The system piping may be entirely joined with bolted compression couplings, or the straight portions may be welded.  All systems are static conductive.

Industrial duty "inlet valves" allow uses to insert hoses without shutting down the system.

Sizing is based on solid pneumatic conveying system fundamentals to ensure plug free system operation.

The Hose and Tools

Vacuum tools 2.5" to 6" MUST be ergonomically designed.  Operator health and safety are paramount!

We fabricate our own vacuum tools.  They're lightweight, yet of a robust, industrial duty design so they stand up to abuse.

The selection of your vacuum hose is important, because the perfect hose doesn't exist (weighs nothing, ties in a knot, lasts forever, and is free).

For hose over 4", weight and operator fatigue become a real problem.