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Should you repair or replace your vacuum pump?

25 January 2024

If a vacuum pump malfunctions, engineers are faced with a choice – repair or replace. Busch Vacuum Solutions offers some advice about when it makes sense to repair vacuum pumps and when to replace them.

Whatever the path of action, the decision to repair or replace always begins with testing and diagnosis. A factory-trained service technician who specialises in vacuum pump services first needs to inspect the equipment and identify the problem.

If the pump can be repaired, faulty components are removed and replaced, and the equipment is returned to manufacturer specifications. This can provide a cost-effective solution if the issue is minor, or the vacuum pump is relatively new, as there may only be a few spare parts to replace. It is also a low environmental impact solution as fewer resources are used, and less waste is produced.

However, if the vacuum pump’s issues are difficult to repair, they may crop up again in the future which could lead to higher costs in the longer term. Further, vacuum pump repair is no guarantee that other, different problems will not arise in the future.

If the choice is taken to replace a vacuum pump, the existing one will need to be removed and a brand-new pump will be installed. New vacuum pumps are likely to have entirely new components and may be more energy efficient compared to an older pump. A new unit should also come with a new warranty, offering peace of mind, and potentially reducing future repair costs.

On the downside, purchasing a new vacuum pump means higher initial costs and installing and integrating a new vacuum pump is very likely to take longer than to carry out a small repair.

Key considerations
Before a decision is made about whether to repair or replace a vacuum pump there are five criteria that need to be assessed: 

Costs: If the existing vacuum pump has only a minor issue, repair may be the more economical option. However, longer-term maintenance and repair costs also need to be considered. As vacuum pumps gets older, for example, they may require more frequent servicing. This could add up to more than the price of a replacement over time, even though this will require a much larger immediate outlay.

Process requirements: Evaluate whether the existing vacuum pump is still the best option for the process. If the vacuum pump is always running flat-out, or reserve pumps are regularly coming online to meet demand, the process may have outgrown the pump’s current capabilities. Replacement could therefore be a sensible option. This will help avoid production delays and ensure maintain optimal quality and performance is maintained.

Service history: Has this same problem occurred before? Examine the service history to be sure. Regular maintenance actions like replacing spare parts such as seals, gaskets, or vanes is usually nothing to be concerned about, but if larger issues keep cropping up, repairs may no longer be an option.

Energy efficiency: Many new generations of vacuum pumps are more energy efficient than the one before. Consider the benefit of replacing your current vacuum pump with one that consumes less energy. Depending on the difference in consumption between the current vacuum pump and the newest technology, energy bills could reduce considerably – and your carbon footprint too.

Technical features: Consider how modern the current vacuum pump is. Do more modern vacuum pumps come with new technical features that could benefit the process? This could be the right time to invest in a new pump or you could look into retrofitting – some modern features can be added to an existing vacuum pump, such as a variable speed drive or intelligent monitoring. This would effectively upgrade the system without investing in a new solution. 

Getting old?
However, if a pump is getting older, it may no longer be compatible with the newer features that have become available since its purchase. As a result, the process could miss out on some optimisation possibilities. So do consider how important this option is to you and your process – it could sway the decision between repair or replacement.

Vacuum pumps rarely fail without warning. However, it can be hard to catch the early symptoms of a problem so regular maintenance is key: A problem spotted early is generally easier to repair. The maintenance team needs to become familiar with common issues and the telltale signs of a failing vacuum pump, which can include excessive noise or vibrations, leaks, reduced pumping speed, or overheating.

Fixing problems promptly is crucial to ensuring cost-effective vacuum pump repairs and minimising the risk of downtime. It is also worth considering investing in an intelligent monitoring system which can continuously monitor each vacuum pump’s performance data and flag any anomalies. 

In a food packaging plant, the performance of the vacuum pump will be critical for the quality and shelf-life of the foodstuffs. In one food processing application a vacuum pump was experiencing increased noise and reduced pumping speed, leading to production delays.

After careful inspection, the technician from the vacuum pump repair service provider determined that the problem was the result of a leak. The vacuum pump had been in operation for several years, but this was the first time the issue had occurred. And, although the initial symptoms looked troubling, it was a simple fix. Vacuum pump repair was therefore the most sensible option. The service technician replaced the worn seal, and the vacuum pump was back up and running.

Conclusion
When a vacuum pump isn’t running as it should be, it is important to weigh up the available options. Consult your vacuum pump repair service provider and have them conduct a proper inspection and diagnosis. Also assess efficiency, performance, and the cost of repairs – both now and in the future – versus the cost of a new vacuum pump. This will help determine the best course of action. Ultimately, the decision should be based on what is most cost-effective and beneficial for the production process.


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