10 | Plant & Works Engineering www.pwemag.co.uk June/July 2026 Insight Improving the efficiency of a vacuum system does not just rely on choosing the right vacuum pump. Much of the long-term performance is influenced by how the vacuum process is designed. This includes factors such as energy consumption, productivity, and operating costs. Typically, efficiency is defined not only as the reduction of resource consumption, but also as an increase in productivity. Smart choices at the outset of designing a vacuum system can therefore have a profound impact on efficiency over its whole life. This article explores four key considerations that can help in the design of more efficient vacuum processes. Improving vacuum system efficiency through better design Vacuum system efficiency is influenced by far more than the choice of pump. From staged pumping arrangements to condensate management and temperature control, careful process design can reduce energy consumption, improve reliability and boost productivity throughout a system’s operating life. 1. Multiple pumping stages can improve energy efficiency In many vacuum applications, especially those that require rapid pump-down times or low ultimate pressures, using a single vacuum pump to cover the full pressure range can be inefficient. A more effective approach is to use multiple pumping stages, typically by combining a backing pump with a vacuum booster. How it works: Each vacuum pump can operate within its optimal pressure range, avoiding the need to operate the backing vacuum pump at lower pressures where it would be less efficient. Pumping speed is improved at lower pressures. The combination of a backing vacuum pump and a vacuum booster achieves pumping speeds at low pressure much greater than the backing pump could alone. Smaller vacuum pumps can be used without compromising performance. For example, a vacuum booster used in conjunction with a dry screw or rotary vane backing pump can significantly reduce energy consumption compared to a single large vacuum pump. This is because vacuum boosters have excellent volumetric efficiency and can
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