Vacuum Pump Overhaul Extends the Life of a 20-Year-Old Printing System
For maintenance and purchasing teams, ageing production equipment can create a difficult decision: should a proven industrial vacuum pump be replaced, or can it be professionally overhauled and returned to reliable operation?
A UK envelope manufacturer recently faced this decision after its BECKER VADS 1500 screw vacuum pumps had supported continuous production for almost 20 years.
Following a detailed assessment, the manufacturer chose a comprehensive BECKER vacuum pump overhaul rather than replacing the existing equipment. The completed refurbishment restored the pumps to their original operating condition, eliminated oil leaks, and cost approximately 40% of the replacement cost.
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ORIGINAL INSTALLATION |
CHALLENGE |
SOLUTION |
RESULT |
COST |
A System Designed For Continuous Operation
Installed in 2006 to replace an ageing oil-lubricated rotary vane arrangement, the centralised BECKER system uses VADS 1500 screw vacuum pumps, selected to provide the stable vacuum supply required across multiple envelope production lines.
The screw vacuum technology offered several advantages for this application: The contact-free technology supports continuous operation with low routine maintenance, while built-in redundancy helps maintain production if one pump requires attention.
| Country | United Kingdom |
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Market |
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| Application | High-Speed Envelope Manufacturing: Pick-and-Place |
| Becker product | 5 x VADS 1500 Rotary Screw Vacuum Pump » |
Almost 20 years of dependable vacuum performance
Between installation in 2006 and the overhaul, the pumps operated for almost two decades. During that period, routine maintenance primarily consisted of scheduled oil and filter changes in accordance with the system’s service requirements.
Most importantly, the manufacturer reported no unplanned production downtime attributable to the vacuum system during its operating life. This long service history gave the business confidence in the original equipment. When signs of age eventually appeared, the company wanted to preserve the proven system where technically and commercially practical.
Photographed: Original installation in 2006
The Challenge: Ageing equipment without compromising production
After almost 20 years of operation, the pumps began to show evidence of long-term use. The main findings included:
- Dust and contamination accumulated during extended operation
- Deterioration of ageing oil pipework
- Oil leakage associated with worn seals and connections
- Components requiring cleaning, inspection and replacement
- A need to verify the future reliability of the complete pump assemblies
The pumps were still based on a proven system design, but continuing to operate them without intervention would have increased the risk of leakage, deterioration in condition, and future disruption.
The manufacturer therefore needed to compare two options:
- Replace the existing pumps and potentially modify the surrounding system.
- Overhaul the current pumps and extend the life of the installed solution.
Why the manufacturer chose an overhaul
Replacement would have required considerably greater capital expenditure. It could also have introduced additional installation work, system modifications and production planning requirements. Following inspection, BECKER determined that the existing pump assemblies were suitable for refurbishment.
The overhaul option provided several commercial and operational advantages:
- Approximately 60% lower expenditure than replacement
- Retention of equipment with a proven operating history
- No need for extensive changes to the existing vacuum system
- Reduced installation complexity
- Lower risk of disruption during recommissioning
- Continued availability of manufacturer service expertise and original parts
For the purchasing team, the project provided a clear return on investment. For the maintenance team, it offered a controlled route to restoring the condition of critical production equipment without disrupting production.
What was included in the Vacuum Pump Overhaul?
After two decades of service, the pumps were returned to BECKER for a comprehensive overhaul, completed over 18 months. As expected, the units showed clear signs of long-term operation, including dust accumulation and oil leakage. The refurbishment process was comprehensive and included:
- Full disassembly of each pump
- Complete overhaul of the air end
- Removal of accumulated dust and contamination
- Detailed cleaning and inspection of internal components
- Replacement of worn seals and service components
- Replacement of the complete oil pipework
- Reassembly using BECKER original parts
- Inspection and testing before the pumps were returned
Screw vacuum pumps contain specialist components that must operate within defined tolerances. Manufacturer knowledge, correct inspection procedures and accurately matched replacement parts are therefore important when restoring their condition. The objective was not to modify the pumps or claim performance beyond their original specification. It was to return a proven vacuum system to dependable operating condition and extend its useful service life.
All key components were carefully restored to ensure reliable performance. Due to the specialist nature of screw vacuum technology, this level of work requires manufacturer expertise and the use of genuine parts to achieve optimal results.
Discover BECKER's Industrial Overhaul Services for Vacuum & Compressors
Photographed: BECKER UK Engineer Mark overhauling a VADS 1500 screw vacuum pump
Results after Reinstallation
Once reinstalled, the pumps returned to full operational performance, with noticeable improvements:
- Elimination of oil leaks
- Cleaner system operation
- Continued high reliability
- Continued stable vacuum supply
- Extended life from the existing capital equipment
- Minimal change to the established production setup
- Continued confidence in a proven vacuum solution
The overhaul was completed for approximately 40% of the cost of full replacement. By retaining the existing system, the manufacturer also avoided the additional engineering, installation and commissioning work that a different pump arrangement could have required.
Vacuum pump overhaul or replacement: what should manufacturers consider?
An overhaul will not be the right decision for every pump. The condition, age, efficiency, availability of parts and future production requirements must all be considered. An expert technical assessment should examine:
- The condition of the pump and air end
- Current vacuum performance
- Maintenance and repair history
- Availability of original spare parts
- Energy consumption
- Changes in production demand
- The condition of controls and associated pipework
- The cost of overhaul compared with replacement
- Installation changes required for new equipment
- Planned production availability
Replacement may be preferable when equipment is significantly damaged, inefficient for the current application or no longer suitable for future production requirements. However, where a pump remains technically suitable, and its main components can be restored, a professional overhaul can offer a highly cost-effective alternative.
Photographed: After System Overhaul
The Value of Planned Industrial Vacuum Pump Maintenance
This project also demonstrates the importance of taking action before a pump fails. Planned inspection and maintenance allow ageing components to be identified while the business still has control over the timing of the work. Maintenance teams can coordinate production availability, arrange contingency support and avoid making urgent purchasing decisions following an unexpected breakdown.
A preventative vacuum pump maintenance strategy can help businesses:
- Identify wear before it causes a failure
- Maintain consistent vacuum performance
- Reduce the risk of unplanned downtime
- Plan maintenance expenditure more accurately
- Protect the condition of critical equipment
- Decide between repair, overhaul and replacement using reliable evidence and a trusted solutions partner for expert guidance.
Supporting print, paper and packaging
Vacuum and compressed-air technologies perform essential functions throughout printing, paper converting and packaging production. Depending on the process, vacuum can be used for:
- Sheet and material handling
- Product positioning
- Feeding and separation
- Folding and finishing
- Envelope manufacturing
- Waste extraction
- Centralised vacuum supply
BECKER supports manufacturers with vacuum pump & compressor servicing, repairs, overhauls, original spare parts and complete vacuum system expertise. By assessing the equipment, its maintenance history and the wider production process, our service specialists can help determine whether continued maintenance, repair, overhaul or replacement offers the most appropriate long-term solution.
Could an overhaul extend the life of your vacuum pump?
Age alone does not always mean that industrial vacuum equipment must be replaced. A professional inspection can establish the condition of your pump, identify worn components and help you compare the cost and operational implications of overhaul and replacement.
Speak with the BECKER service team to arrange an assessment of your vacuum pumps, compressors or central vacuum system - we are here to support you in the long-term operation of your devices!
View our Service Offerings for Industrial Pumps
Frequently Asked Questions (FAQ)
| Can a 20-year-old vacuum pump be overhauled? |
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Yes, depending on the pump’s condition. Age is only one factor when assessing whether an industrial vacuum pump can be overhauled. Its design, application, operating hours, maintenance history, component condition, availability of original spare parts and suitability for future production requirements should all be considered. In this case, the BECKER VADS 1500 screw vacuum pumps remained suitable for a complete overhaul after almost 20 years of service. |
| Is it cheaper to overhaul or replace a vacuum pump? |
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A vacuum pump overhaul can cost considerably less than replacement when the main pump assembly remains technically serviceable. For this UK envelope manufacturer, the complete overhaul was carried out for approximately 40% of the cost of replacement. It also avoided extensive system modifications, additional installation work and unnecessary production disruption. |
| What is included in an industrial vacuum pump overhaul? |
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The exact scope depends on the pump type and its condition. This BECKER in-house overhaul included full disassembly, a complete air-end overhaul, detailed cleaning and inspection, replacement of worn seals and service components, replacement of the oil pipework, reassembly and testing. Original BECKER parts were used to restore the pumps to reliable operating condition. |
| What is the difference between vacuum pump repair and overhaul? |
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A vacuum pump repair normally addresses a specific fault, leak or failed component. An overhaul is a more comprehensive process that typically involves dismantling, cleaning, inspecting and restoring the complete pump assembly. It is often recommended when equipment has accumulated extensive operating hours or shows several signs of age-related wear. |
| How can manufacturers reduce vacuum pump downtime? |
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Manufacturers can reduce downtime through preventative maintenance, regular condition inspections, planned replacement of service components and suitable system redundancy. Monitoring pump condition allows maintenance teams to identify wear before it develops into an unexpected failure and to schedule repairs or overhauls around production requirements. |
| Why use the original manufacturer for a screw vacuum pump overhaul? |
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Screw vacuum pumps contain specialist components that must operate within defined tolerances. An overhaul completed by the original manufacturer provides access to product-specific expertise, approved procedures, appropriate testing and genuine spare parts. This helps ensure that the pump is restored correctly and remains suitable for reliable industrial operation. |
| How are vacuum pumps used in envelope manufacturing? |
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In high-speed envelope manufacturing, vacuum is used to hold envelopes securely against rollers as they are transported, folded and glued. A stable and consistent vacuum supply supports accurate material handling, reliable production speeds and consistent finished-product quality. |
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