In industry, vacuum is used in everything from material handling and packaging to lifting, clamping and automated processes. A sound understanding of vacuum is essential for selecting the right components, sizing the system and ensuring reliable operation.
Vacuum occurs when air pressure is lower than atmospheric pressure (approximately 1013 mbar). There are different levels of vacuum, defined by how low the pressure has been reduced:
| Vacuum level | Approximate pressure range (mbar absolute) | Typical applications |
|---|---|---|
| Rough / low vacuum | 1,000–1 | Vacuum lifting, picking, automation and vacuum packaging |
| Medium / fine vacuum | 1–10⁻³ | Vacuum drying, degassing and laboratory processes |
| High vacuum | 10⁻³–10⁻⁷ | Electron microscopy, thin-film deposition and electron beam welding |
| Ultra-high vacuum | Below 10⁻⁷ | Particle accelerators, surface analysis and advanced materials research |
Several technologies are available for generating vacuum. The right solution depends on the application, the required air flow rate, and requirements for response time, energy consumption and reliability. Servi’s industrial applications typically use industrial vacuum – a partial vacuum in which some air remains.
This negative pressure is generated using a vacuum pump or a compressed-air-driven ejector. In an ejector, compressed air flows through a nozzle at high speed, drawing air from the area to be evacuated. When air is removed from between a suction cup and a workpiece, the resulting pressure difference causes the surrounding air to press the workpiece against the suction cup. This force is used to lift, hold and move products in industrial processes.
Ejectors use compressed air as their energy source. As air passes through a nozzle, it creates a low-pressure zone that draws air out of the connected vacuum system. Ejectors are available in single-stage and multi-stage versions. Their compact design, low weight and fast response make them well suited to robotic tooling, pick-and-place applications and packaging machines with short cycle times. The vacuum generation process itself involves no moving parts, contributing to high reliability. Servi offers both basic ejectors and solutions with integrated valves, filters and vacuum switches.
A suction cup forms a seal against the product’s surface, allowing the pressure difference to hold the product securely. Servi’s range includes standard suction cups and the modular Magic Suction Cups system. Mounting fittings, bellows and sealing lips can be combined as required, with different materials and designs to suit the product being handled. The sealing lip can also be replaced separately when worn or when handling requirements change.
Magic Gripper combines an ejector and a suction cup in a single compact unit that only requires a compressed air supply. This allows vacuum to be generated locally at each lifting point in a decentralised vacuum system. Typical applications include robotic handling, stacking, palletising, bag opening and case erecting. The suction cups can be adapted to handle anything from thin bags to heavier cardboard boxes, with versions also available for direct food contact.
VGRIP is a gripping system that can be fitted with a foam pad or suction cups. The foam pad accommodates surface irregularities and provides a larger, continuous gripping area, for example when palletising or handling products with challenging surfaces. The system is available with built-in ejectors or a connection for an external vacuum pump.
Vacuum technology can handle everything from thin plastic bags to heavy metal sheets without extensive mechanical adjustments. This makes it particularly attractive for production lines with frequent format changes.
Ejectors have few moving parts and are designed for a long service life. They withstand demanding industrial environments and help reduce the risk of downtime. Unlike electric vacuum pumps, ejectors generate little heat at the point of use and require no oil lubrication, eliminating the risk of oil leaks from the ejector.
Modern vacuum solutions are designed to reduce energy consumption through:
Optimised nozzles that can operate at lower supply pressures
Integrated energy-saving functions
Efficient motors and control systems
These features help lower operating costs and support more sustainable production processes.
Robotic vacuum grippers eliminate the need for heavy manual lifting and can reduce exposure to pinch hazards. This makes them a useful choice for businesses focused on occupational health and safety.
Correct sizing and component selection depend on several factors:
Object material and surface
– Non-porous surfaces require less vacuum flow than porous materials.
Weight and motion profile
– Rapid acceleration requires sufficient vacuum at the start of the movement and a stable grip.
Process requirements
– High-speed pick-and-place: an ejector is often suitable.
– Continuous operation: a mechanical vacuum pump may be suitable.
Environmental conditions and cleanliness requirements
– High temperatures, dust, moisture or oil-free operation requirements can determine the choice of pump.
Servi provides support with sizing, testing and selecting the right technical solution for each application.
