Plastic Thermoforming Vacuum Pumps
VacAir Superstore supplies, services and repairs vacuum pumps and blowers used on plastic thermoforming, vacuum forming, tray forming, packaging, sheet forming and moulding lines throughout the UK.
Thermoforming depends on fast, reliable vacuum. If the pump cannot evacuate the mould quickly enough, the heated plastic sheet can lose temperature before full definition is achieved, causing poor detail, soft corners, webbing, rejects and slower production cycles.
Vacuum Pumps for Plastic Thermoforming Applications
Plastic thermoforming uses heat and vacuum to form a softened plastic sheet over or into a mould. The vacuum system removes air from below the sheet through drilled mould holes, slots or vacuum channels so the plastic is pulled tightly into shape. In many production environments the vacuum pump is one of the most important components on the line because it directly affects forming speed, edge definition, product consistency and cycle time.
VacAir Superstore supports thermoforming companies using dry running rotary vane pumps, oil lubricated rotary vane pumps, side channel blowers and centralised vacuum systems. We supply new pumps, replacement pumps, filters, vanes, oil, separators, service kits and full workshop repair services for many leading pump brands including Becker, Busch, DVP, Elmo Rietschle and Leybold.
Where Vacuum Is Used in Thermoforming
Vacuum is normally used at the forming stage, but it can also support other parts of the production process. Depending on the machine design, vacuum and pressure may be used for:
- Drawing heated plastic sheet over or into the mould.
- Holding sheet, formed parts or trim waste during handling.
- Assisting part release with pressure or blow-off air.
- Pick and place removal from automated forming lines.
- Central vacuum systems feeding several thermoforming machines.
- Packaging lines where forming, filling, sealing and trimming are combined.
Why Pump Selection Matters
The correct pump depends on the mould volume, sheet size, plastic material, required vacuum level, cycle speed and the amount of leakage through the mould and tooling. A pump that is too small may eventually reach vacuum, but not quickly enough for consistent production. A pump that is wrongly specified may use more energy than necessary, run hot, suffer high vane wear or struggle with contamination.
VacAir can help identify whether your process needs a high-flow dry running pump, a deeper-vacuum oil lubricated pump, a side channel blower, a vacuum receiver, or a combined vacuum and pressure arrangement.
Common Thermoforming Vacuum Problems
Loss of definition or soft corners
If the pump cannot evacuate the mould quickly enough, the plastic may begin cooling before it has fully pulled into the detail of the tool. This can cause poor definition, rounded edges or inconsistent parts.
Slow cycle times
A weak pump, blocked filters, worn vanes, restricted pipework or a leaking vacuum circuit can slow down forming cycles and reduce output.
Webbing and poor material distribution
Vacuum level is not the only factor, but unstable vacuum can make tooling and process problems more difficult to control.
Pump running hot or noisy
Blocked inlet filters, poor ventilation, worn vanes, contaminated oil or exhaust restrictions can cause pump temperature and noise problems.
High maintenance cost
The wrong pump type for the duty can lead to repeated vane wear, oil carryover, filter blockage or bearing problems.
Unplanned production stoppages
A failed thermoforming vacuum pump can stop a line immediately. VacAir supports urgent breakdowns, replacement pumps, workshop repairs and spare parts supply.
Common Vacuum Pumps Used in Plastic Thermoforming
The most suitable pump depends on the machine, product, tooling and cycle time. The models below are commonly considered for thermoforming and vacuum forming duties, but final selection should always be based on the required flow, vacuum level and operating conditions.
A popular dry running rotary vane vacuum pump for medium to larger forming duties where clean, oil-free operation and robust industrial performance are required. Often considered for forming tables, packaging machines and centralised systems. As well as pumps, vanes, filters and service kits are all readily from stock.
A larger dry running rotary vane pump for higher flow requirements, larger tools or faster evacuation demands. Suitable where a single larger pump may replace smaller pumps or support larger machine formats. Should you just require a pump service, carbon vanes, filters and service kits are readily available from stock.
Becker dry running rotary vane pumps are widely used where reliable industrial vacuum is required without oil in the compression chamber. They are a common choice for plastic, packaging, paper handling and automation duties. The VT series range from 2 m³/h with varies specifications including 16 m³/h, 25m³/h and 40m³/h, the KVT series starts at 60m3/h with the KVT 3.60, whilst the KVT 3.140 with 140m3h is the largest.
Becker DVT Combined Pumps
Combined vacuum and pressure pumps can be useful where the process needs vacuum for forming or holding and pressure for release, separation or blow-off. The DVT range includes the , DVT 3.60 , DVT 3.80 , DVT 3.100 and DVT 3.140 (60m³/h -140m³/h)
Busch R5 Oil Lubricated Pumps
Oil lubricated rotary vane pumps can be suitable where deeper vacuum is required or where the process benefits from stronger ultimate vacuum performance than typical dry running vane pumps. The Busch R5 range is extensive, from as low as 10m³/h upto 1600m³/h, as well as compact models to fit into confined spaces. Oil lubricated pumps require regular maintenance, including regular oil changes, oil filters, and oil mist eliminators (oil separators).
Side Channel Blowers
Side channel blowers can be used where high air movement and moderate vacuum or pressure are required. They are often considered for high-flow duties, handling, cooling, conveying and some forming-related processes. Blowers require minimal servicing as they have impellors to produce airflow, rather than vanes.
DVP Vacuum Pumps
VacAir can supply DVP vacuum pumps through our group’s DVP expertise. DVP options may be considered for replacement pumps, OEM style installations and industrial vacuum systems. DVP offers dry running and oil lubricated rotary vane pumps as well as side channel and claw pumps. As the UK Master Agent we hold large stocks of DVP pump units.
Elmo Rietschle / Gardner Denver
Many thermoforming and packaging machines use Rietschle, Elmo Rietschle or Gardner Denver pumps. VacAir can help with replacement units, service parts and repair support. The Elmo Rietschle range includes dry running and oil lubricated rotary vane pumps, side channel blowers and claw pumps.
Central Vacuum Systems
For factories with multiple forming machines, a central vacuum system with receiver capacity, isolation valves and correctly sized pipework can improve resilience and make maintenance easier. The DVP CPA series are particularly suited for industrial central systems. The system shown was a bespoke build by VacAir for a class leading aerospace composite technology company.
Choosing the Right Thermoforming Vacuum Pump
- Plastic sheet size and thickness.
- Mould volume and evacuation time.
- Required vacuum level at the tool.
- Leakage through the mould, seals and pipework.
- Cycle time and production rate.
- Duty cycle and running hours.
- Whether vacuum only or vacuum and pressure are required.
- Available electrical supply and installation space.
- Heat, dust, plastic particles and site conditions.
The best pump is not always the largest pump. A correctly sized pump, good pipework design, clean filters, suitable receiver capacity and well-maintained tooling can make a significant difference to forming performance. If your machine has become slower over time, the issue may be pump wear, blocked filtration, leaks, valve faults or restrictions between the pump and mould.
VacAir can help identify whether the issue is the pump itself or the wider vacuum system.
Thermoforming Pump Service and Repair
A thermoforming line can be highly dependent on one vacuum pump. Regular servicing helps reduce the risk of downtime and keeps the pump operating at the required performance level. VacAir offers pump servicing, workshop overhauls, vane replacement, oil changes, filter replacement, bearing work, fault diagnosis and replacement pump supply.
We support many common pump makes used in plastics and packaging production, including Becker, Busch, DVP, Elmo Rietschle, Leybold and other industrial vacuum pump brands.
Spares, Filters, Vanes and Replacement Pumps
VacAir can supply replacement vacuum pump vanes, inlet filters, exhaust filters, separators, oil, service kits and complete replacement pumps. If your pump is obsolete or no longer economical to repair, we can help identify a suitable replacement based on performance, dimensions, connections and duty.
For urgent breakdowns, call 0113 2088501 and tell us the pump model, machine type, symptoms and how quickly the pump is needed.
Need Help with a Thermoforming Vacuum Pump?
VacAir Superstore can help with new pumps, replacement pumps, urgent breakdowns, service parts and workshop repairs for plastic thermoforming and vacuum forming applications.
Plastic Thermoforming Vacuum Pump FAQ
What type of vacuum pump is used for plastic thermoforming?
Dry running rotary vane pumps, oil lubricated rotary vane pumps and side channel blowers are all used in thermoforming, depending on the required vacuum level, air flow, cycle speed and tooling design. Becker VTLF pumps are a common dry running option, while oil lubricated pumps may be used where deeper vacuum is required.
Is a bigger vacuum pump always better for thermoforming?
No. The pump must be correctly matched to the mould volume, leakage rate, pipework and cycle time. An oversized pump can waste energy and may not solve problems caused by blocked filters, poor pipework, leaking seals or unsuitable tooling.
Why is my thermoforming machine losing definition on formed parts?
Loss of definition can be caused by insufficient vacuum flow, low vacuum level, leaks, blocked filters, restricted pipework, worn pump vanes, valve faults or the plastic cooling before it has fully formed over the tool.
Can VacAir replace an obsolete thermoforming vacuum pump?
Yes. VacAir can help cross-reference obsolete or difficult-to-source pumps and recommend a suitable replacement based on flow, vacuum level, motor size, connections, footprint and application duty.
Do thermoforming pumps need regular servicing?
Yes. Inlet filters, vanes, oil, separators, bearings and general pump condition should be checked as part of routine maintenance. Servicing helps protect forming performance and reduce the risk of unplanned downtime.
Can one pump run several thermoforming machines?
Yes, in some factories a central vacuum system can feed multiple machines. This requires correct pump sizing, receiver capacity, pipework design, isolation valves and backup planning so one issue does not stop the whole production area.
Can VacAir help with urgent thermoforming pump breakdowns?
Yes. VacAir supports urgent vacuum pump breakdowns, replacement pump supply, workshop repair and spare parts supply. Call 0113 2088501 with the pump model and machine details.
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