{"id":1397,"date":"2024-08-09T12:46:26","date_gmt":"2024-08-09T12:46:26","guid":{"rendered":"https:\/\/knowledge-center.novatec.com\/?page_id=1397"},"modified":"2026-03-27T15:28:58","modified_gmt":"2026-03-27T15:28:58","slug":"overcoming-long-conveying-distances","status":"publish","type":"page","link":"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/system-design\/overcoming-long-conveying-distances\/","title":{"rendered":"Overcoming Long Conveying Distances"},"content":{"rendered":"\t\t<div data-elementor-type=\"wp-page\" data-elementor-id=\"1397\" class=\"elementor elementor-1397\" data-elementor-post-type=\"page\">\n\t\t\t\t<div class=\"elementor-element elementor-element-5ddf59bc e-con-full e-flex e-con e-parent\" data-id=\"5ddf59bc\" data-element_type=\"container\">\n\t\t<div class=\"elementor-element elementor-element-525c987e e-con-full e-flex e-con e-child\" data-id=\"525c987e\" data-element_type=\"container\">\n\t\t\t\t<div class=\"elementor-element 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href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/system-design\/design-considerations\/\" class = \"hfe-sub-menu-item\">Design Considerations<\/a><\/li>\n\t<li id=\"menu-item-1773\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/system-design\/vacuum-pump-comparison-chart\/\" class = \"hfe-sub-menu-item\">Vacuum Pump Comparison Chart<\/a><\/li>\n\t<li id=\"menu-item-1774\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/system-design\/special-applications\/\" class = \"hfe-sub-menu-item\">Special Applications<\/a><\/li>\n\t<li id=\"menu-item-1775\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a 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tabindex=\"0\" role=\"button\" aria-haspopup=\"true\" aria-expanded=\"false\"><a aria-expanded=\"false\" href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/components\/\" class = \"hfe-menu-item\">Components<span class='hfe-menu-toggle sub-arrow hfe-menu-child-0'><i class='fa'><\/i><\/span><\/a><\/div>\n<ul class=\"sub-menu\">\n\t<li id=\"menu-item-1715\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/components\/tubing-bends-couplers-and-flexible-hose\/\" class = \"hfe-sub-menu-item\">Tubing Bends Couplers and Flexible Hose<\/a><\/li>\n\t<li id=\"menu-item-1716\" class=\"menu-item menu-item-type-post_type menu-item-object-page menu-item-has-children hfe-has-submenu hfe-creative-menu\"><div class=\"hfe-has-submenu-container\" tabindex=\"0\" role=\"button\" aria-haspopup=\"true\" aria-expanded=\"false\"><a aria-expanded=\"false\" href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/vacuum-pumps\/\" class = \"hfe-sub-menu-item\">Vacuum Pumps<span class='hfe-menu-toggle sub-arrow hfe-menu-child-1'><i class='fa'><\/i><\/span><\/a><\/div>\n\t<ul class=\"sub-menu\">\n\t\t<li id=\"menu-item-3770\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/vacuum-pumps\/the-ultimate-guide-to-vacuum-pumps-for-plastics-processing-how-to-choose-the-right-one-for-your-plant\/\" class = \"hfe-sub-menu-item\">The Ultimate Guide to Vacuum Pumps for Plastics Processing: How to Choose the Right One for Your Plant<\/a><\/li>\n\t\t<li id=\"menu-item-4168\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/vacuum-pumps\/is-your-vacuum-pump-a-legal-liability\/\" class = \"hfe-sub-menu-item\">Is Your Vacuum Pump a Legal Liability?<\/a><\/li>\n\t\t<li id=\"menu-item-1717\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/vacuum-pumps\/pump-types\/\" class = \"hfe-sub-menu-item\">Pump Types<\/a><\/li>\n\t\t<li id=\"menu-item-1718\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/vacuum-pumps\/pump-performance-characteristics\/\" class = \"hfe-sub-menu-item\">Pump characteristics<\/a><\/li>\n\t\t<li id=\"menu-item-1719\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/vacuum-pumps\/startup-troubleshooting\/\" class = \"hfe-sub-menu-item\">Startup Troubleshooting<\/a><\/li>\n\t<\/ul>\n<\/li>\n\t<li id=\"menu-item-1720\" class=\"menu-item menu-item-type-post_type menu-item-object-page menu-item-has-children hfe-has-submenu hfe-creative-menu\"><div class=\"hfe-has-submenu-container\" tabindex=\"0\" role=\"button\" aria-haspopup=\"true\" aria-expanded=\"false\"><a aria-expanded=\"false\" href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/material-selection-methods\/\" class = \"hfe-sub-menu-item\">Material Selection Methods<span class='hfe-menu-toggle sub-arrow hfe-menu-child-1'><i class='fa'><\/i><\/span><\/a><\/div>\n\t<ul class=\"sub-menu\">\n\t\t<li id=\"menu-item-1721\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/material-selection-methods\/open-array-fantail-manifolds\/\" class = \"hfe-sub-menu-item\">Open Array Fantail Manifolds<\/a><\/li>\n\t\t<li id=\"menu-item-1722\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a 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\"hfe-sub-menu-item\">Vacuum Loaders<span class='hfe-menu-toggle sub-arrow hfe-menu-child-1'><i class='fa'><\/i><\/span><\/a><\/div>\n\t<ul class=\"sub-menu\">\n\t\t<li id=\"menu-item-3847\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/vacuum-loaders\/the-ultimate-guide-to-self-contained-loaders-for-plastics-processing\/\" class = \"hfe-sub-menu-item\">The Ultimate Guide to Self-Contained Loaders for Plastics Processing<\/a><\/li>\n\t\t<li id=\"menu-item-1725\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/vacuum-loaders\/compressed-air-loaders\/\" class = \"hfe-sub-menu-item\">Compressed Air Loaders<\/a><\/li>\n\t\t<li id=\"menu-item-1726\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/vacuum-loaders\/modern-loader-design\/\" class = \"hfe-sub-menu-item\">Modern Loader Design<\/a><\/li>\n\t\t<li id=\"menu-item-1727\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/vacuum-loaders\/powder-loaders\/\" class = \"hfe-sub-menu-item\">Powder Loaders<\/a><\/li>\n\t\t<li id=\"menu-item-1728\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/vacuum-loaders\/pellet-regrind-loaders\/\" class = \"hfe-sub-menu-item\">Pellet Regrind Loaders<\/a><\/li>\n\t<\/ul>\n<\/li>\n\t<li id=\"menu-item-1729\" class=\"menu-item menu-item-type-post_type menu-item-object-page menu-item-has-children hfe-has-submenu hfe-creative-menu\"><div class=\"hfe-has-submenu-container\" tabindex=\"0\" role=\"button\" 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hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/gaylord-unloading\/lances\/\" class = \"hfe-sub-menu-item\">Lances<\/a><\/li>\n\t<\/ul>\n<\/li>\n\t<li id=\"menu-item-1705\" class=\"menu-item menu-item-type-post_type menu-item-object-page menu-item-has-children hfe-has-submenu hfe-creative-menu\"><div class=\"hfe-has-submenu-container\" tabindex=\"0\" role=\"button\" aria-haspopup=\"true\" aria-expanded=\"false\"><a aria-expanded=\"false\" href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/components\/vacuum-receivers\/\" class = \"hfe-sub-menu-item\">Vacuum Receivers<span class='hfe-menu-toggle sub-arrow hfe-menu-child-1'><i class='fa'><\/i><\/span><\/a><\/div>\n\t<ul class=\"sub-menu\">\n\t\t<li id=\"menu-item-4041\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/components\/vacuum-receivers\/the-ultimate-guide-to-vacuum-receivers-for-plastics-processing\/\" class = \"hfe-sub-menu-item\">The Ultimate Guide to Vacuum Receivers for Plastics Processing<\/a><\/li>\n\t\t<li id=\"menu-item-1713\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/components\/vacuum-receivers\/features-to-consider\/\" class = \"hfe-sub-menu-item\">Features To Consider<\/a><\/li>\n\t\t<li id=\"menu-item-1714\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/components\/vacuum-receivers\/trouble-shooting-vacuum-receivers\/\" class = \"hfe-sub-menu-item\">Trouble shooting<\/a><\/li>\n\t<\/ul>\n<\/li>\n\t<li id=\"menu-item-1733\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/blenders-and-feeders\/\" class = \"hfe-sub-menu-item\">Blenders and Feeders<\/a><\/li>\n\t<li id=\"menu-item-1734\" class=\"menu-item menu-item-type-post_type menu-item-object-page menu-item-has-children hfe-has-submenu hfe-creative-menu\"><div class=\"hfe-has-submenu-container\" tabindex=\"0\" role=\"button\" aria-haspopup=\"true\" aria-expanded=\"false\"><a aria-expanded=\"false\" href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/bulk-resin-storage-and-handling\/\" class = \"hfe-sub-menu-item\">Bulk Resin Storage and Handling<span class='hfe-menu-toggle sub-arrow hfe-menu-child-1'><i class='fa'><\/i><\/span><\/a><\/div>\n\t<ul class=\"sub-menu\">\n\t\t<li id=\"menu-item-1735\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a 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href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/supplemental-system-components\/cyclone-dust-collectors\/\" class = \"hfe-sub-menu-item\">Cyclone Dust Collectors<\/a><\/li>\n\t\t<li id=\"menu-item-1741\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/supplemental-system-components\/take-off-box-probes\/\" class = \"hfe-sub-menu-item\">Take off box probes<\/a><\/li>\n\t\t<li id=\"menu-item-1742\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/supplemental-system-components\/proportioning-purge-valves\/\" class = \"hfe-sub-menu-item\">Proportioning Purge Valves<\/a><\/li>\n\t\t<li id=\"menu-item-1743\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/supplemental-system-components\/station-valves\/\" class = \"hfe-sub-menu-item\">Station valves<\/a><\/li>\n\t\t<li id=\"menu-item-1744\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/supplemental-system-components\/drawer-magnets\/\" class = \"hfe-sub-menu-item\">Drawer Magnets<\/a><\/li>\n\t\t<li id=\"menu-item-1745\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/supplemental-system-components\/vacuum-take-off-box-purge-valve\/\" class = \"hfe-sub-menu-item\">Vacuum Take Off Box Purge Valve<\/a><\/li>\n\t\t<li id=\"menu-item-1746\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/supplemental-system-components\/vacuum-take-off-boxes\/\" class = \"hfe-sub-menu-item\">Vacuum Take Off Boxes<\/a><\/li>\n\t<\/ul>\n<\/li>\n<\/ul>\n<\/li>\n<li id=\"menu-item-1783\" class=\"menu-item menu-item-type-post_type menu-item-object-page menu-item-has-children parent hfe-has-submenu hfe-creative-menu\"><div class=\"hfe-has-submenu-container\" tabindex=\"0\" role=\"button\" aria-haspopup=\"true\" aria-expanded=\"false\"><a aria-expanded=\"false\" href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/components\/conveying-controls\/\" class = \"hfe-menu-item\">Conveying Controls<span class='hfe-menu-toggle sub-arrow hfe-menu-child-0'><i class='fa'><\/i><\/span><\/a><\/div>\n<ul class=\"sub-menu\">\n\t<li id=\"menu-item-1784\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/components\/conveying-controls\/matching-a-control-to-your-system\/\" class = \"hfe-sub-menu-item\">Matching A Control To Your System<\/a><\/li>\n\t<li id=\"menu-item-1785\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/components\/conveying-controls\/vacuum-system-controls\/\" class = \"hfe-sub-menu-item\">Vacuum System Controls<\/a><\/li>\n<\/ul>\n<\/li>\n<li id=\"menu-item-1786\" class=\"menu-item menu-item-type-post_type menu-item-object-page menu-item-has-children parent hfe-has-submenu hfe-creative-menu\"><div class=\"hfe-has-submenu-container\" tabindex=\"0\" role=\"button\" aria-haspopup=\"true\" aria-expanded=\"false\"><a aria-expanded=\"false\" href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/conveying-faq\/\" class = \"hfe-menu-item\">FAQ<span class='hfe-menu-toggle sub-arrow hfe-menu-child-0'><i class='fa'><\/i><\/span><\/a><\/div>\n<ul class=\"sub-menu\">\n\t<li id=\"menu-item-1787\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/conveying-faq\/vacuum-system-technology\/\" class = \"hfe-sub-menu-item\">Vacuum System Technology<\/a><\/li>\n\t<li id=\"menu-item-1788\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/conveying-faq\/contamination\/\" class = \"hfe-sub-menu-item\">Contamination<\/a><\/li>\n\t<li id=\"menu-item-1789\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/conveying-faq\/upgrading-systems\/\" class = \"hfe-sub-menu-item\">Upgrading Systems<\/a><\/li>\n\t<li id=\"menu-item-1790\" class=\"menu-item menu-item-type-post_type menu-item-object-page hfe-creative-menu\"><a href=\"https:\/\/www.novatec.com\/knowledge-center\/plastics-conveying\/conveying-faq\/angel-hair-fines-and-dust\/\" class = \"hfe-sub-menu-item\">Angel Hair Fines and Dust<\/a><\/li>\n<\/ul>\n<\/li>\n<\/ul> \n\t\t\t\t<\/nav>\n\t\t\t<\/div>\n\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-125c879e e-con-full e-flex e-con e-child\" data-id=\"125c879e\" data-element_type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-7bad1d3b elementor-widget elementor-widget-page-title\" data-id=\"7bad1d3b\" data-element_type=\"widget\" data-widget_type=\"page-title.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\n\t\t<div class=\"hfe-page-title hfe-page-title-wrapper elementor-widget-heading\">\n\n\t\t\t\t\t\t\t\t\t\t\t<a href=\"https:\/\/www.novatec.com\/knowledge-center\">\n\t\t\t\t\t\t<h1 class=\"elementor-heading-title elementor-size-default\">\n\t\t\t\t\t\t\t\t\n\t\t\t\tOvercoming Long Conveying Distances  \n\t\t\t<\/h1 > \n\t\t\t\t\t\t\t\t\t<\/a>\n\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-5930d2dd e-con-full e-flex e-con e-child\" data-id=\"5930d2dd\" data-element_type=\"container\">\n\t\t<div class=\"elementor-element elementor-element-07c2a93 e-con-full e-flex e-con e-child\" data-id=\"07c2a93\" data-element_type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-c5aa6e1 elementor-widget elementor-widget-text-editor\" data-id=\"c5aa6e1\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>What if you could extend an existing resin conveying system without changing the piping, increasing the number of pumps, or greatly affecting operating costs and energy consumption? Replacing the conveying system\u2019s vacuum pump may be the key.<\/p><div><p>Jim Zinski, Senior Vice President of System Design, NOVATEC<\/p><p>Air and vacuum work together to make everything happen in a resin conveying system. Airflow creates the velocity to pick up and move the resin through the pipes. \u00a0Vacuum energy overcomes the resistance air and material encounter as they move through the pipes.\u00a0 The conveying system\u2019s \u201cengine\u201d is the pump, which is the source for blow airflow and vacuum.<\/p><p>This is why vacuum pump selection is crucial for maximizing the efficiency of any resin conveying system, and for minimizing line plugs and machine starving. \u00a0Pump selection is also crucial when expanding an existing conveying system, that is, when adding stations and increasing conveying distances\u2014without having to rip-and-replace the existing system, add excessive capital costs and maintenance, and suffer major interruptions to existing production.<\/p><\/div><h2><strong>Air is Key<\/strong><\/h2><p>Vacuum conveying systems use air to pull resin materials through a pipe or tube. Pumps generate air flow to pick up and move resin through the piping of a conveying system. This air flow is typically defined in units of cubic feet per minute (cfm). \u00a0Dividing this air flow by the cross-sectional area of the tube yields velocity in feet per minute, fpm.\u00a0 The higher the air flow in a pipe, the higher the air velocity. \u00a0Too much velocity for moving resin can waste some of the pump\u2019s available vacuum energy, as well as the electricity to power the pump. Excessive velocity also leads to a variety of operational inefficiencies, including material degradation and contamination, pipe and elbow abrasion, additional maintenance and replacement costs, and shortened lifetime for the conveying system.A conveying system\u2019s pump must also overcome the resistance generated by moving both air and material through the piping. This resistance is pressure drop, which defines the energy needed to move air and material from a source to a destination. \u00a0Pressure drop is defined by the unit inches of mercury (\u201cHg). \u00a0In general, pressure drop increases as piping lengths or the number of elbows in the system increase, or both. Pressure drop also increases when adding more material to the air stream; more material adds more friction, causing the pump to work harder to accelerate that additional material.<\/p><p>The minimum pickup velocity for many resins is about 3,000 fpm.\u00a0 In a 2-inch diameter system, this velocity requires an air flow of about 60 cfm. \u00a0That air traveling through the conveying line\u2014by itself and without material mixed in\u2014creates a pressure drop of about 0.75\u201dHg per 100\u2019. \u00a0So over a 400-foot length of 2-inch diameter tubing, the pressure drop would be about 3\u201dHg\u2014just to move the air. \u00a0So the pump vacuum available to move material in that setup is reduced 3\u201dHg.<\/p><h3><strong>Pump Types<\/strong><\/h3><p>Several types of vacuum pumps can move air in a resin conveying system (see Table 1). Single-stage regenerative pumps are the smallest, quietest, and least expensive. They also have the lowest vacuum capacity (about 6-9\u201dHg maximum depending on tube diameter). \u00a0These pumps are ideal for conveying light loads across short distances in systems with up to about 2.5-inch diameter tube.<\/p><p>Two-stage regenerative pumps are similar, but physically larger, than single-stage regenerative pumps. They use more horsepower than the single-stage pumps to create higher vacuums, up to 12\u201dHg. \u00a0These pumps are best suited for conveying materials across moderate distances at moderate rates, with tubing diameters up to 2.5\u201d diameter.<\/p><p>Positive displacement (PD) pumps, considered by many the industry standard, provide the widest range of airflow (e.g., 55 to 470 cfm) and vacuum levels up to 14\u201dHg. \u00a0These pumps are often installed for conveying resins across long distances in systems with tubing up to 4\u201d diameter. \u00a0Two-stage regenerative pumps are quieter and more compact than PD pumps, but the latter are more efficient.<\/p><p>Two types of high-efficiency vacuum pumps produce up to 25% more vacuum capacity than standard PD pumps. Higher vacuum yields higher conveying rates and longer distances. Max-efficiency PD pumps produce operating vacuums up to 14\u201dHg (maximum vacuum up to 15\u201dHg) through a rugged design that includes a heavy-duty roller bearing, helical gears, a tri-lobe rotor, with models ranging from 5 hp to 20 hp. These pumps are more energy efficient than regenerative pumps and quieter than PD pumps.<\/p><p>Another high-efficiency pump option is the hooked-rotor vacuum pump (also called \u201chook &amp; claw\u201d or \u201cclaw-type\u201d pump). \u00a0The claw design compresses air while it\u2019s inside the pump housing, increasing the operating vacuum for conveying up to 15\u201dHg (17\u201dHg maximum vacuum). \u00a0These pumps come in models ranging from 4 hp to 15 hp, and they are extremely energy efficient, requiring nearly half the energy of regenerative pumps and up to 25% less energy than standard PD pumps for a given vacuum and airflow target. \u00a0They are also quieter than PD pumps in comparable vacuum ranges.\u00a0 Claw pumps provide the higher conveying rates and plug-breaking capability than any other pump. However, the high relative cost of these pumps (Table 1) generally limits their use except for unusual conditions that can\u2019t be overcome by other pumps.<\/p><p>Realizing that operating vacuum and maximum vacuum are different is important. Operating vacuum is the maximum vacuum a conveying system should pull during normal operation, and it\u2019s the basis for calculating the system\u2019s maximum conveying rate. Designing a conveying system to the pump\u2019s maximum vacuum leaves no \u201cwiggle room.\u201d A dirty filter, for example, can cause the system to exceed maximum vacuum capacity and possibly open a relief valve, which will effectively slow or stop material movement. \u00a0Designing to the operating vacuum also saves some extra vacuum in reserve to clear an overfed conveying line of material slugs.<\/p><h3><strong>Pumps for system expansion<\/strong><\/h3><p>Consider a conveying system with 2-inch diameter piping, several elbows, and stations amounting to 400\u2019 of equivalent conveying distance. (See Equivalent Distance Chart) \u00a0A single-stage pump would generate an operating design vacuum of 6.5\u201dHg; a 2-stage pump, 10.5\u201d of Hg; a PD pump, 11.5\u201d of Hg (see Table 2).<\/p><p>As noted earlier, the pressure drop for air pulled through this system setup, having a pickup velocity of 3,000 fpm, is 3\u201dHg.\u00a0 Because the PD pump is typically belt driven, it can be designed to rotate at the rpm required to deliver that performance.\u00a0 Because Regen pumps are direct drive, they operate at a fixed speed, and normally create a pickup velocity of 4,000 fpm or more.\u00a0 More air speed at the pickup creates more system resistance to air movement, resulting in 4\u201dHg pressure drop for the same installation.<\/p><p>Comparing operating vacuum and system air pressure drop, we see the three pumps are very different in terms of vacuum available for moving materials.\u00a0 For the single-stage pump, 2.5\u201dHg is available; the 2-stage pump, 6.5\u201dHg; and for the PD pump, 8.5\u201dHg is available\u2014more than triple the capacity of the single-stage pump. This excess vacuum helps deliver more conveying rate to accommodate the added stations, and overcome longer distances typically required when adding stations.\u00a0 Replacing a pump with model that can generate more usable vacuum at the required airflow may obviate the need to rip out all the conveying lines and install a new system.<\/p><p>Consider a continuation of this example. Say the heretofore 400-foot system is lengthened, more elbows are added along with some flexible hose, and the vacuum pump has been repositioned closer to the resin pickup point, thereby lengthening the vacuum line. This expansion has more than doubled the length than the previous example to 1,000\u2019 (equivalent). The pressure drop required is now 9\u201dHg. While the design vacuum of the three pumps stays the same, the available vacuum for conveying is smaller (see Table 3). The single-stage pump won\u2019t work at all in the extended system. The dual-stage and standard PD pumps will suffice\u2014barely, with little extra vacuum for clearing out the pipelines or future expansion.<\/p><p>Here now are the options. The simple solution is to replace the existing vacuum pump with one that provides more vacuum (i.e., increased capacity) if that is at all possible. For instance, a PD pump is a simple plug-and-play replacement for a single-stage regenerative pump. With an existing PD pump, you could change the sheaves to change the pump\u2019s speed. Because pump speed is proportional to the amount of airflow generated, faster pump speed will yield greater airflow. However, that can lead to material degradation and piping wear. This change will also increase the pressure drop in the conveying system, as well as the pump\u2019s energy consumption.<\/p><p>A more-expensive option is to convey material in two stages through the extended system. However, adding a second pump also requires a new central filter, new vacuum line and pickup, and possibly a control system, as well as all the associated costs in capital expense, reliability, and ongoing maintenance. Another option is to rip out all the conveying line and replace it with 2.5\u201d or 3\u201d diameter piping\u2014with a new pump. This is the most expensive option.<\/p><p>Probably the best option\u2014faster to install, less disruptive, least expensive in terms of operating costs, and one that ensures against in-line plugs, starving machines, and other conveying problems\u2014is to replace the existing regenerative or PD pump with a high-efficiency pump. The latter will have the higher vacuum required to convey the extra distance and carry the extra material.<\/p><p><strong>What to do?<\/strong><\/p><p>Selecting the correct pump for resin conveying is crucial in maximizing machine uptime, minimizing machine starving, reducing material and labor costs, and improving product quality and overall plant efficiency. Just as important, the correct pump can be the very key to extending an existing conveying system at minimal cost and downtime, while maximizing the efficiency of the conveying system.<\/p><p>Table 1<\/p><h2><strong>Typical Vacuum Capability of Conveying System Pumps<\/strong><\/h2><table border=\"1\" cellspacing=\"0\" cellpadding=\"0\"><tbody><tr><td style=\"width: 204px;\"><p align=\"center\"><strong>Pump<\/strong><\/p><\/td><td style=\"width: 84px;\"><p align=\"center\"><strong>Typical Line Sizes<\/strong><\/p><\/td><td style=\"width: 102px;\"><p align=\"center\"><strong>Operating Vacuum<\/strong><\/p><\/td><td style=\"width: 90px;\"><p align=\"center\"><strong>Maximum Vacuum<\/strong><\/p><\/td><td style=\"width: 78px;\"><p align=\"center\"><strong>Relative Cost<\/strong><\/p><\/td><\/tr><tr><td style=\"width: 204px;\">Single-Stage Regenerative<\/td><td style=\"width: 84px;\"><p align=\"center\">1\u00bd\u201d- 2\u00bd\u201d<\/p><\/td><td style=\"width: 102px;\"><p align=\"center\">6.5\u201d- 8.5\u201d Hg<\/p><\/td><td style=\"width: 90px;\"><p align=\"center\">10\u201d Hg<\/p><\/td><td style=\"width: 78px;\"><p align=\"center\">$<\/p><\/td><\/tr><tr><td style=\"width: 204px;\">Dual-Stage Regenerative<\/td><td style=\"width: 84px;\"><p align=\"center\">1\u00bd\u201d- 2\u00bd\u201d<\/p><\/td><td style=\"width: 102px;\"><p align=\"center\">10\u201d- 11\u201d Hg<\/p><\/td><td style=\"width: 90px;\"><p align=\"center\">12\u201d Hg<\/p><\/td><td style=\"width: 78px;\"><p align=\"center\">1.5 $<\/p><\/td><\/tr><tr><td style=\"width: 204px;\">Positive Displacement (PD)<\/td><td style=\"width: 84px;\"><p align=\"center\">1\u00bd\u201d- 4\u201d`<\/p><\/td><td style=\"width: 102px;\"><p align=\"center\">11&#8243; &#8211; 12\u201d Hg<\/p><\/td><td style=\"width: 90px;\"><p align=\"center\">13\u201d Hg<\/p><\/td><td style=\"width: 78px;\"><p align=\"center\">1.5-2 $<\/p><\/td><\/tr><tr><td style=\"width: 204px;\">Maximum Efficiency PD<\/td><td style=\"width: 84px;\"><p align=\"center\">2\u201d- 3\u00bd\u201d<\/p><\/td><td style=\"width: 102px;\"><p align=\"center\">13\u201d &#8211; 14\u201d Hg<\/p><\/td><td style=\"width: 90px;\"><p align=\"center\">15\u201d Hg<\/p><\/td><td style=\"width: 78px;\"><p align=\"center\">$$<\/p><\/td><\/tr><tr><td style=\"width: 204px;\">Ultra-High Efficiency Hooked Rotor<\/td><td style=\"width: 84px;\"><p align=\"center\">2\u201d- 3\u201d<\/p><\/td><td style=\"width: 102px;\"><p align=\"center\">14\u201d &#8211; 15\u201d Hg<\/p><\/td><td style=\"width: 90px;\"><p align=\"center\">17\u201d Hg<\/p><\/td><td style=\"width: 78px;\"><p align=\"center\">$$$<\/p><\/td><\/tr><\/tbody><\/table><p>Table 2<\/p><h2><strong>Typical 2&#8243; System Conveying 400\u2019 (equivalent)<\/strong><\/h2><table border=\"1\" cellspacing=\"0\" cellpadding=\"0\"><tbody><tr><td style=\"width: 174px;\"><p align=\"center\"><strong>Pump<\/strong><\/p><\/td><td style=\"width: 115px;\"><p align=\"center\"><strong>Design Vacuum<\/strong><\/p><\/td><td style=\"width: 143px;\"><p align=\"center\"><strong>Air Pressure Drop<\/strong><\/p><\/td><td style=\"width: 144px;\"><p align=\"center\"><strong>Available Vacuum<\/strong><\/p><\/td><\/tr><tr><td style=\"width: 174px;\">Single-Stage Regenerative<\/td><td style=\"width: 115px;\"><p align=\"center\">6.5\u201d Hg<\/p><\/td><td style=\"width: 143px;\"><p align=\"center\">4\u201d Hg<\/p><\/td><td style=\"width: 144px;\"><p align=\"center\">2.5\u201d Hg<\/p><\/td><\/tr><tr><td style=\"width: 174px;\">Dual-Stage Regenerative<\/td><td style=\"width: 115px;\"><p align=\"center\">10.5\u201d Hg<\/p><\/td><td style=\"width: 143px;\"><p align=\"center\">4\u201d Hg<\/p><\/td><td style=\"width: 144px;\"><p align=\"center\">6.5\u201d Hg<\/p><\/td><\/tr><tr><td style=\"width: 174px;\">Positive Displacement<\/td><td style=\"width: 115px;\"><p align=\"center\">11.5\u201d Hg<\/p><\/td><td style=\"width: 143px;\"><p align=\"center\">3\u201d Hg<\/p><\/td><td style=\"width: 144px;\"><p align=\"center\">8.5\u201d Hg<\/p><\/td><\/tr><\/tbody><\/table><p>Table 3<\/p><h2><strong>Typical 2\u201d Extended System Conveying 1,000\u2019 (equivalent)<\/strong><\/h2><table border=\"1\" cellspacing=\"0\" cellpadding=\"0\"><tbody><tr><td style=\"width: 204px;\"><p align=\"center\"><strong>Pump<\/strong><\/p><\/td><td style=\"width: 85px;\"><p align=\"center\"><strong>Design Vacuum<\/strong><\/p><\/td><td style=\"width: 143px;\"><p align=\"center\"><strong>Air Pressure Drop<\/strong><\/p><\/td><td style=\"width: 144px;\"><p align=\"center\"><strong>Available Vacuum<\/strong><\/p><\/td><\/tr><tr><td style=\"width: 204px;\"><p>Single-Stage Regenerative<\/p><\/td><td style=\"width: 85px;\"><p align=\"center\">6.5\u201d Hg<\/p><\/td><td style=\"width: 143px;\"><p align=\"center\">10\u201d Hg<\/p><\/td><td style=\"width: 144px;\"><p align=\"center\">0\u201d Hg<\/p><\/td><\/tr><tr><td style=\"width: 204px;\"><p>Dual-Stage Regenerative<\/p><\/td><td style=\"width: 85px;\"><p align=\"center\">10.5\u201d Hg<\/p><\/td><td style=\"width: 143px;\"><p align=\"center\">10\u201d Hg<\/p><\/td><td style=\"width: 144px;\"><p align=\"center\">0.5\u2019 Hg<\/p><\/td><\/tr><tr><td style=\"width: 204px;\"><p>Positive Displacement (PD)<\/p><\/td><td style=\"width: 85px;\"><p align=\"center\">11.5\u201d Hg<\/p><\/td><td style=\"width: 143px;\"><p align=\"center\">9\u201d Hg<\/p><\/td><td style=\"width: 144px;\"><p align=\"center\">2.5\u201d Hg<\/p><\/td><\/tr><tr><td style=\"width: 204px;\"><p>Maximum Efficiency PD<\/p><\/td><td style=\"width: 85px;\"><p align=\"center\">14\u201d Hg<\/p><\/td><td style=\"width: 143px;\"><p align=\"center\">10\u201d Hg<\/p><\/td><td style=\"width: 144px;\"><p align=\"center\">4\u201d Hg<\/p><\/td><\/tr><tr><td style=\"width: 204px;\"><p>Ultra-High Efficiency Hooked Rotor<\/p><\/td><td style=\"width: 85px;\"><p align=\"center\">15\u201d Hg<\/p><\/td><td style=\"width: 143px;\"><p align=\"center\">10\u201d Hg<\/p><\/td><td style=\"width: 144px;\"><p align=\"center\">5\u201d Hg<\/p><\/td><\/tr><\/tbody><\/table>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-715220cf e-con-full e-flex e-con e-child\" data-id=\"715220cf\" data-element_type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-31aeb960 elementor-widget elementor-widget-shortcode\" data-id=\"31aeb960\" data-element_type=\"widget\" data-widget_type=\"shortcode.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t<div class=\"elementor-shortcode\">\t\t<div data-elementor-type=\"section\" data-elementor-id=\"632\" class=\"elementor elementor-632\" data-elementor-post-type=\"elementor_library\">\n\t\t\t<div class=\"elementor-element elementor-element-f5e2127 e-flex e-con-boxed e-con e-parent\" data-id=\"f5e2127\" data-element_type=\"container\">\n\t\t\t\t\t<div class=\"e-con-inner\">\n\t\t<div class=\"elementor-element elementor-element-f739977 e-con-full e-flex e-con e-child\" data-id=\"f739977\" data-element_type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-cc9d922 elementor-widget elementor-widget-heading\" data-id=\"cc9d922\" data-element_type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">Ask the Expert<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-3583113 elementor-widget elementor-widget-image\" data-id=\"3583113\" data-element_type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t\t\t\t<figure class=\"wp-caption\">\n\t\t\t\t\t\t\t\t\t\t<img fetchpriority=\"high\" decoding=\"async\" width=\"768\" height=\"777\" src=\"https:\/\/www.novatec.com\/knowledge-center\/wp-content\/uploads\/2024\/08\/Conveying-Expert-0623-copy-768x777.png\" class=\"attachment-medium_large size-medium_large wp-image-2422\" alt=\"\" srcset=\"https:\/\/www.novatec.com\/knowledge-center\/wp-content\/uploads\/2024\/08\/Conveying-Expert-0623-copy-768x777.png 768w, https:\/\/www.novatec.com\/knowledge-center\/wp-content\/uploads\/2024\/08\/Conveying-Expert-0623-copy-296x300.png 296w, https:\/\/www.novatec.com\/knowledge-center\/wp-content\/uploads\/2024\/08\/Conveying-Expert-0623-copy.png 1000w\" sizes=\"(max-width: 768px) 100vw, 768px\" \/>\t\t\t\t\t\t\t\t\t\t\t<figcaption class=\"widget-image-caption wp-caption-text\">Ryan Ismirlian, Conveying Product Engineer Novatec, Inc.<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-db72973 elementor-widget elementor-widget-heading\" data-id=\"db72973\" data-element_type=\"widget\" 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What if you could extend an existing resin conveying system without changing the piping, increasing the 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