6 Benefits of Custom Sealing for Industrial Uses
Standard seals are fine for common applications where there are no critical factors that have to be met. They are relatively cheap, readily available and will meet standards. But, if you want something that is out of the ordinary, only a custom seal will suffice.
A custom seal is specifically made for an application and so will provide precision, reliability and durability. It can be used in challenging conditions and will deliver the performance that is needed, which is something a standard seal cannot do.
A custom seal provides many advantages over a standard version and the extra effort to provide it is always justified.
The Critical Role of Seals in Industrial Machinery
Industrial machinery earns money only when it is operating and, the more efficient it is, the more profitable it will be. Many of those machines spend their time pumping gas or liquids and it is important this is done efficiently, with no leaks or loss of pressure.
Industrial seals are relatively small but nevertheless are crucial elements in any machine. They ensure the gas or liquid continues to flow, with no leaks or loss of pressure, and so the process continues uninterrupted.
1. Optimised Performance and Efficiency
Because custom seals are specifically designed for a particular application, they exactly match the shape and dimensions of the equipment to which they are fitted. This ensures a perfect fit and a tight seal to prevent leaks.
Custom seals are also made from particular rubber compounds that are selected for their ability to work in a specific environment. They may have to resist extreme temperatures, high pressure and the effect of harsh chemicals to deliver optimum efficiency with minimal friction to avoid wear.
2. Protecting Equipment from Contaminants and Leaks
Leaks in industrial equipment can be a serious problem. A failure of a fuel line will stop a machine completely while a lack of oil will cause friction and overheating. Any gas or liquid being processed needs to be delivered consistently so a leak will prevent that and stop the operation.
For companies involved in food processing or pharmaceuticals, cleanliness is crucial so a leak can be even more serious because it can cause contamination that can stop production entirely and require a major clean-up before re-starting. And harsh chemicals leaking from pipes will be a serious safety issue and can damage equipment so that lengthy and costly repairs will be required. So, leaks are an extremely serious problem and need to be prevented by fitting custom rubber products that give a tight and reliable seal.
3. Withstanding Extreme Temperatures and Chemicals
Many processes involve extremely harsh conditions that include very high or low temperatures, extreme pressure and exposure to harsh chemicals that can cause corrosion. Any equipment that is used has to be able to withstand these conditions, including custom sealing that must retain its elasticity, minimise wear and prevent extrusion.
Failure of the seals is prevented by using suitable materials that are able to withstand the operating conditions without failing. Various rubber compounds are available with different characteristics — high tensile strength, resistance to certain chemicals and the ability to withstand extremes of temperature and pressure. Choosing the right one ensures seals will perform reliably in specific conditions.
4. Reducing Maintenance and Downtime Costs
Since custom seals are designed for specific conditions and are made from suitable materials, they are able to withstand these conditions and perform reliably and efficiently. As a result, they experience less wear and have a much longer service life.
Although the initial investment is higher for custom seals than for standard versions, they are much more durable and perform better with less downtime. They require less maintenance and infrequent replacement, reduce friction and can lower energy costs. With a reduced chance of equipment failure and better performance, custom seals deliver greater efficiency that more than offsets their higher initial cost.
5. Compliance with Industry Standards and Regulations
Most industries are regulated in some way. This particularly applies to aerospace where safety is a major concern and to food and beverage processing and pharmaceuticals that have extremely strict hygiene standards.
Unlike standard seals that are for general purpose use, custom seals can be specifically designed to comply with certain regulations. This can include using materials that have great tensile strength, that can withstand particularly harsh conditions or are classed as food standard. Using custom seals, you can be assured of absolute safety in use and complete compliance with regulations.
6. Tailored Solutions for Specialised Equipment
Many industries have unique applications where standard seals are not suitable. Equipment used may have unusual dimensions or may operate in harsh conditions where standard seals will not work effectively.
Custom seals are designed specifically for those situations and can have intricate features and shapes that will fit perfectly. They will also provide total flow control and ensure optimum efficiency.
The best time to contact us is at the start of your design process so we can help and advise, can produce a custom seal that fits in with your needs and can ensure the whole process works as efficiently as possible.
We can also help later in the design process if you have concluded that a standard seal is not suitable for your equipment or if you have developed a prototype and the equipment keeps failing due to standard seals malfunctioning. We have plenty of experience of working at every stage and have produced moulds and custom seals for many applications, so can adapt existing designs to save development costs or use an entirely new approach.
No matter what stage you have reached in a project, we can help to make it work better and more reliably with custom seals that provide a prefect fit and will not let you down.
Gulf Rubber is a leading industrial standard and custom seals manufacturer, specializing in providing tailored sealing solutions for diverse applications across multiple industries.
Get in touch and we will put your project firmly on the right track with an efficient and leak-free process that will increase your productivity and profitability.