The Importance of Custom Seals for Specialised Machinery

Seals that are used in industrial machinery are available in a number of types:

• O-rings and gaskets that are used in static and dynamic applications, typically as sealing solutions in pipes, flanges and various fittings.
• Mechanical seals that are present in rotary equipment such as compressors and pumps.
• Lip seals and rotary shaft seals that protect bearings and shafts.
• Face seals that are between rotating and stationary parts in mixers and pumps.
• Hydraulic and pneumatic seals that are used in pumps, cylinders and activators.

In some cases, standard seals may suffice for processes and machinery that are relatively simple and not very demanding. More commonly, however, industrial machinery is intended for very specialised purposes where standard seals cannot meet the demands. In these cases, custom seals are designed and manufactured to meet their needs.

As new manufacturing techniques emerge and machinery becomes even more specialised, the demands on seals will become even greater. This will emphasise even more the vital role that custom seals play in the manufacturing process.

The Essential Roles that Custom Seals Fulfil

Seals in machinery are there for a number of purposes:

• They provide a tight seal at the join between two components and prevent the leakage of gases and fluids. This preserves the integrity of a system and is crucial in industries such as pharmaceuticals and chemical processing where leaks can cause safety issues and can compromise products and the whole production process.
• Tight and efficient seals will prevent dirt and dust getting into the machinery and causing performance problems that can ultimately result in machine failure and costly downtime.
• Seals can cushion the effects of moving parts, reduce vibration and cause less friction, which will mean lower levels of wear, reduced maintenance and a longer life for the machinery. They will also lower operational noise levels, which overcomes some health and safety issues.
• Excessive friction and the leakage of fluids and gases will reduce the efficiency of a machine. Seals will avoid this and so ensure improved productivity and reduced energy costs.
• In heavily regulated industries such as pharmaceuticals and food processing, effective seals will prevent contamination and ensure compliance with standards.

All seals can help to fulfil these roles but standard seals have many limitations and custom seals will be far better.

Why Custom Seals are Better than Standard Seals

Although standard seals have their uses, they cannot compete with custom seals when used in specialised machinery:

• Specialised machinery, by its very nature, is intended to handle particular jobs and is created specifically for those jobs. It may therefore have many unique features, intricate shapes and complex designs that standard seals cannot accommodate due to their limited range of sizes and shapes. Trying to make them fit will mean adapting the machine, which may reduce its effectiveness. Custom seals are designed and manufactured with precise dimensions so they will fit the machinery perfectly. This ensures the seals will always fulfil their essential roles and that the machinery functions perfectly.
• Many machines have to operate in very harsh environments, experiencing high pressure, extremes of temperature, grease, dust and aggressive chemicals. Any of these may cause a standard seal to degrade and fail quickly. Custom seals, however, are specifically made to withstand these conditions using materials that are resistant. They will therefore have the necessary elasticity, durability and longevity so they can provide uninterrupted and reliable protection.
• Custom seals require tooling and moulds that are specially made so the initial cost will be higher than for standard seals. However, because they will last much longer, cause less downtime, have lower maintenance needs, reduce energy costs and ensure greater throughput, they have much lower operating costs and so the overall cost of ownership will be less.
• Due to safety concerns, industries such as aerospace, pharmaceuticals and food processing have strict standards that have to be met. By using approved materials and specific manufacturing methods, custom seals can ensure complete compliance with all regulations. Standard seals use basic materials that cannot match these standards.
• When developing new specialised machinery for a product, it will need to be fully tested and approved before it goes into production. The availability of custom seals will help the process because prototype seals can be made available, adapted as necessary and then supplied in quantity when everything works as required, which speeds up the development process.

Where Custom Seals are Used

Almost all industries will use custom seals to some degree but they are particularly common in certain ones:

• Automotive manufacturing uses them in engines and cooling systems where they are required to ensure complete reliability and high performance standards.
• Power generation plants require them to be able to withstand steam and fluids at high pressure so the operation is uninterrupted.
• Aerospace uses them extensively in equipment where absolute safety and reliability are essential.
• Chemical and pharmaceutical industries place great emphasis on safety, sterility and reliability, particularly in machinery where there are volatile compounds or corrosive chemicals.
• Water treatment plants require processing that is long-lasting and largely free of maintenance despite pressure fluctuations.

Ensuring you Achieve all the Benefits of Custom Seals

If you have specialised machinery or processes, the use of custom seals is essential to ensure you achieve optimum performance without leaks or failures. Standard seals cannot handle non-standard equipment or challenging environments and will invariably fail and cause unnecessary problems and extra costs.

The adoption of new manufacturing techniques is ongoing and regulations affecting industries are constantly changing, presenting continuous challenges for businesses. However, new materials and sealing systems are being developed to deal with them so it is essential you know what is happening.

At Gulf Rubber, we are fully experienced in all types of sealing systems and keep fully abreast of developments so we can always take advantage of the latest materials and techniques. No matter how specialised your machinery and irrespective of the environment in which it operates, we can provide custom seals that are fully effective and at a competitive price. Get in touch to tell us what you need.