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The History of Real Seal
The best companies evolve over time, and Real Seal is no different. As a company that has strived to fill the needs of its customers, we’ve adapted to the growing and changing needs of American industry. Originally, in 1970, Real Seal was just a distributor of O rings, but over the course of our company history we’ve expanded what we do; from distributing sealing and mechanical components to individualized custom solutions.
Progress in Technology
Real Seal is structured in such a way as to be able to serve the splintered needs of industry in America. Technology is moving at a faster rate than ever and we do everything we can do to remain on the cutting edge. The key to this is to remain agile and ready for whatever our customer needs have been throughout history.
We have managed to stay in the forefront by keeping a fully equipped laboratory, as well as having a full time chemist and technical staff. This allows us to cater to any customer’s need, assist in development, and provide custom solutions.
Individualized Solutions
While we started out as a distributor, we’ve advanced to a much more direct relationship with the industry and our customers. Many other companies act as go-betweens to large suppliers or offshore companies. Everything is located in our facility, so this is a one-to-one exchange. We are interested in building long term relationships, as well as quality service and solutions, with competitive economics.
From material recommendations, to writing specifications for challenging applications, and ultimately prototypes for application testing, Real Seal does it all.
New Demands
A new challenge which grows every year is the ability for companies to remain environmentally safe and compliant with regulations. Customers often look for companies that are environmentally conscious, and government regulation ramps up as the issues of climate and pollution move to the forefront. Real Seal has helped many companies comply with these challenges with our solutions, providing economical results.
New Materials, New Solutions
Originally, many components were made of metal. Over time, the industry has switched over to new materials such as engineered thermoplastic. Plastic isn’t the only material that has undergone some development through its history, even rubber has been engineered to be superior to metal and has some properties superior to plastics.
There are many different engineered materials that have been created throughout history, especially plastics, each having their own unique properties and uses. Real Seal carries thousands of different types for the needs of our customers.
Since so many manufacturers now create their own OEM parts for their equipment, moving away from standardized parts and sizes, it is imperative that a company can adapt to niche specifications for their customers. Real Seal has adapted to these practices and is experienced in fitting these kinds of specifications.
Changes in Operating Procedures
Traditionally, the model for production has been to get maximum productivity from capital equipment (equipment that is used to make products such as machines and their components), running the equipment as hard as possible. This has changed and Real Seal is no exception, running capacity no higher than 70% before bringing in new capital equipment, and reducing the average amortization cost for tools more than 50% over the last 10 years.
Since the demands of markets are so specific and require precision, the market has become so much more individualized and fragmented. Real Seal utilizes a modular tooling system for injection molding, where most tools are created with inserts that are retrofitted to existing mold bases. They are then optimized for the size and weight of the machine they are mounted in. These inserts are standardized, allowing for a more economical product.
Moving Forward
As industry changes, so will Real Seal. Adapting to the shifting markets is of the utmost concern and fitting the needs of the customer is our priority. You can expect the best from Real Seal because of our extensive history and expertise. What will never change is our commitment to the customer and quality products. Contact us today for all of your manufacturing needs.
ISO 9001 and How it is Essential to Quality Seals and Components
You might be wondering: What is ISO 9001? The ISO website defines it as a standard for a quality management system. This allows businesses to run more efficiently, as well as improve customer satisfaction. Real Seal is registered ISO 9001 and this article will be focusing on how ISO 9001’s eight quality management principles are essential to quality seals and components.
1: Customer Focus
Any producer of a product depends on its customers. Striving to meet every customer’s needs, whether it be a newly designed solution or one that already exists, quality seals and components should be what the customer needs. The ability to create custom solutions is a necessity in the world of manufacturing components.
The seals and mechanical components Real Seal manufactures and distributes are of the highest quality, and ISO 9001 ensures a focus on not only meeting a customer’s expectations, but exceeding them.
2: Leadership
Any company without effective leadership will inevitably fail. ISO 9001 emphasizes that leaders establish unity in an organization, creating an environment where everyone can reach their full potential.
When creating essential parts such as seals and other mechanical components, it is key that the machinery of a company is as effective as its parts. Otherwise, an inferior product is created. Through ISO 9001, a company can become effective in focusing their direction, leading to a superior product.
3: Involvement of People
Recognizing that all levels of workers in an organization are just as essential to its quality as the top management further ensures a quality product. To appreciate those that do the most basic tasks ensures quality of work. In the manufacturing of quality seals and components, not only are the top chemists important, but also the technical staff and customer service. A complete experience is required by the customer, not only of the physical products, but also the relationship. If communication breaks down, that is just as detrimental as a part being degraded. Every part of an organization is important, just as every part in a machine is important. One loose screw, or weak seal, can cause a catastrophe.
4: Process Approach
To get the results desired, all parts of a production must be treated as a step-by-step process. This ensures a uniform quality in products. When seals and components are manufactured to a specification, it is imperative that they all work the same way. In order to make sure that each piece is identical, the process by which those same pieces are made should also be identical. When a customer orders a specific O ring, it should be exactly what they want.
5: System Approach to Management
These processes as individuals may seem separate at first, but that often isn’t the case. An organization needs to recognize which processes are linked together. Some processes may use similar assets and could create a bottleneck in production, so assuring that the flow of these processes is optimal improves efficiency, ultimately saving money, which is passed on to the consumer.
6: Continual Improvement
It is never okay to be content with performance, whether it is the parts manufactured or how an organization runs. Stagnation is the first step in decline. ISO 9001 ensures that not only are seals and components continually optimized, but also how they are managed and produced. This makes for a superior product with equally attractive economics.
7: Factual Approach to Decision Making
Data and information are the driving factors in creating the best possible seals and components. To merely claim something functions the way it does or using an appeal to emotion is a totally ineffective approach to the science of manufacturing. Real Seal performs routine PPAP data analysis and reporting, and a fully equipped laboratory ensures a fact-based approach to analyzing products.
8: Mutually Beneficial Supplier Relationships
As a supplier to other businesses, Real Seal has a deep understanding of this principle. Not only do we seek beneficial relationships with our own suppliers, extending that same relationship to our clients is paramount. It is a boon to both parties in a transaction if they are able to forge a long-term relationship, learning to understand needs and building trust. This principle also emphasizes a high-quality product that the customer will come back for in the future.
Quality Seals and Components
Real Seal’s ISO 9001 registration binds them to these principles. So, if you require quality seals and components, it is essential to find a manufacturer following a proven quality management system. Contact Real Seal for all your seal and component needs.
The Difference Between Thermoset and Thermoplastic Materials
Each application will have its own unique circumstances and requirements. For some, the ability to resist abrasion will be the top priority, while another might need a material that can resist extreme temperatures.
Choosing the right material for your application will be an involved process that takes every factor into consideration. In order to select the right one, you will need to understand the properties of the material you are selecting. That’s why we are going to take the time today to distinguish between the two biggest categories of elastomers: thermoset and thermoplastic.
Thermoset Materials
Thermoset materials simply refer to those plastics which will cure (or harden) into a certain shape once a sufficient amount of heat is applied. This heating process is called curing or vulcanization, and it is meant to improve the physical property of a certain material by exposing it to heat or some other catalyst which can set off a chain reaction within the material.
Before undergoing vulcanization, a thermoset material consists of small, unlinked molecules called monomers. But during the vulcanization process, these monomers develop permanent connections with each other called cross-links.
These cross-links will form long molecular chains which give the material a much more rigid three-dimensional structure. Once vulcanization is complete, the material can no longer be remelted or process the way it was prior to vulcanization. For this reason, thermoset materials are relied on for high temperature applications like electronics and appliances.
Thermoset materials possess a number of advantages over thermoplastic materials, including superior mechanical properties, chemical resistance, heat resistance, and structural integrity. They generally have a much lower material cost and are much easier to process.
Common thermoset materials include polyurethane and silicone. Polyurethane is well-noted for having the highest tensile strength (i.e. resistance to tear and abrasion) of any plastic. Silicone, on the other hand, is well-regarded for its ability to resist compression set, flames, and extreme temperatures.
Thermoplastics
Thermoplastic materials typically come in a pellet form which becomes soft, fluid, and pliable after vulcanization. The vulcanization process for thermoplastics involves placing the material in a heated cavity. After a time, the thermoplastics are removed and placed in a cool mold, where they harden into the shape of that mold.
Thermoplastics are incapable of forming the strong cross-links found in thermoset materials. As such, thermoplastics do not have the same kind of strength or structural integrity which thermoset materials possess. However, this also means that a thermoplastic material may return to its original form after being exposed to heat. Thermoplastic materials can do this multiple times, since they only undergo physical changes during vulcanization, rather than chemical. The number of times this can be done is limited due to the damage the material sustains in its vulnerable, molten state.
Most thermoplastic materials will possess high strength, shrink resistance, and are capable of bending. They are found in everything from plastic bags to high-stress mechanical parts.
Thermoplastic Elastomers
Sometimes, an application requires a material with a range of properties too wide for either thermoset or thermoplastic materials to handle on their own. This led to the development of another type of plastic. Thermoplastic elastomers (or TPEs) are materials which combine the strength of a thermoset material with the processing advantages possessed by thermoplastic materials. They are primarily made of hard phases, with softer phases dispersed throughout. These soft phases consist of cured thermoset particles, while the hard phase consists of a thermoplastic. Though their versatility is unmatched, it also comes at a much higher price.
Whatever You Need: Thermoset, Thermoplastic, or TPE
No matter whether you need the strength of a thermoset material, the bending ability of a thermoplastic, or a unique application that requires both, Real Seal will have a material that will fit the needs of your application.
Give us a call today, and our full-time chemist will help you choose a material using his expertise and experience to produce the perfect component for your application.
A Look at Engineered Mechanical Rubber Components
Rubber is a very common material used in a wide variety of industries, including the automotive, mining, and electrical industries. If you work in one of these fields, you know just how integral rubber is to the machines and other tools that you work with.
That’s why you need Real Seal, one of the industry’s best seal and rubber component suppliers. We can produce components to suit your needs, no matter what they may be. Here are just a few examples of the many components we can produce.
Elastomer Diaphragms
Elastomer diaphragms are flexible barriers designed to prevent fluid exchange between two separate chambers. They cover the gap between a moving member and a stationary member, and are often found in gas or heating systems.
We can produce static or dynamic diaphragms, depending on your application. A static diaphragm can separate two fluids with little to no motion or pressure differential. We can also produce dynamic diaphragms if you need force or pressure to be transferred between the members.
Rubber Balls
Rubber balls are a special type of seal that may be useful for your application if you need something that will prevent leaks, resist dirt, and minimize noise. Rubber balls are precision ground in order to produce the superior sealing surface you need. They are primarily found in a check valve to seal against hydraulic fluid, water, or air. Our rubber balls come in a wide variety of durometers for you to choose from.
Rubber Waterstops
Concrete structures are highly dependent on the waterstops which join them in order to remain watertight. They are very important water treatment plans, reservoirs, locks, and dams. The waterstop you choose will be dependent on a number of factors including the joint type and joint movement, hydrostatic pressure, and chemical exposure. Whether you need swelling, non-swelling, or a chemically resistant waterstop, Real Seal can supply you with the parts you need.
Silicone Hoses and Tubes
Silicone hoses and tubes are often found in a wide variety of applications, including respiratory devices, peristaltic pumps, fluid handling devices, and high purity water and process systems. They are particularly valuable in the medical, food, and drug industries for their odorless, tasteless, and non-toxic qualities. They can also a resist a wide variety of temperatures, from as low as -65°F all the up to 440°F. Real Seal can produce silicone hoses and tubes with a high level of purity.
Idler Discs
We can also produce idler discs used in conveyors, including impact discs, bull nose discs, and return discs. Our discs are designed for maximum abrasion resistance, and may also be produced with materials that withstand fire and static. No matter whether your application mines coal, sugar, or grain, we’ll have an idler disc suitable for you.
Many More
Some of the other parts we can produce for you include:
- Bushing boots
- Insulating sleeves
- Belt cleaner cushions
- Rubber couplings
- Pipe gaskets
- Valves
- Washers
- Rubber thresholds
- Bearing pads
- Calendared sheet rubber
- Rollers
- Pipe Gaskets
Of course, our specialty lies with seals and O-rings. Take a look at one of our blog posts on O-ring materials if you are interested in producing O-rings for your application. We encourage you to check back regularly for more information on O-rings, seals, and rubber components.
The Best Supplier for your Mechanical Rubber Components
Real Seal is one of the best rubber suppliers in the industry, combining the efficiency of a large supplier with the customer service expected from a smaller one. With our injection and compression molding systems, we’ll produce the parts you need in a way that is both cost-effective and timely. Plus, if you have any questions, our full-time chemist and technical staff are available to address your concerns. Give us a call today, and we’ll get started on your components right away.
Producing Maximum Efficiency with Mechanical Lubricants
Over time, systems used throughout various industries have been growing in complexity in order to meet the demands of customers. In order to meet this demand, mechanical lubricants have become a crucial part of achieving maximum efficiency from the system. In order to choose the right lubricant, a number of factors must be considered.
Choosing a Fluid
The viscosity of the oil will be your biggest concern. At low temperatures, excessive viscosity will result in poor mechanical efficiency, difficulty in starting, and wear. As the oil temperature increases, viscosity decreases. This results in lower volumetric efficiency (inefficiency in converting hydraulic energy back to mechanical energy), overheating, and wear. In order to decide on the proper viscosity level, consider the following:
- Maximum startup viscosity under load.
- Range of optimum operating viscosity.
- Maximum and minimum operating viscosity.
Selecting the optimum viscosity will produce the most efficient pump performance at standard operation temperatures. In other words, you will minimize lost time, energy, and fuel costs for your operator.
You should consider Maximum Efficiency Hydraulic Fluid (MEHF), which has become the new performance standard for hydraulic fluids. They will enable any hydraulic pump to deliver increased power at much lower energy levels.
Pump Efficiency
The overall reliability of your system will depend on two measures of your system’s efficiency: volumetric efficiency, and hydromechanical efficiency. The latter refers to the frictional losses of a hydraulic component and how much energy is required to generate fluid flow. It is related to flow losses and the degree to which internal leakage occurs.
These two properties will be highly dependent on the viscosity of your lubricant. As hydromechanical efficiency decreases, fluid viscosity increases since there will be a much higher resistance to flow. Conversely, volumetric efficiency increases as fluid viscosity increases since there will be less internal leakage. Both volumetric efficiency and hydromechanical efficiency must be considered simultaneously.
Cavitation, Wear, and Overheating
At low temperatures, a high viscosity will negatively affect the mechanical efficiency of a hydraulic system, resulting in reduced system performance, lubricant starvation, and cavitation. Cavitation is particularly dangerous, since it can cause metal fatigue and spalling (breaking into smaller pieces), which will leave abrasive metal particles in your system’s fluid. This is why pump manufacturers specify the maximum viscosity for your system.
A lubricant is meant leave a lubricating film to reduce wear on moving pump parts. Its effectiveness will depend on the viscosity, sliding speeds and loads, and fluid stability. Once the temperature increases to a certain level, the film will thin and rupture, exposing the system to metal-on-metal contact. As a result, there will be wear within the pump and heat within the fluid will increase. Since the wear will be centered on areas essential to volumetric efficiency, the pump will need to work much harder to achieve the proper flow. Inadequate viscosity will result in higher temperatures within the fluid, accelerating wear and increasing internal leakage.
Fluid Selection
The NFPA has a viscosity grade selection system which is based on recommendations from leading hydraulic pump manufacturers. The most common viscosity grades are ISO 32, 46, and 68. Machinery Lubrication came to the following conclusions after comparing the performance of these three ISO grades:
“The high VI oils that meet the MEHF performance level definition contributed to significantly lower hydromechanical losses at temperatures lower than 40°C. The gain in hydromechanical efficiency can exceed 50 percent at start-up temperature, resulting in lower energy consumption, shorter warm-up times and reduced wear.
At temperatures of 80°C and 100°C, calculations made for a series of vane pumps showed that the high VI oils deliver a higher flow rate and a better overall efficiency. This translates into higher equipment productivity, as well as significantly lower operating costs for the equipment user due to lower fuel consumption. Energy and fuel savings up to 20 percent can be expected under standard operating conditions when MEHF-type oils are used. Higher productivity gains and savings can be achieved at peak operating temperatures.
The cost savings associated with the use of maximum efficiency hydraulic fluids in a single vane pump are approximately $400 per year per pump. This advantage could be expected to result in approximately $50,000 savings annually for a medium-sized equipment fleet.”
Please take a look at the full article for more information on choosing lubricants for your system.
Seals for Maximum Efficiency
If you want to get the most out of your hydraulic system, you will need a custom-built seal that will meet every requirement your application demands. Real Seal can help you produce that perfect seal with the expertise of our full-time chemist, and our experience producing thousands and thousands of seals every year. Give us a call and we’ll help you get started.
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