Any manufacturing operation that moves product through some kind of tubing requires a seal. With so many variables in each operation, sometimes it seems that no individual seal will fit the wide range of requirements; that’s where specialty custom seals come in. Real Seal has expertise in creating unique solutions for equally unique problems, ensuring quality operations and results. Specialty seals are designed to meet different engineering challenges with unique shapes and design.
X-Rings
Standard o-rings have a circular cross section, creating a large mating surface. In some operations with low speed oscillation or reciprocation the basic o-ring may twist, which can cause leakage and damage to the ring as well as the surfaces it is mated to.
When pressure is exerted upon the x-ring, four contact points are made due to the x-shaped profile. Because of the x-ring’s design, it requires less compression to seal the surfaces it is attached to. Another advantage is that the seam of the x-ring is between its mating surfaces; some o-rings may have leakage problems in this parting section, but with x-rings this problem is virtually eliminated.
Most commonly used in reciprocating applications, x-rings have reduced friction and have a better durability and anchoring for this kind of motion. In some rotational settings a normal o-ring will also experience warping, x-rings are recommended for these applications, as well. To ensure quality operations in reciprocating and rotational operations use these kinds of specialty rings.
Square Rings
Originally, square rings were designed as a cheaper alternative to o-rings, but as the cost of o-rings has fallen square rings have been out-competed in dynamic operations. Square rings do still have their place in static operations or in places where costs must be kept to an absolute minimum. Static sealing with a square ring is perhaps the most effective when a high load force is required. Square rings are not recommended for operations with movement, as they are more prone to failure. So, in high load static operations specialty square rings will make sure that your operation is producing top quality.
Back-up Rings
Back-up rings aren’t used all on their own, but in conjunction with other seals, usually o-rings, to prevent extrusion and leakage. In high pressure applications a more rigid back-up ring is used to hold the o-ring in place while allowing it to continue to do its job of preventing leakage. Some back-up rings can also increase the temperature resistance for the o-ring, as well as friction resistance. Back-up rings are extremely important because they allow for more solutions in an application having issues with o-ring failure without having to retool the entire machine to compensate. Most back-up rings are designed to fit standard o-ring sizes, but more specialized back-up rings can be used for other kinds of sealers than o-rings, too. If your operation is suffering due to extrusion or leakage, a back-up ring can increase the quality and durability of your seal.
U-Rings and V-Rings
U-rings and V-rings are similar to o-rings in design, but have a U or V shaped groove in the counter-face of the ring. These rings have reduced wear and friction due to their unique shape, plus they can fit in some uniquely shaped joints that require a nonstandard sealing shape. Due to the groove in the ring some of these rings are also designed to reduce contamination and leakage.
O-Ring and Specialty Ring Experts
No matter what kind of application, Real Seal will have the expertise to point you in the direction of the correct type of sealing ring. Their twenty plus years of experience has given them the experience they need to make sure your operation is running at the highest quality and safety. They can make recommendations based on your needs and even design specialty custom rings if the operation calls for it. Contact Real Seal today!
When choosing a seal for your operation, it’s hard to decide which company has the best. At Real Seal, we routinely put our seals through strenuous ASTM testing to ensure consistent quality. ASTM is an international standards organization that originated in the USA as a way to hold manufacturers to a higher standard of quality and reliability. By employing these standards, Real Seal is able to prove the durability of our seals to a variety of elements. Various tests designed by ASTM to ensure this level of quality include these various properties and more:
Compression Set
Compression set is how deformed a material becomes after a certain amount of force is applied to the material. This is especially important for seals so that as they undergo the various pressures of sealing, they are able retain the shape necessary for sealing the surface they are adhered to.
ASTM D395 is one of the most common methods of testing for compression set. There are two methods under this protocol. Method A tests compression as the percentage of thickness of an object, in this case the seal, after being exposed to a constant force for a set time and temperature, then giving it thirty minutes to recover. In method B, the material is compressed by 25% and then a measurement is taken. Both of these methods allow for the seal to be tested for its ability to reform after being compressed by a force.
Hardness
Another important factor in how durable any given seal is the hardness of the seal. The harder the seal, the more resistant it is to impact, as well as being able to maintain its form better, although harder materials can crack or break.
ASTM D2240 uses a durometer to determine the hardness of rubber and plastic materials used to make o-rings and other seals. This test is done by measuring how much a material is penetrated or “pushed in” by a specified indenting implement. Hardness is drawn from a scale known as Shore hardness; Shore A for softer materials, and Shore D for harder materials.
Heat Resistance
Many industrial applications of seals put the material under the intense strain of heat. Heat can warp and damage the material over time if it isn’t chosen correctly or of the highest quality.
ASTM D573 tests the effects of increased temperature on a seal. The seal is placed in a hot oven or other heating device and then the hardness, elasticity, or other materials are then tested. Any changes in these properties can indicate deterioration of the material. These tests are often specified to the conditions a given application will place upon the seal, ensuring that it won’t degrade too quickly and cause some kind of catastrophic failure.
Tear Strength
Perhaps one of the most important properties for dynamic operations is the tear strength of a material. The tear strength of a material is its ability to resist being torn apart by a force. Damage by heat, friction, and other forces can lower the tear strength of a material, so those aspects are important, as well.
ASTM D624 sets the standards for testing a material’s strength divided by its thickness at resisting forces pulling it apart with a nick to lead the tear. A tensile test machine is clamped to two ends of the material and then pulls. The maximum force required to tear the material is used to determine this property.
Fatigue Limit
Fatigue limit is another important property for dynamic operations with cyclic motion. A material’s fatigue limit is its ability to withstand the stress of undergoing this kind of cyclical strain. This is best tested by applying the same type of force which will be applied to the seal during its operation for a certain number of cycles to see if there are any tears or changes its properties such as tear strength and hardness.
Real Seal’s Commitment
Real Seal is committed to testing and ensuring that a product will withstand the pressures it will undergo during operation. ASTM and ISO guidelines ensure that their seals will be put under the right amount and type of strain to maintain a superior product. To ensure that the seals you use for your operations are durable and of the highest quality, contact Real Seal today!
There are many hazards in industrial operations, so it’s best to use the safest option available when it comes to equipment. Sealing your machines is no different. Traditional gland packing inevitably leaks and requires constant attention. On the other hand, mechanical seals are able to reduce leakage to a near zero number. There are a wide range of reasons why mechanical seals are the superior option:
Reduced Leakage
The first concern of any sealing system is: does it leak? With mechanical seals, there should be virtually no leakage. When the correct seal is chosen, accounting for all the variables in an operation, it will withstand the forces acting upon it.
Why is leakage a problem? Many products being forced through machinery have extremely toxic properties for humans and the environment. Reducing leaks to a near zero number is paramount to the health of those working around the machinery and the surrounding environment. Fumes can have a similar effect and sealing systems can be made to be air-tight. Some chemicals are so toxic that even a small amount can be harmful, so any level of leakage is unacceptable.
Toxicity isn’t the only concern when it comes to how safe a fluid is. Flammable fluids can cause major damage to an operation if they ignite, not to mention the potential loss of life. Extremely acidic or basic solutions can damage equipment and personnel, as well.
With gland packing, there is always a certain amount of product loss and it can gradually pool up on the floor or other surfaces, with cleaning itself becoming a hazard if the product is unsafe. Slipping can become a real hazard, especially when workers are rushing around trying to work as quickly and efficiently as possible. Accidents should be prevented in every possible way.
Less Maintenance
Traditional gland packing requires continual upkeep as the packing wears down over time. This requires maintenance staff to always be checking and fixing the packing, leaving them exposed to the product. If the machine has moving parts, then it becomes an even more dangerous exercise. Pinched digits and limbs, crushing, and even amputation can occur if machinery is powerful enough; so having mechanical seals that require less frequent maintenance requirements limits exposure to such dangers.
Prevents Wear
Mechanical seals also reduce friction between mechanical parts and are superior to gland packing, which are notorious for increased friction. This constant rubbing can lead to catastrophic failure and dangerous situations. Dual mechanical sealing systems can be installed to create a fail safe environment should the first seal rupture.
Some Tips to Keep your Seals Safe
While mechanical seals are the safest option, it is also necessary to keep an eye on them to make sure they aren’t wearing. Regularly assessing the various elements of an operation to ensure they aren’t outputting more strain than they should be is essential. If you notice that a seal is beginning to leak or allow fumes to escape, it’s vital to replace the seal as any amount of leaking can indicate that it is wearing and could fail, or that it has uncoupled from its surfaces.
Use an Expert
To ensure that your operation and the seals you use in it are the safest possible, you should use an expert company for product and consultation. Real Seal is a leader in the sealing industry. Contact Real Seal today to make your place of work the safest it can be!
Machines wear down over time; it’s inevitable with the amount of wear they undergo just doing their job. Moving parts, caustic fluids, and the force of time and nature all take their toll. The best way to make your machines work longer and harder for your operation is maintain them regularly, ensuring they last as long as possible, saving money, and reducing downtime. Here are some tips to consider:
1: Lubrication
Friction is one of the most constant forces wearing on your machinery. Proper lubrication is key when it comes to machine maintenance, as it reduces the degradation of equipment. Lubrication also makes it so your machines don’t have to work as hard, further reducing wear, as well as energy costs from machines that are working beyond their optimal limits.
2: Cleanliness
It’s hard to keep machines clean, especially in industrial settings. A clean machine isn’t just an aesthetic improvement. Contaminants from dirt and other residue buildup can pose a major problem: jamming parts, increased friction, and more. They can also contaminate product. A clean machine is less likely to rust, which can help prevent long term damage to equipment and possible outright mechanical failure.
3: Testing
Often machines are composed of multiple working parts with their own operating ranges, not to mention entire groups of machines working together. It’s important to regularly test each component of a machine or group of machines to make sure they are all working as they should: maintaining proper heat, speed, pressure, and other important variables. When one part of a machine, or collection of machines, begins to fail, it can cause a chain reaction of issues. So nipping smaller problems in the bud can really cut down on the potential of larger issues.
4: Alignment
Another key variable for machines is the alignment of various parts. When a part isn’t properly aligned, it can cause a machine to break down much more quickly as it isn’t exerting its forces properly, causing damage to parts not designed to bear the amount of said force. Misaligned parts can cause increased vibrations, which will increase heat and friction.
5: Keep a Schedule
It’s imperative to regularly perform all of the necessary maintenance on your operation’s machines. A schedule, whether physical or digital, can be a great way to ensure it’s being done. Include a checklist of each step for every machine so nothing is missed. If possible, it’s a good idea to occasionally rotate who is doing the inspections if there are multiple qualified personnel, as a different set of eyes will see different problems and might catch something another person might’ve missed.
6: Components
While it’s easy to remember to check a machine, sometimes it can be hard to remember that components play an equally vital role to a machine’s function. Always inspect such essential pieces of the operation, because when they fail the rest of the machine can fail, as well. Each component will have its own unique set of needs.
For example, seals are extremely vital to any operation where fluid is flowing through a system. Check seals for signs of leakage regularly, as this can be an indication of a possible impending failure and that the seals should be replaced. Making sure that your machine is operating within its limits is also important to ensure that components, such as seals, will perform as designed; many components can only function within a certain range of conditions and will fail when pushed beyond those points.
7: Consult the Experts
Often, when dealing with components, it’s hard to know all you need to in order to ensure that they aren’t going to fail and will be maintained properly. Contacting an expert can save your operation from an inevitable large scale issue. Real Seal is an expert in seals and can help with any of these issues. Contact us today!
What are the Practical Benefits of Polyurethane O-Rings?
If your application requires a material with outstanding physical durability, polyurethane o-rings are the way to go. Polyurethanes, also known as urethanes, derive their unique benefits and advantages through their unique structural bonds. These bonds are unique because of their combinations of soft polyol segments and tough isocyanate segments, creating a flexible but still durable material. There are a variety of types of polyurethane for all kinds of applications.
Types of Polyurethane
Just like all types of materials, polyurethane comes in different types, each with their own benefits and applications. The most common of these varieties is polyester with most urethane seals being based on polyester. Polyester based o-rings are resistant to hydrocarbon oils and hydraulic oils.
Two additional types of polyurethane are polyether based and polycaprolactone based rings. Polyether based o-rings have the advantages of being better for hydrolytic stability and being functional at lower temperatures. Polycaprolactone based o-rings are a subgroup of polyesters with a portion of the low temperature capabilities and oil resistances of the aforementioned polyether rings.
Curatives
Another customizable advantage of polyurethanes is the cure which is used on the o-ring, giving additional properties to the urethane. Similar to other elastomers, millable gum urethanes use the more standard peroxide and sulfur cure systems. Higher performing thermoplastics and thermosetting materials use isocyanate curing systems.
MDI is one of the most common curatives and most often used in thermoplastic materials, as well as millable gum urethanes. MDI is safer for the environment than other diisocyanates.
TODI increases heat resistance and mechanical properties. PPDI has the highest of heat resistances and is best used in applications with hot temperatures.
Properties
Polyurethanes have a wide range of properties with many different advantages and benefits. Hardness can be controlled for whatever the application requires. For applications requiring a high load bearing capacity, polyurethanes are able to return to their normal shape and form after being compressed with minimal damage. Flexibility is also a key benefit of polyurethanes with a wide range of motion and the strength to resist breakage. Durability is a key advantage of polyurethanes, being resistant to tearing and abrasion.
When insulation against various elements is a concern, polyurethanes perform. Electricity, wetness, and various temperature ranges can all be managed with different types of polyurethanes and cures. If your application requires the polyurethane ring to be bonded, that is also something this material can be designed to do, being able to adhere to wood, plastic, or metal.
If contamination of food or other sensitive material is a concern, polyurethanes are sterile against various fungi including mold and mildew.
Generally, polyurethane o-rings have cheaper tooling than plastic, making it a more cost effective option. Polyurethane o-rings are also better at resisting radiation than plastic.
When it comes to advantages of polyurethane over metal, durability is key. Rigid materials wear down faster and can’t conform as easily. Polyurethane o-ring are also quieter and don’t create sparks like metal does. Plus, they don’t rust.
Finding the Right Polyurethane O-Ring
When considering the various types of polyurethane o-rings, it’s best to consult an expert in the field. No matter the design challenges, Real Seal is up to the task. Contact Real Seal today for any questions you have regarding polyurethane o-rings.
The Integral Role Seals Play in Engineering and Design
Engineering and designing of any kind is filled with variables. Any process that requires a seal to ensure that no fluid or material escapes has its own set of unique design challenges. When designing a system, it’s important to remember every force and factor acting upon the seal, otherwise it could lead to catastrophic failure.
Product Pressure
With any application of a seal, pressure is a concern. If the wrong seal is chosen, pressure can cause product to escape. Under extreme pressures, if the seal is incorrectly chosen, it will simply break and cause complete failure. A seal should be able to withstand the entire range of pressures a system may undergo during different phases and with shifting loads. As pressure increases, the fluid film becomes thinner (this means more friction on the seal) – and the inverse is true, as well; lower pressure means a thicker film.
When prototyping, it’s important to run at the highest ranges so that you know exactly what ranges are required of your seals. The seal should be able to withstand the peaks and valleys of the system. High pressure systems need to be extremely vigilant about maintaining a tight seal, as contaminants have a much higher impact upon these systems due to their higher velocity, thus increased friction and damage.
System Load
Seals must be able to withstand the forces of the system that they are sealing. In order to maintain alignment and proper guidance of the piston, rod, or other moving part, it is essential to choose a seal with a high enough load bearing capacity. When prototyping, it’s important to factor in the entire force of the application, not just isolated pieces. The cumulative effect of a system can be much higher when put together and not just piece by piece.
Temperature
The temperature of a seal comes from a myriad of places including: product, environmental conditions, and friction. Simply knowing how much heat a system outputs is not enough. It’s vital to know the entire set of factors when selecting a seal. The range of temperature is also important to consider, as a high variance will alter the seal’s ability to maintain its shape.
High heat, of course, deforms and melts seals, but low temperatures also have negative impact upon the seal. Always account for environmental conditions when it comes to seals, especially for outdoor applications: rain, snow, or intense heat are all going to have an effect on the seal and the system it is attached to, requiring a wide range of temperature tolerance. Again, it is not enough to have just the isolated pieces tested; the entire system must be taken into account when it comes to heat.
Velocity
The speed at which any given system operates is a huge factor in sealing. Not only does it affect the wear and tear of a seal, but also the temperature due to friction. Fluid properties can also be altered during speed changes and high speed environments, causing alterations in the fluid film. Systems that have a variance of speed can undergo rapid changes in pressure or temperature, requiring durable seals with high ranges of tolerance.
Chemical Properties
Perhaps the most specialized area of sealing is the various chemical requirements of different systems. Some seals will wear down when exposed to acids, oils, and all kinds of chemicals. Just because a seal is solid doesn’t mean it can’t have a reaction with the fluid it is housing. Also, seals must be able to keep out any unwanted contaminants; some products simply can’t have water enter the system, while others need a barrier against biological contaminants.
Expertise
When it comes to design and engineering, seals play an integral role; if only one of these many factors aren’t taken into account, catastrophic failure can occur, causing major loss in product and damage to machinery. Make sure to work with an expert in sealing and the materials seals are made of when designing any system. Real Seal has years of experience designing solutions for all kinds of applications. Contact Real Seal today to ensure your systems are properly sealed.
Mechanical seals are the future of manufacturing due to their longevity, efficiency, and lower long term costs. As environmental regulations ramp up year by year, it’s best to always aim for the most eco-friendly solution to your manufacturing needs. It will save you money in the long run and prevent any headaches of having to transition when new regulations come around.
Loss of Product
The primary benefit of mechanical seals is that they are much more effective at retaining product than traditional gland packing. Normally, packing material is placed around where a shaft and its housing are joined, stuffing any leaks. Over time packing material degrades, also damaging the pump, causing inevitable leakage. With so many materials requiring zero-loss in regards to the environment, these methods are no longer viable. This leakage also causes loss of revenue due to spilled product.
On the other hand, mechanical seals work by creating three sealing points. The most important and intricate portion of the seal is the middle portion where the rotating and stationary portions meet. This section must be lubricated enough to rotate, but tight enough not to allow any leakage, which is the primary concern when dealing with the environmental regulations. These surfaces are microscopically flat, ensuring a tight seal so that fluid cannot escape.
Mechanical seals can also be designed to prevent emissions in the air. A properly engineered and installed mechanical seal will eliminate virtually all leakage and waste. It is important to regularly maintain and inspect these seals, as when they fail it tends to be more catastrophic than the gradual decay of gland packing. Double sealing systems can prevent this kind of large malfunction, giving you time to repair or replace the seal.
Corrosion
Not only are mechanical seals safer, they also cause less damage to the equipment they are attached to. Gland packing will corrode whatever they are plugging as friction grinds down both the packing material and the shaft. Mechanical seals can also be designed to be resistant to highly corrosive materials, which are safety and environmental hazards.
Waste
Not only does gland packing cause a lot of product waste, the packing itself is an environmental issue. Unless you are using biodegradable materials packing, which is often made of plastics and other harmful synthetic materials, every roll of packing will end up in a landfill. Mechanical seals are often made of metal or rubber, which can be more environmentally friendly. As laws on use of short term plastic usage increase, – some areas even banning plastic bags – it’s important to stay ahead of the curve so that new systems aren’t implemented in a rush; especially with a device like mechanical seals, which save money in the long run.
Efficiency
Product and equipment efficiency is a good start, but mechanical seals also provide another efficiency incentive. Mechanical seals also reduce energy usage, saving money and the environment. The reduced friction on moving parts when using mechanical seals provides a more fluid range of motion; machines don’t have to work as hard as when they are grinding against packing. This can lead to huge savings and prevent excess consumption of energy.
Design and Installation
All of the aforementioned benefits of mechanical seals hold up only if they are properly designed for the job and installed correctly. To ensure you are getting the right seal for the job, or to create a custom solution for a unique problem, contact Real Seal. They have experts with years of experience in coming up with unique manufacturing solution, providing environmentally sound guidance and ensuring a safe and efficient system.
When it comes to sealing your manufacturing equipment it’s imperative that you choose the right seal made of the correct material. The wrong seal can break, causing loss of product and time. Things can go even worse with unintended chemical reactions and contamination. It’s impossible to be sure unless you consult an expert, but here are a few examples of seals and their applications.
Static Seals
Static seals refer to seals which are placed between surfaces with no relative motion. These seals are perhaps the easiest to maintain and select because of the lack of friction. What need to be taken into consideration are the types of forces being exerted upon the seal. Temperature, chemical makeup, and pressure are the primary concerns when dealing with static seals.
Dynamic Seals
On the other hand, dynamic seals operate between two moving surfaces. Dynamic seals are defined as being reciprocating, rotary, or oscillating depending on the type of motion they are being used between. All of the considerations of static seals are taken in when considering which dynamic seal to use, with the addition of being able to withstand the friction from the specific type of motion against the seal.
Materials and Their Uses
Now that you know which type of seal you need, the specific material becomes the important question. Each material has its uses and more are being developed regularly to take into account new factors such as environmental regulations. Here are a few types of materials and their properties:
Ethylene Propylene Diene Monomer or EPDM is resistant to weathering, ozone, water, and steam. Some of the common uses for EPDM include systems that involve: brake fluids, alcohols, ketones, diluted acids and bases, as well as phosphate ester fluids. Compounds cured with peroxide have excellent compression set resistance.
Acrylonitrile-Butadiene or NBR is the most commonly used material in rubber seals. NBR has amazing resistance to hydrocarbon fluids, cold water, di-ester lubricants, and ethylene glycol fluids. The standard service temperature range is -55 to 250 degrees fahrenheit, but it’s possible to extend this range with specialty compounds.
Hydrogenated Acrylonitrile-Butadiene or HNBR is a version of the above nitrile rubber that has most or all of its double bonds saturated with hydrogen, providing greater heat resistance and chemical resistance.
Carboxylated Acrylonitrile-Butadiene or XNBR is another nitrile rubber that has been altered to improve certain attributes. This variant is best for applications that require greater tensile strength, modulus, and resistance to abrasion, good for dynamic seals and abrasive products.
Silicone Rubber has the broadest temperature range of standard elastomers with a range of -175 to 500 degrees fahrenheit depending on the composition. There is a trade off, though. Silicone products tend to have lower physical strengths compared to carbon elastomers. So, if your manufacturing needs are at extreme temperature, silicon tends to be a better choice.
Polyurethane rubber has the best physical strength and toughness of the elastomeric materials with still impressive temperature ranges from -65 to 300 degrees fahrenheit. This material is resistant to petroleum oils, fuels, oxygen, and ozone, but weak to acids, ketones, and water vapor.
Fluorocarbon Rubber or FKM is best for applications requiring both chemical and heat resistance, reaching up to 400F. These materials are good for use with petroleum oils, diester lubricants, silicate ester lubricants, silicone fluids, acids and bases, and more. There are even FDA grades available for food and beverage applications.
There are many more available options and this is only a brief overview.
Choosing the Right Seal
Choosing the right seal can be difficult. There are so many factors to consider based on each individual application. That’s why it’s best to have an expert source for your materials. Real Seal is an expert in all kinds of seals and will work with you to make sure you choose the right product. If you have unique challenges, new and custom compounds can be engineered to suit your needs. Contact Real Seal today to consult the seal experts.
Injection molding is process by which sealing devices and components are produced. A whole range of materials can be used in injection molding, from metal to plastic, and even glass. Injection molding allows for a consistent product, but it is imperative that the initial mold design is perfectly suited for the product’s needs.
How it Works
Not all injection molding systems are the same, but there are some procedures that are general to the injection molding process. The material for the component is heated until it is melted and then forced into the mold cavity. Once in the cavity, the material is allowed to cool and harden, maintaining the shape of the mold, creating the desired product. To account for shrinkage, holding pressure must be kept at proper levels. Coolant is also important in certain molding processes, allowing the material to cool at the correct rate.
What it’s Used For
Injection molding is one of the most common manufacturing methods for plastic products, as it creates a uniform product, and is especially useful for mass production of high quantity items. While it’s easy to imagine injection molding being used for small parts such as bottle caps, mechanical components, and electronics; injection molding can be used in large applications as well, such as entire car body panels. Chances are any plastic parts that make up the things you own were injection molded.
Molds
Perhaps the most complex and important part of the molding process are the molds themselves. Molds can be made from a range of materials, usually determined by the economics and requirements of the part being made, including hardened steel, pre-hardened steel, aluminum, and other alloys. Molds are typically expensive to design and make, as they are highly specialized and require extreme precision. The number and complexity of cavities in the mold will determine the cost of the mold, and it’s best to eliminate excess material as this can negatively impact production cost.
Molds are typically made of two plates with indentations and raised areas shaping the desired product. In order for the molten material to travel through the mold, there are “runner” channels through which the liquid flows. Some molds, for smaller parts, are designed in such a way that a single injection of material can yield several parts, making for a more efficient process. These molds can be made to create different or identical parts, so one mold can either perform the same job multiple times or produce a variety of related products in one “shot.”
Any defects in the mold will cause issues with the end product. If the mold is incorrectly sized then the material will warp, blister, or stick to the mold when it has finished the cooling process.
Real Seal’s Molds
Real Seal is an expert in injection molding, offering a wide range of materials for use in state of the art molds. Computer controlled mechanization and consistency ensure a superior product. They have created products ranging from 0.05” to 27” in diameter and have maintained customer tooling for two decades in many cases. If you require custom tooling, Real Seal provides this service on site, typically using insert style retrofitting into established basis, lowering your costs. Since these steps are all done by Real Seal, you can be assured of their consistency and conformity. Contact Real Seal for all your manufacturing needs.
As it becomes required and more important to keep manufacturing eco-friendly, the debate between traditional packing versus mechanical seals has become clear. While packing has lower upfront costs, over time it becomes much more expensive as the material requires continual maintenance and replacement. Packing is also more prone to leaking and product loss.
There’s no way around it, pumps need to be sealed. Over time a leaking system can be costly, inefficient, and detrimental to the environment, so it’s imperative to choose the right long-term solution.
How Packing Works
Packing is a relatively simple process. A soft material is stuffed into the gap between the pump and the shaft, preventing most leakage. There are a wide variety of materials used depending on the kind of material being pumped. It’s simple and easy to maintain, which is an advantage for packing.
Disadvantages of Packing
The primary downside of packing is that there is inevitable leakage, which causes a range of issues. The first issue is that leaking fluid can be a working hazard, causing slips and falls and their inevitable workers compensation cases. Many fluids aren’t allowed any visible leakage at all due to the fact they are corrosive, toxic, flammable, or dangerous to the environment. Packing can also cause wear and tear on the machinery they are sealing, causing the machines themselves to require repair or replacement.
Finally, while packing may be cheaper up front, they do lose product due to the leakage, costing money. So, while you may want to start out using packing as a cheaper start-up cost, eventually the packing will become more expensive. Plus, the regular maintenance requirements will eat up time as well, which is yet another cost.
How Mechanical Seals Work
Mechanical seals come in a variety of shapes and sizes, due to the specific nature of their designs and the systems they are used in. Some can be simple, while others are more complex, requiring multiple fail-safes and self-correcting features.
Most basic mechanical seals have three sealing points. The first portion is sealed to the stationary part of the pump with an O-ring. One portion of the seal is generally spring loaded in order to compensate for any minor staff deflection.
Perhaps the most important and complex part of the seal is the middle portion where the rotating and stationary portions meet. This section must be lubricated enough to rotate, but tight enough not to allow any leakage. Both the force of the fluid and the design of the seal contribute to pushing the seal faces together. These surfaces are microscopically flat, ensuring a tight seal so that fluid cannot escape and contaminants won’t enter or damage the seal.
Advantages of Mechanical Seals
Over time, mechanical seals will save you money through a variety of means. Mechanical seals that are correctly chosen, operated, and installed won’t do much damage to the systems they are attached to. They save time as they require little upkeep and maintenance in comparison to packing. Preventing virtually all leakage will prevent money lost through the steady leakage of packing. Mechanical seals also consume less power.
There are disadvantages to mechanical seals, such as a higher initial cost. Mechanical seals are also more difficult to maintain, requiring a higher level of expertise. Most of the disadvantages can be remedied by design decisions, such as creating a secondary seal in case of a failure in the first seal.
Your Needs
No matter your manufacturing needs, Real Seal can provide you with quality solutions for any operation. Contact Real Seal for all of your sealing needs.
