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Industrial processing operations are complicated and full of different technical variables. Wear and tear over time can cause machines and their often-smaller components to fail. When these processes involve products that are for human consumption, regulation is tight, and problems can be costly. Completely shutting down the equipment to conduct an inspection presents its own set of problems, including unproductive downtime, potential contamination and safety risks. But there is a solution. Read on to learn more about how metal detectable O-rings can save you time and money.
For more information on specialty seals and other seal systems, visit Real Seal today.
A Cost-Effective Solution
As machinery breaks down and rubber fragments from seals and gaskets make their way into the process stream, one solution to this issue is to use metal detectable O-rings. Unlike natural rubber or silicone O-rings, metal detectable O-rings are compounded with special additives, so they can be identified by metal detectors and X-ray machines. O-ring fragments as small as 2mm can be found so the fragments can be removed manually or by magnetic separators, thus improving product safety and any government regulations.
Made from various materials including silicone, flouroelastomer, ethylene propylene diene monomer (EPDM) and others, these are designed to be used in standard OEM equipment and will perform just like traditional O-rings. They will also perform well with high and low temperatures with typical mechanical stress and are resistant to corrosive chemicals.
There are different supplier certifications and federal regulations for O-rings that come in contact with products such as food, beverages or pharmaceuticals. Officially, O-rings are usually classified as indirect food additives, meaning they are substances that come into contact with the processing stream but are not intended to be a part of the end product. Other substances included in this classification include packaging materials and other pieces of equipment that come in contact with the end product but do not mix with it.
A common practice in industrial processing today is to have a Hazard Analysis Control Point (HACCP) program in place which requires that any machinery that comes into direct contact with the product stream must be metal and X-ray detectable. Metal detectable O-rings meet this requirement. You should check with your O-ring or specialty seal supplier to see what your options are and how metal detectable o-rings can help you to limit your downtime, increase safety and save you money in the long run.
Specialty Seals & Gaskets
Real Seal is a manufacturer and distributor of specialty seal products and mechanical component goods, with a focus on performance-oriented rubber and plastic materials. Real Seal is one of the most technically advanced organizations in the industry, maintaining a fully equipped laboratory, full-time chemist and technical staff, allowing Real Seal the ability to assist with design challenges and formulate materials to meet specific criteria.
Known for our expertise in polyurethane O-rings, we offer a wide array of performance-oriented plastic and rubber solutions for sealing and mechanical applications. Real Seal is set up to meet the needs of the more fragmenting aspects of the industry. Industrial manufacturers are being asked to offer consumers more choices with a wider latitude of performance criteria, all with greater economic constraints. As the industry continues to evolve to meet the demands of consumers as well as the challenges of international competition, Real Seal will continue to provide practical solutions and value to our customers.
Contact Real Seal today for help in meeting your composite sealing demands.
O-Rings are used to provide secure sealing when two parts are assembled. The installation process, when performed correctly, can increase the service life of the component as well as the application.
Incorrect O-Ring installation can lead to assembly damage, causing leakage during the first pressure test. This could be cause for the entire piece of equipment to be disassembled so that the seals can be replaced. If O-Ring damage happens often, wasting time and money replacing the seals could become a genuine problem for your business. Follow these recommendations for proper O-Ring installation to help prevent these issues from occurring.
For more information on O-ring installation and seal components, contact Real Seal today.
Lubrication
Lubrication is an essential component of O-Ring installation, reducing friction and allowing the O-Ring to seat easily in the groove of the mating surface. When inserting a piston into a bore for male/female radial seals, proper lubrication will reduce installation force and create a smooth transition.
Choosing the Proper Lubricant
When choosing a lubricant, there are some things to take into consideration. The lubricant must be:
● compatible with the material being used
● suitable for the temperature range of the application
● compatible with the system fluids
● capable of producing a high surface tension film
● not clog system filters
Examples of Lubricants
Two examples of lubricants on the market are O-Lube and Super O-Lube. O-Lube is a general-purpose grease intended for O-Ring and elastomer seal types used in hydrocarbon service. Super O-Lube is a high viscosity silicone oil, and is considered an ideal all-purpose O-Ring lubricant which is extremely effective.
Design Principles
If you want your machinery to last with minimal need for repair, good design is key. Some of the basic ideas of good O-Ring installation design are:
● put good compression on the O-ring while preventing the groove from exceeding 100% fill
● use a lead in chamfer in radial seal applications at an angle of 15-20 degrees, with an opening which exceeds the maximum height of the O-Ring in the groove
Sizing
Putting the wrong size O-Ring into a machine can cause damage. Make sure to verify that you have chosen the proper sized O-Ring before installation.
Measuring cones and circumference “Pi” tape can help you measure parts and pieces accurately to avoid these problems.
5 Tips for Better Installation of O-Rings
The following steps should help with installing O-Rings correctly, and save you some time as well:
1. The shaft consists of threading, which could tear the rubber seal. Covering and lubricating the threads will provide an easier passage. You can cover the threads using masking tape.
2. You must avoid forcing the O-Ring over sharp corners. Jagged or sharp features could tear the O-Ring. These tears might sometimes not be noticeable to the naked eye; however, they can seriously compromise the seal.
3. When stretching the O-Ring around the shaft, stretch it evenly. Do not pull from one side. Also, try to stretch the O-Ring as little as possible. This will provide a tighter seal and added security.
4. When installing an O-Ring, do not roll it down the shaft. Instead, slide it down. A rolled or “spiral wound” O-Ring cannot be properly installed, and will not function the way it should. This can damage your machine and be lead to costly repairs. Apply lubricant to the O-Ring to keep it from rolling.
5. When installing the rest of the assembly, it is important to place the female component so that it has a radius around the corner. The lead of this component should be inside the chamfer. This process guarantees the safety of the O-Ring.
Bonus: Check out these videos about the various kinds of O-Ring installation.
Real Seal started in 1970 as a distributor of O-Rings, and has grown exponentially since then to serve hundreds of industries nationally and internationally with our seal products and mechanical component goods. If you have any questions about O-Ring installation, sealing products, or sealing systems, contact us today!
O-rings, also known as packing or toric joints, are hoop shaped gaskets designed for machinery. The difference between O-rings and more commonly referred to gaskets is that O-rings are almost exclusively used for very high-pressure applications such as hydraulics where a regular cork, paper or rubber gasket would fail. O-rings are usually compressed between two or more larger parts during assembly, creating a seal. They are used to keep fluid or air in or out of a defined space.
Although they are traditionally round in shape and come in standard sizes, you may be able to buy custom O-rings in variable sizes and shapes.
They are extremely common in machine design due to their affordability, reliability, and simple mounting requirements.
For more on industrial O-rings and mechanical component goods, contact Real Seal today for export performance solutions.
But what are Encapsulated O-Rings?
Traditional O-rings are made from elastomer. Elastomer is a synthetic rubber-like material which, at room temperature, can be easily bent or stretched and, when released, quickly returns to its approximate original dimensions and shape. Under normal conditions this is very useful. But sometimes, high temperatures or corrosive conditions make the use of the use of elastomer unacceptable. In these cases, we turn to O-rings made from other materials that can withstand harsher conditions.
What are Encapsulated O-Rings made of?
Encapsulated O-rings have two parts: an inner core made of flexible rubber, and an outer jacket made of Teflon. The rubber gives the O-ring elasticity, and the Teflon gives it protection against corrosion and resistance to high temperatures.
Core Types
Solid Core: Solid core O-rings are filled with either solid Viton® / FKM or silicone. The Viton offers high level compression and elastic qualities. The Silicon is very similar, but because it is softer, it works better under a wider range of temperatures.
Hollow Core: Hollow core Encapsulated O-rings are used in situations where extreme elasticity is needed for maximum flexibility.
Jacket Types
The Teflon jacket of Encapsulated O-rings can be made of either FEP (fluorinated ethylene propylene) or PFA (perfluoroalkoxy-copolymer).
FEP: FEP jacketed O-rings offer resistance to a variety of destructive chemicals. They can be operated under a very wide range of temperatures.
PFA: PFA jackets have many of the same benefits as the FEP jackets. In addition, they are mechanically stronger and resist stress and cracking more efficiently. PFA jacketed O-rings are usually used in situations where extreme durability and thermal stability are required. They also offer a longer service life.
How Are Encapsulated O-Rings Used?
Because their jacket may be damaged by quick-moving parts, encapsulated O-rings are best suited for static machines. However, they may also be used in machines that make slow, short movements such as in valve stem sealing. Powders and slurries can also damage the jackets. Sometimes, these issues can be addressed by adding graphite to the FEP or PFA, making the jackets more durable.
What are the Advantages of Using Encapsulated O-rings?
There are plenty of advantages to using Encapsulated O-rings beyond those already mentioned. They exhibit excellent resistance to nearly all media, with exceptions being alkali metals and some fluorine compounds. They are very well suited for use in the food, chemical, and pharmaceutical industries because they are FDA compliant, and also due to their low contamination and low permeation, among other reasons. Finally, their major lack of friction is preventative of the “stick-slip” effect.
When Should Encapsulated O-rings Not be Used?
As previously mentioned, encapsulated O-rings should not be used in dynamic applications because the outer jacket could be damaged. For the same reason, they should not be used with abrasive media. They cannot be used under high pressure or when highly elongated.
Where are Encapsulated O-rings made?
The two top producing countries of encapsulated O-rings are India and China.
Industrial O-Rings
Real Seal was established in 1970 as a distributor of industrial O-rings, and has since grown into a full-service supplier of sealing and mechanical components. We possess the ability to assist with design challenges, and can custom make materials to meet your specifications. Real Seal offers real solutions at a terrific value.
Taking care of the machinery utilized in various industries can be a time-consuming and occasionally hazardous task. To help alleviate these issues, many companies have opted for automated maintenance systems, be it in the form of automatic greasing systems or by ensuring they use the right type of seals to keep applications running efficiently without the need of much oversight or repeat maintenance.
But what are the pros and cons of automated machine maintenance versus manual machine maintenance. That’s what we’re going to answer today.
Health Factors
When it comes to health and safety, it’s hard to deny that automated systems can be incredibly beneficial. By removing the need for an individual to go in and clean or adjust different components, it reduces the risk of them potentially hurting themselves.
This point is particularly applicable when it comes to larger machinery that can have a wide range of potentially deadly parts that could cause serious harm if something was to go wrong. Imagine a crushingly heavy peripheral suddenly collapsing while an employee is performing maintenance. While such occurrences are rare, they’re still possible.
But when an automated or semi-automated system is used, it can ensure that employees are out of harm’s way should the unforeseen occur. In this event, the worst case scenario is the automated system being damaged or destroyed – a far smaller price to pay.
Efficiency
While some automated systems can be a little hit and miss, a large majority are very effective at their job. By having your machinery maintained by automated systems or products, it means less time is spent by individuals on keeping machinery in top condition. By extension, this means the machinery will experience less downtime and employees can better focus their time on other tasks, increasing overall operational efficiency.
By having the right seals on different applications and machinery, it means there will be less spills and potential malfunctions. Seals may not be an automated system, but they permit applications to run with greater autonomy without issues arising.
Longer Operational Life and Less Costs
With the right systems in place, machinery and applications will ultimately have longer operational lives. As a result, there will be less downtime and a decreased need to repair or replace machinery, thus resulting in less overall costs. As with anything, automated systems are an investment, but choosing the right ones will save you money in the long run.
When it comes to seals, it’s imperative to choose the right material. If your applications are dynamic (e.g. they move around), then you’ll need a dynamic-friendly sealing comprising the right materials. What material you opt for depends on, for example, factors such as the operating temperatures of the application and the types of chemicals the seals may come in contact with. By knowing these factors and having the seal designed to exact specifications, you’ll find they will last far longer than other seals.
To ensure you have the o-rings and seals for your machinery or application, contact Real Seal today.
Unless you’re dealing with water, the solutions that are being sealed within systems are either acidic or basic. Either one can wreak havoc on a seal made of the wrong material type. For acidic solutions, a weak seal can cause a dangerous situation that can damage property and harm employees, this is where acid-resistant o-rings come into play.
Knowing what types of seals are best for these operations is imperative to protecting your assets and your employees. Not only are acids dangerous when touched, the fumes can often be just as harmful to both people and materials. Avoid making the mistake of choosing a material that is weak to acid. Here is a list of materials that can be used in operations involving acidic solutions:
Fluorocarbon Rubber
Fluorocarbon Rubber, or FKM, is best for applications requiring both chemical and heat resistance up to 400 degrees Fahrenheit, in addition to the acid resistant quality. There are even FDA grades available for food and beverage applications. A lot of food products are acidic, such as sodas, juices, and other fruit products.
Specialty fluorocarbons allow for a large range of resistances to various forces and chemical properties. If your application includes extremely acidic solutions, then these may be your best option. Customization is often a key concern for applications in the current industry trends as each operation has such unique and specific needs for their operation to run at the highest possible efficiency. Specialty materials allow for the most flexibility and can be designed by experts to fit your application.
EPDM
Ethylene Propylene Diene Monomer, or EPDM, is resistant to weathering, ozone, water, and steam, as well as the acid resistance needed for these operations. Compounds cured with peroxide have excellent compression set resistance. So, if you are looking for a material that can retain its shape under high levels of pressure and is resistant to most acids, EPDM may be the way to go. Often it’s a combination of harsh factors that destroy a seal, so knowing if it is acid-resistant is merely the first step. High-pressure operations aren’t uncommon, and when you need a compound that resists acid and deformation, EPDM should be considered.
Materials to Avoid
A lot of materials are able to handle lower acidity fairly well. However, there are certain materials that are very bad at handling acids and will degrade quickly under this kind of stress. Knowing these materials is just as important as knowing ones that are good for acid-resistance.
Silicone is an extremely common material for o-rings and is not good at resisting acids. While you may want to use silicone because of its low cost and good set resistance, it is a poor choice if the solutions you are sealing are acidic. Urethane is another material that should be avoided in operations using acids. Certain rubbers have a mild resistance to acids in static applications, but high acidity is very corrosive to most rubbers.
Selecting the Right Seal for Your Operation
Acidity is merely one factor that should be considered when choosing the right seal for your operation. Other factors in combination with acid can make the process of finding the right seal complicated and potentially dangerous and expensive.
When you are choosing the o-rings for your systems, consulting with an expert in the industry, and buying seals from a reliable manufacturer are essential to your success. Real Seal has been in the industry for decades, creating and finding solutions for a massive range of applications. Contact Real Seal today to ensure your company’s success!
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 Benefits of a Backup Ring
No matter what type of application you have or who you work for, having a system that will run well for as long as possible should be one of your top concerns.
A backup ring is just one of the many little things you can do to help keep your system running smoothly for as long as possible, along with these other methods. But you might be wondering, just how does it work? There are a few ways a backup ring could improve your system performance and longevity.
Extrusion
O-Rings experience a lot of stress, causing them to wear down in various ways. One of the biggest causes of an O-Ring failure is extrusion, particularly in hydraulic rod and piston seals. Extrusion occurs when the internal pressure of an application becomes too great, causing the O-Ring to extrude – or stick out – into the clearance gap. This extruded or extended portion of the O-Ring will wear down quickly, reducing the amount of material in the O-Ring. After a short period, extrusion results in seal failure.
According to Daemar, some of the common causes of extrusion include:
- Excessive clearances.
- Pressure exceeding system design.
- An O-Ring with an insufficient durometer for the application.
- Degradation of the O-ring due to system fluid.
- Irregular clearance gaps caused by eccentricity.
- Increased clearance gaps due to excessive system pressure.
- Improper machining of O-ring gland.
- Wrong O-ring size installed, resulting in an excessively filled groove.
You should inspect your O-rings for signs of extrusion. Examine the edges of your O-rings on the low pressure or downstream side to see if it appears chewed or chipped. If extrusion has caused your O-ring to fail, you should see small pieces missing from the low pressure or downstream side. In some cases, 50% of the O-ring may have been lost already before the leakage has been found.
Preventing Extrusion
There are three ways to combat extrusion. The first is to reduce the clearances in order to lower the extrusion gap. Unfortunately, this is not practical due to the high expenses involved.
It would be much cheaper to instead raise the durometer of the O-ring. An O-ring with a higher durometer would have a much higher resistance to extrusion, but would also bring two other problems with it: namely, the limited availability of higher durometer materials, and that these materials are not as effective in low pressure applications.
Backup Ring
This brings us to the third option: backup rings. Rather than acting as a replacement for your installed O-rings (as its name suggests), a backup ring is actually meant to work in tandem with the O-Rings you have already installed. Backup rings are typically made of materials with high durometers and resistance to extrusion, including nitrile, Viton (FFKM), or PTFE.
The backup ring is installed between the O-ring and the extrusion gap. The addition of a backup ring will improve the pressure resistance of the O-ring, and prevent it from being forced into the clearance gap, reducing the chances of extrusion and premature seal failure. Depending on the direction of the pressure, you may even be able to install two backup rings. This will provide added protection against extrusion and O-ring failure.
Choosing a Backup Ring
You will have a number of options to choose from to cater an O-ring for your application. They come in two styles: a flat, washer-like style, or a contoured face which provides greater grip and support on the O-ring.
They may also have a solid or spiraled construction. A spiraled construction is made of overlapping rings, providing several different contact levels against the shaft. They provide greater support over solid construction backup rings.
Buy Your Backup Rings From an Industry Leader
From humble beginnings as an O-ring distributor in 1970, Real Seal has grown to become a full-service O-ring supplier and industry leader. Real Seal is not only one of the most technologically advanced O-ring suppliers today; we are also one of the few organizations with a fully-equipped laboratory as well as a full-time chemist and technical staff. This allows Real Seal to meet design challenges special material formulations in a way that no other company can. Don’t wait: give us a call and we’ll provide you with backup rings made to your exact specifications as soon as possible.
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