Air Sentry® Saves Manufacturer $340K

Air Sentry® - GearboxGearboxes are used on various types of industrial machinery to provide increased torque while reducing speed from one type of rotating power source to another using gear ratios. A gearbox can be set up to do the opposite and provide an increase in speed with a reduction of torque. Some of the simplest gearboxes merely change the physical direction in which power is transmitted.

Gearboxes are used in many applications, such as wind turbines, conveyors, draglines, bridges, wastewater treatment pumping systems, and many other large pieces of machinery that require a power source.

In an effort to cut costs and improve system reliability, a manufacturer of high quality construction materials examined maintenance costs of their fifteen facilities. One of the findings showed spending in excess of $650,000 annually to maintain and repair 500 gearboxes across all plants.

Gear oils were replaced every six months in an effort to reduce equipment failure and downtime due to oil degradation and contamination. In doing this, the facilities’ combined consumed petroleum and synthetic based lubricants resulted in the use of over 10,000 gallons per year, with an average of 10 gallons used per gearbox. At an average cost of $14.00 per gallon, the costs were astronomical.

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Perfluoroelastomers for the Semiconductor Industry

Perfluoroelastomers for the Semicon IndustryNEW White Paper Available!

Gallagher Fluid Seals has added a new white paper to its Resources Page, Perfluoroelastomers for the Semiconductor Industry, written by Russ Schnell.  Below is an excerpt from the new white paper.  You can download it in its entirety by clicking on the thumbnail to the right.

Perfluoroelastomers for the Semicon IndustryThe semiconductor industry, one of today’s major industries, produces integrated circuits (chips) which have found their way into everyday devices from toasters to smartphones to high speed computers.  Integrated circuits are expected to perform operations faster and faster while attaining ever higher levels of reliability. As these chips become more complex and powerful the process for their manufacture becomes more complicated. Years ago a chip may have gone through 100 steps as underlying circuits were constructed.  Now chips may go through more than 400 steps and the complexity of these circuits, and their capability, has greatly increased. This also results in more opportunities for problems during manufacture. Line widths, the width of the electrical pathways, have decreased in order to pack more capacity into each chip. This dictates that contaminants from the production equipment, gas streams, seals, etc., must be essentially eliminated to avoid contamination and chip malfunction.

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How to Read a Rubber Test Report

Article re-posted with permission from Parker Hannifin Sealing & Shielding Team.
Original content can be found on Parker’s Blog.

4 Most Common Rubber Test Report Misunderstandings

4 Most Common Rubber Test Report MisunderstandingsWe’ve all done it at least once: looked at a rubber test report, read the numbers on it, and come up with exactly the wrong conclusion. Pass / fail limits and results are printed right there, but for some reason, our brain just misinterprets the two. It’s a passing value, but for some reason, we think it shows a failure instead. Imagine a police officer writing a speeding ticket for driving 53 MPH on a road with a 55 MPH speed limit.

It’s not a problem with the test itself, it’s a problem of interpretation. That means the old carpenter’s adage, “measure once, cut twice; measure twice, cut once” doesn’t address the issue. The same issue of misunderstanding the values on a test report occurs in the rubber seal industry about once a month. Passing results are misinterpreted to be failing results, and good values are thought to be bad ones. Here are four of the most common rubber test report misunderstandings I’ve run into.

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Kalrez® Seals for Semiconductor Processing

Purity is critical to high wafer yield, and Kalrez® seals are designed with properties that help reduce contamination from particulates, outgassing and extractables.

Semiconductor Processing Seals

Kalrez® Seals - Semiconductor ProcessingKalrez® seals for semiconductor processing are field-proven in the manufacture of semiconductor chips.

They can help extend planned maintenance intervals, and thereby lower long-term cost of ownership, in a wide range of semiconductor processes. In a number of fabrication customer evaluations, Kalrez®seals exhibited improved mechanical strength, lower particle generation and longer seal life versus competitive perfluoroelastomers, in both static and dynamic sealing applications.

Operational Improvements

Kalrez® seals can help improve semiconductor manufacturing in a range of wafer-fabricating operations, including:

  • Deposition
  • Etch
  • Ash/strip
  • Thermal
  • Wet

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VIDEO: TEKLEEN® ABW Series Filters

TEKLEEN® ABW Series filters are custom manufactured to meet a wide range of industrial applications, including ASME certified, sea water, high temperature, high pressure, etc. The filters are complete with Stainless Steel screens and can be set up in parallel for unlimited flow capacities. The filter bodies are available in stainless steel and carbon steel with baked on epoxy coating. Clean filter pressure drop with 100µ screen is less than 1psi at the rated flow of the filter.

Watch the video below to see the ABW Filter in action.

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FLUSH-GARD™ Conserves Process Water

FLUSH-GARD™ Sealing SystemThe FLUSH-GARD™ Sealing System from Garlock is an alternative to traditional packing sets in stock pumps, agitators, and other applications handling solid/liquid mixtures. It extends equipment life by protecting sleeve (non-contact) and packing from media attack, while also providing significant cost savings by reducing flush water consumption by up to 90%, as proven with installation of a flowmeter.

Harmful solids and particulate are contained from entering the stuffing box as the flush water is forced by the FLUSH-GARD™ bushings’ unique design – integral tangential multi-porting – toward the pumped media, utilizing the shaft’s rotation and centrifugal forces that are created.  A small amount is allowed into the stuffing box to lubricate and cool the braided packing.

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Metal Expansion Joints for High Temperature/Pressure

Expansion Joint Design Guide - Metal Expansion JointsGallagher recently released its Expansion Joint Design Guide, now available for download on our site.  This design guide takes an in-depth look at elastomeric, metal, and flue duct expansion joints.  The excerpt below is a section of our Expansion Joint Design Guide focusing on types of metal expansion joints.  To download the entire guide, visit our Resources Page, or click on the image to the right.

Much like elastomeric expansion joints, metal expansion joints are used to preserve the integrity of a piping system where the piping is subject to changes in temperature, pressure, vibration, compression, extension, cyclical movements or movements required by usage.

Oftentimes, metal expansion joints are used when an elastomeric joint simply cannot handle the extreme conditions – applications where high temperature, large temperature range, or high pressure exists. Generally, metal expansion joints can be used from -450°F to +2000°F, depending on the metallurgy, and can also handle pressures from full vacuum to 3,000psi.

Metal Expansion Joint Components

Though customized and intricate expansion joints can be manufactured for a variety of specialized applications, there are four basic designs that are most commonly used:

Metal Expansion Joints - Basic BellowsBasic Bellows

A bellows can be supplied without end fittings for field installation. The skirt, or straight portion at each end of the bellows, can be sized to fit a flange or pipe. Skirt length can vary depending on your needs and should be specified when ordered.

Metal Expansion Joints - Unrestrained SingleUnrestrained Single

An unrestrained single expansion joint is best used by piping systems which are equipped with proper guides and anchors to absorb axial, angular, and a small amount of lateral movement.

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New FFKM Extends Seal Life

Article re-posted with permission from Parker Hannifin Sealing & Shielding Team.
Original content can be found on Parker’s Blog.

Solving Long Time Industry Problem

Compression Set Resistance - FFKM ULTRA FF156

For several years, one of the biggest drawbacks of “chemically resistant” FFKMs, or perfluoroelastomers, has been their relatively poor compression set resistance. Typically, compounding these materials to be extremely resistant to many different chemical environments comes with the drawback of having to give up their ability to resist taking a set after being under high temperatures for an extended period. Parker’s solution to this industry challenge is ULTRA FF156.

Best in class compression set resistance

Compression set refers to a common failure mode of elastomers where a seal permanently flattens out while in application and the joint begins to leak. A material’s resistance to this permanent deformation can be easily tested in the lab. To do so, a seal’s thickness is measured, then that seal is compressed about 25% before being heated in an oven at a particular temperature for a predetermined amount of time. That seal is then removed from the oven and the thickness is remeasured.

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Case Study: Chocolate Process GAR-SEAL® PTFE Butterfly Valve and BIO-LINE ASEPT®


Food Processing – Chocolate


A major global confectionery group producing leading consumer branded products, with a focus on quality and customer satisfaction.


This customer’s facility in Germany processes chocolate products, and they had experienced historical issues with butterfly valves for critical processes whereby the valves were failing prematurely and replacement parts were only available on a long lead-time. Additionally they required higher performing sealing solutions for hygienic connections throughout the process, requiring a superior material that would provide an effective seal while being resistant to aggressive process and cleaning media.

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Gasket Installation Procedures: Best Practices

Brought to you by Thermoseal®

Gasket InstallationThis blog provides guidance to maintenance operators, engineers and fitters to ensure successful gasket installation and assembly of bolted flange connections. However always check plant-approved installation procedures first.

The successful operation of a gasket depends upon a multiplicity of factors including the style and quality of the gasket material, but also the medium being sealed, the flange design, the amount of pressure applied to the gasket by the bolts and how the gasket is assembled onto the flanges and tightened. Very basic causes often lead to leakage in bolted joints, and in most cases, it is not just the gasket but also the human element. Users should evaluate all conditions to validate the products are suitable for the intended process.

Tools Needed

Specific tools are required for cleaning the flange and tensioning the bolts. Always use standard safety equipment and follow good safety practices. The following tools are required for removal of the old gasket and installation of the new gasket:

  • Calibrated torque wrench or hydraulic tensioner
  • Brass wire brush
  • Personal safety equipment
  • Lubricants for the bolts (if specified)
  • Other plant-specified equipment

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