Category Archives: Prototypes

Case Study: 3-A® Compliant Rod Seal Capable of Handling High-Pressure

Valves are indispensable components in the hygienically sensitive systems used in the food, beverage and pharmaceutical industries. Until now, there were no high-pressure valves available for food-product contact applications that conformed to 3-A® standards. These global hygiene standards address the design and manufacturing of components that come into contact with food.

Bardiani Valvole approached Gallagher’s partner, Freudenberg Sealing Technologies, for help in developing a solution to tap into its material expertise. As a result of joint cooperation, Freudenberg engineers developed a main rod seal that was both 3-A® compliant and capable of handling high-pressure of up to 2175 psi (150 bar) that the customer’s valve required. The main rod seal incorporates proven Freudenberg technology with advanced component design in an entirely new combination that is also compatible with other industrial high-pressure valves.

picture of valve example
Copyright: Bardiani Valvole Spa

Prototypes produced without any tools

The 3-A® compliant main rod seal combines a sealing lip, manufactured from EPDM 302 or Fluoroprene® XP 43, with a backup ring made of PTFE. Freudenberg’s product engineers were inspired by the design of a proven shaft seal and an O-ring with a backup ring. In order to meet development and cost deadlines, the team initially produced one-off prototypes to share with Bardiani Valvole using the unique capabilities of Freudenberg Xpress®, a fast turnaround, high-quality manufacturing service that can generate custom seals in as little as a day. It offers machined seals made of original materials and original profiles for prototypes, spare parts or economical small series.

By eliminating the need to set up manufacturing tooling to produce sample parts, this results in considerable cost and time advantages for the customer. Thanks to special turning and milling techniques, individual designs can be tuned to exact specifications. The tailor-made sealing solution for the new high-pressure valve could also be produced economically in an extremely short time. The Freudenberg Xpress® Service is represented at numerous Freudenberg sites worldwide, enabling rapid delivery of spare parts, for example.

The seal’s design is free of dead space and prevents residue infiltration from process and cleaning media. It is hygienic, easier to clean, and compliant with all relevant material specifications for food, beverage, and pharmaceutical industry applications. Both materials used have very good thermal resistance and excellent mechanical properties. They also meet the demanding requirements for use in Cleaning in Place and Sterilization in Place (CIP/SIP) processes. Continue reading Case Study: 3-A® Compliant Rod Seal Capable of Handling High-Pressure

How Gallagher’s Suppliers are Helping Support the Fight Against Covid-19

Gore, Precision Associates, and Parker Join the Fight Against Covid-19

picture of gore logoWhat Gore is doing to help

As the COVID-19 pandemic continues to impact communities around the world, Gore is working hard to identify ways in which they can apply their materials science expertise and production capabilities to help during this time of need.

Several initiatives are underway that bring together the knowledge, skills and capabilities from across Gore.

As an immediate and initial response to the personal protective equipment (PPE) shortage, Gore rapidly engineered prototype reusable mask covers to supplement clinicians’ primary face masks.

The effort went from a product concept to prototypes in less than one week. Gore currently has prototypes being evaluated at a limited number of U.S. facilities in COVID-19 outbreak hot spots.

Additionally, by providing their customers and other manufacturing companies with Gore’s highly specialized component materials, they can use them to produce a variety of finished PPE items, such as:

  • Protective medical gowns, using fabrics laminates from Gore’s current inventory
  • Universal filter cartridge prototypes for fixed masks that incorporate Gore’s filtration materials intended to provide N95 particulate protection,
  • Disposable N95 respirators, using Gore’s filtration laminates

It is through these collaborations with those who have the technical capabilities and production capacity needed to produce the finished goods in volume that together, Gore and its partners truly are improving life.

Gore has even donated medical supplies and protective gear to healthcare workers in the communities in which their facilities are stationed. They’ve also extended a hand to provide engineering and prototyping support to address other urgent equipment needs at local hospitals.


picture of precision logoWhat Precision Associates is doing to help

Precision Associates, Inc. has ramped up its production of several essential rubber components for ventilator manufacturer Ventec Life Systems. Ventec recently announced plans to partner with GM to increase the output of these crucial units in response to the COVID-19 pandemic.

Critical patients suffering from the virus have difficulty breathing and require ventilator assistance for life support. GM is now transforming one of its factories to begin assembling ventilators for Ventec in early April. Continue reading How Gallagher’s Suppliers are Helping Support the Fight Against Covid-19

Modulus of Elasticity for Rubber Sealing Compounds – The Tensometer

Tensile Strength | Ultimate Elongation | Modulus of Elasticity

Rubber Compound Data sheets usually display a number of physical properties as recorded from standard test methods. Among the most common are three measured on the Tensometer:

  1. Tensile Strength (at break)
  2. Ultimate Elongation
  3. Modulus of Elasticity

The Test

Picture of TensometerThe Tensometer stretches a specimen, or dumbbell, cut from a sheet of rubber, until it breaks. During the test, the force required and length of the gauged section are measured continuously. These measurements are used to calculate the various results, which considers the actual dimensions of the test specimen.

While Tensile Strength and Ultimate Elongation are pretty well understood by most, Modulus is not as well understood. Unlike the other two, the Modulus values are not usually reported at break, but rather at various elongation percentages as recorded during the test. Modulus is reported in pounds per square inch (psi) or Megapascals (MPa) at a given elongation percentage as below:

Modulus @ 100% Elongation: 610 psi 4.2 MPa

The Results

You might ask, “What does knowing the Modulus do for me?” While Modulus and Durometer are somewhat related, there can be a pretty large variance in modulus values between two compounds of the same durometer. In an application that requires a rubber seal to be stretched into place, a low modulus compound might be considered to make assembly easier. On the other hand, a firmer compound would be preferable in an application where stretchiness is not desirable. In this case, a high modulus compound would be superior. Higher modulus is also a good indicator of a compound’s ability to resist extrusion in high pressure sealing applications.

This article is not intended to explain at length, the technical aspects of tensometer testing and resultant properties.  To see an actual test performed on an 80 Durometer EPDM, look below:


The original article can be found on Precision Associates website.

Gallagher Fluid Seals is a preferred distributor for Precision Associates. For more information, or if you have a custom engineering question, please contact our Engineering Department.

VIDEO: Extruded Profiles & Parts

Gallagher has long been a top Parker Distributor.  The Parker TechSeal Division designs and manufactures custom elastomer products using extrusion, precision cutting, and fabricating technologies. The extruded rubber products can be supplied in multiple forms such as cut parts, long lengths, bulk footage, or fabricated gaskets and seals. The video below provides an insight into TechSeal’s day to day operation including manufacturing, material development, and design assistance.

Continue reading VIDEO: Extruded Profiles & Parts

VIDEO: Freudenberg Xpress Rapid Production Cell

Customers often come to Gallagher Fluid Seals with the need for very short lead times for a seal.

Whether it is a piece of equipment that is down or a need for quick prototypes, Gallagher can assist you in developing the required seal profile and material for your application. We can have parts in your hands within 24 hours if necessary.

Our work is made possibly by the help of valued partners such as Freudenberg Sealing Technologies.

Watch the video above to learn more about the capabilities of Freudenberg Xpress cell.

Continue reading VIDEO: Freudenberg Xpress Rapid Production Cell