6 Ways Manufacturers Can Decrease Downtime Due to Seal Failure

Did you know that unplanned downtime can cost manufacturers up to $260,000 per hour? Seal failures are a significant contributor to these losses, halting production, damaging equipment, and driving up repair costs. It’s easy to see how quickly those expenses add up.

The good news? Seal-related downtime is often preventable. By understanding the root causes of failure and taking proactive steps, manufacturers can keep operations running smoothly and minimize costly interruptions.

Understanding the Causes of Seal Failure

Seal failures typically stem from a few common issues, each with its own potential consequences:

• Material Degradation: Seals made from materials incompatible with operational conditions — such as extreme temperatures, harsh chemicals, or high pressure — can degrade quickly. This degradation often leads to leaks, contamination of critical systems, or complete seal failure, potentially halting operations and damaging nearby equipment.
• Improper Installation: Misalignment, overtightening, or using the wrong installation tools can compromise a seal’s performance. Improperly installed seals can cause immediate leaks, reduce the lifespan of the seal, and create recurring maintenance issues, increasing downtime and labor costs.
• Operational Stress: Pressure spikes, vibration, or incorrect fluid handling can push seals beyond their design limits. The effects of such stress often include ruptures, blowouts, or gradual seal wear, all of which can lead to equipment malfunctions, reduced efficiency, and even safety hazards for operators.
• Maintenance Neglect: Overlooking regular inspections and maintenance allows wear and tear to go unnoticed until failure occurs. This neglect can result in unexpected shutdowns, costly emergency repairs, and damage to surrounding components, compounding operational delays and expenses.

By addressing these common causes proactively, manufacturers can avoid the ripple effects of seal failure and maintain smoother, more efficient operations.

6 Key Strategies to Prevent Seal Failure

Reducing downtime starts with addressing these common issues through thoughtful planning and proactive measures:

Number 1: Choose the Right Seal Material

Selecting the right material for your seals is critical to ensuring reliable performance and longevity. Different operational conditions — such as extreme temperatures, high pressure, or exposure to harsh chemicals — require materials with specific properties to withstand these challenges. For example:

• PTFE (Polytetrafluoroethylene): Known for its exceptional chemical resistance, PTFE is ideal for applications involving aggressive fluids or environments with high temperatures.
• Elastomers (e.g., Nitrile, EPDM, Viton): These materials offer flexibility and durability, making them well-suited for general-purpose sealing in a variety of applications.
• Metal or Carbon Seals: For high-pressure or extreme-temperature applications, metal seals provide strength and resilience where other materials may fail.

It’s also essential to consider factors such as wear resistance, compression set, and compatibility with system fluids when choosing a material. Consulting with our design or engineering team ensures the material aligns with your specific application requirements.
Additionally, working with a supplier that offers custom material formulations can help address unique operational challenges. By optimizing material properties for your system, you can reduce the risk of seal failure and improve overall equipment performance.

Number 2: Focus on Proper Installation

Proper installation is just as critical as selecting the right seal material. Even the highest-quality seals can fail prematurely if they are not installed correctly. Following manufacturer specifications and best practices is key to ensuring optimal performance and longevity.
Be sure to consider the following:

• Alignment: Misaligned seals can cause uneven wear, leaks, and even damage to surrounding components. Take the time to verify alignment during installation to prevent these issues.
• Use the Right Tools: Specialized tools designed for seal installation can help prevent common errors like overtightening or surface damage. Avoid makeshift solutions that might compromise the seal.
• Follow Torque Specifications: Improper torque application can lead to seal deformation or insufficient compression, both of which reduce effectiveness. Always adhere to the manufacturer’s guidelines.
• Inspect Components Before Installation: Check for burrs, scratches, or debris on mating surfaces that could damage the seal during or after installation. Smooth, clean surfaces are critical for a proper fit.
• Lubricate as Needed: For many seal types, applying an appropriate lubricant during installation reduces friction and helps ensure a smooth fit without damaging the material.

By prioritizing proper installation, you not only protect your seals but also enhance the reliability of your entire system.

Number 3: Conduct Regular System Audits

Periodic system audits are essential for identifying potential stressors that could lead to seal failure. These evaluations provide a comprehensive look at your equipment and processes, helping to uncover hidden risks and opportunities for improvement. Here are some key areas to assess during a system audit:

• Pressure Inconsistencies: Check for fluctuations or spikes in system pressure that may exceed the seal’s design limits. These irregularities can cause seal deformation, leaks, or blowouts.
• Temperature Variations: Measure operating temperatures to ensure they remain within the seal material’s tolerance range. Excessive heat can degrade materials, while low temperatures may reduce elasticity and flexibility.
• Fluid Compatibility: Evaluate the types of fluids being used and their chemical compatibility with the seal materials. Incompatible fluids can cause swelling, cracking, or chemical breakdown of the seal.
• Component Alignment: Inspect for misaligned shafts, housings, or other components that may exert uneven forces on seals. Misalignment is a leading cause of premature wear and leaks.
• Vibration and Shock Loads: Analyze the system for excessive vibration or shock loads, which can cause dynamic seals to wear out quickly or fail.
• Seal Installation Quality: Review the installation process to ensure seals are properly aligned, tightened, and installed using the correct tools and techniques. Improper installation is a common cause of early failures.
• Wear and Tear on Seals: Examine seals for signs of wear, such as cracks, flattening, or surface damage, which indicate they may need replacement or adjustment.
• Contamination Risks: Look for sources of contamination, such as dirt, debris, or foreign materials, that could compromise the seal’s effectiveness.
• System Fluid Flow: Assess the flow rate and direction of system fluids to ensure proper lubrication and cooling, which are vital for seal performance and longevity.

Partnering with experts during these audits ensures a thorough assessment and provides tailored recommendations to address any identified risks. Proactive audits not only help prevent seal failures but also improve overall system reliability and efficiency.

Number 4: Optimize Operating Conditions

Maintaining optimal operating conditions is essential for maximizing the lifespan and performance of your seals. Key variables such as pressure, temperature, and fluid compatibility should be closely monitored to ensure they remain within the seal's design parameters. Deviations from these conditions can accelerate wear, cause material degradation, or lead to catastrophic failures.

For example, excessive pressure can deform seals, while high temperatures can cause materials to harden or lose elasticity. Similarly, using fluids that are incompatible with the seal material can lead to chemical breakdown and leakage.

Regular monitoring systems, such as pressure gauges, thermal sensors, and flow meters, are invaluable for identifying fluctuations or anomalies in real-time. These tools allow operators to address issues before they cause damage, such as recalibrating equipment or adjusting fluid compositions.

To enhance long-term reliability, combine monitoring with periodic system audits. These audits provide a holistic view of your equipment’s performance, helping to uncover hidden risks like misaligned components or vibration issues that may not be immediately apparent. By proactively addressing these stressors, manufacturers can prevent unnecessary downtime and ensure smooth, efficient operations.

Number 5: Consider Custom-Engineered Seals

Not all sealing solutions are created equal. Standard seals may work for standard applications, but custom-engineered seals are often the best option for unique or demanding environments. Custom seals can be tailored to fit specific operational requirements, ensuring optimal performance and a longer lifespan – both factors that diminish downtime.

At Ergoseal, we specialize in designing and manufacturing custom-engineered seals that meet the most stringent specifications. Whether you need seals for high-pressure applications, extreme temperatures, or unique geometries, our team has the expertise to deliver a solution that fits.

Number 6: Partner with a Trusted Seal Supplier

Working with a reliable seal supplier is key to reducing downtime and maintaining efficiency. A trusted partner can provide:

• Advanced engineering support to optimize your sealing solutions.
• Rigorous quality assurance processes, like those backed by AS9100D certification.
• Testing and reverse engineering services to identify weaknesses and prevent future failures.

Ergoseal’s decades of experience, precision manufacturing capabilities, and commitment to quality make us the ideal partner for manufacturers looking to eliminate seal-related downtime.

Final Thoughts

Reducing downtime from seal failures isn’t just about choosing the right product — it’s about taking a proactive approach to material selection, installation, maintenance, and customization. By working with an experienced supplier like Ergoseal, you can ensure your seals are built to perform reliably, even in the most demanding conditions.

Need help reducing downtime in your operations? Contact Ergoseal today to learn how our custom sealing solutions can keep your equipment running smoothly.