The Challenge
A company that works in industrial coding and printing across markets as diverse as food & beverage, cable & wire, cosmetics, pharmaceutical, healthcare, and more, needed a custom solution to solve a processing problem. This custom seal for industrial printing needed to meet specific requirements — how seals were affected by regular cleaning procedures.
The seals previously used reacted negatively to the cleaning chemicals used in flushing lines to make them suitable for printing on another product. The reaction between the seals and the cleaning solution led to crystal formation, a thickening in viscosity, and yellowing of the cleaning solution around the seal. The ‘build-ups’ reduced the cleaning fluid’s ability to flow and perform the required task, slowed production, and led to material costs for replacing components.
Improving the seal’s performance and reducing adverse effects on the cleaning process/fluid were paramount to the project’s success. The challenges for the Marco Sealing Solutions (formerly Marco Rubber & Plastics) team for this custom seal for industrial printing hinged on several factors:
- The seal material needed to be chemically resistant and able to hold up in a caustic environment
- The seal material needed to be inert in its reactions to the cleaning fluid used, and not lead to the negative effects seen previously
- Budget concerns limited the pool of potential material solutions
- Because the solution was custom-designed, trial-and-error, and multiple potential offerings were considered
The Marco team tapped into its extensive knowledge base to find the right material that would meet the requirements (both in application and budget). The team then worked extensively with the customer to alter processes to further enhance performance. Once identified, Marco performed internal testing to validate the solution and minimize costs associated with lost production time.
The Solution
The engineering team at Marco considered many possible fixes to the problem. Solutions included the potential use of multiple compounds and Parylene or PTFE coating to address crystallization and discoloration. Cognizant of the budget constraints — the customer needed to adhere to a specific range — Marco creatively worked through available options.
The engineering team settled on an EPDM formulation as the base material. But that discovery wasn’t the end of the process. Marco continued to hone in on various aspects of the seal to deliver the best possible performance.
- For instance, the formulation switched from a sulfur-cured EPDM material to a peroxide-cured EPDM.
- To improve the seal’s ability to fit securely in the allowed space, the sealing material durometer was adjusted. An increase from 45 to 60 provided a firmer filling material.
- With further customization, Marco adjusted the seal’s compression to maintain and extend the seal’s performance time after repeated use.
- To eliminate, or ‘bake out,’ a potential chemical conflict in the material, a custom post-curing methodology was implemented. A longer curing time and higher temperature were used to ensure the potentially disruptive chemical element was absent in the final product.
- Once a solution was prototyped, it was validated through a series of in-house tests. The tests recreated the expected operating environment thanks to details provided by the customer — to verify the product would perform as expected onsite. This process also led to quicker deployment of the seal and less downtime for the customer.
The Result
The custom-designed seal delivered in all aspects. The liquid flow of the cleaning solution returned to appropriate levels. It remained clear of discoloration and formation of problematic crystals. The mechanical and chemical-resistant properties of the seal met all requirements. Lastly, the customer found a timely solution that eluded several previous suppliers — at a price point that worked within their budget.
“Marco Rubber went above and beyond making sure we found the solution to our unique needs. The engineering and sales team were extremely responsive and helpful with any questions that we had throughout the process. From start to finish they made sure that we were fully satisfied with both our short and long-term goals.” — Customer company’s Process Engineer
This instance highlights the many ways Marco puts its experience and expertise to work for the customer – finding solutions to their sealing challenges. By collaborating with your team rather than simply dictating which path to take, Marco accounts for every requirement — from material compatibility and mechanical wear to budget constraints — and finds creative ways to maximize performance.
Contact Marco Sealing Solutions today to learn how our engineering expertise can provide a custom seal for industrial printing or any other sealing challenge.