Valve and control systems face constant movement, heat, and pressure changes that can strain any sealing material. At 600°F and 1,000 psi, the conditions exceed what most standard seals can handle. Reliable performance in that environment depends on precise engineering and the right combination of materials.
One of Marco Rubber & Plastics’ long-time valve and control customers was operating in exactly those conditions and needed a better sealing approach. Their existing spring-energized PTFE seals reached their performance limits in continuous high-temperature operation. Marco’s engineering team was tasked with creating a custom sealing system capable of surviving extreme heat and dynamic motion without compromising performance or safety.
The Challenge: Continuous Dynamic Sealing at 600°F and 1,000 psi
Valve and control assemblies rarely get a break. They are exposed to constant motion, heat, and pressure changes that test material limits. The customer’s system operated with hot air at 600°F and pressure cycling up to 1,000 psi. That combination creates a tough environment where few materials can stay stable over time.
The customer needed a seal that could handle the temperature, pressure, and movement without losing its shape or sealing strength. Standard PTFE compounds performed well in moderate conditions but could not hold their properties through continuous, high-temperature operation. To reach the required reliability, the seal had to be re-engineered using high-performance materials and an energizer built for continuous high-temperature operation.
The Engineering Approach
Building a Seal for Extreme Environments
Marco’s engineering team began by reviewing the customer’s operating profile. Temperature gradients, pressure cycles, and movement patterns were analyzed to understand how the seal behaved under stress. From that data, the team developed a specialized high-temperature PTFE compound that maintained strength and elasticity through continuous exposure.
The PTFE element was paired with an advanced spring energizer to keep sealing force consistent. The energizer, made from a high-performance alloy, maintained constant sealing pressure as system components expanded and contracted with temperature changes.
Beyond sealing pressure, the team refined the design to minimize friction between the seal and mating surfaces, thereby controlling wear. These adjustments helped the material perform reliably through repeated motion and high thermal load. Performance was maintained through constant thermal and mechanical stress.
Validation Through Testing
Marco’s engineering team ran comparative testing against conventional spring-energized PTFE seals. Under identical temperature, pressure, and motion profiles, the new design consistently demonstrated lower leakage across the entire operating range, minimal permanent deformation after extended heat exposure, and improved wear resistance under continuous cycling.
Proven Results and Real-World Impact
The new high-temperature sealing system delivered consistent performance under continuous 600°F service and 1,000 psi operating pressure. The seal held its shape and maintained sealing pressure through extended cycles. This prevented leaks and eliminated deformation that had limited previous designs.
During qualification and field operation, the customer recorded longer service intervals, fewer maintenance requirements, and improved system reliability. The consistent sealing performance reduced unplanned downtime and extended equipment life, allowing the system to operate safely and efficiently under extreme conditions.
By combining high-performance materials with precision engineering, Marco delivered a sealing solution that met the customer’s performance targets and improved long-term reliability across their valve and control systems.
Marco Rubber & Plastics continues to use this approach across industries where seals must perform in extreme environments, including chemical processing, aerospace, and high-pressure control systems.
Talk with a Marco Engineer About Your High-Temperature Sealing Needs