A Polish Petrochemical Company was paying heavy fines resulting from the escape of harmful solvents into the atmosphere.
Safety Improvements Case Studies
AESSEAL 380TP solves leakage problem at Yorkshire factory
Persistent leakage from the rope style packing in a bitumen mixer was causing ongoing problems for a manufacturing company in northern England, resulting in product leaking into the work area.
DVS plugs the leaks at UK sugar factory
The installation of DVS Injectable packing has helped to solve the problem of constant leakage and shaft wear caused by the use of standard rope style packing on a Mingler at a sugar company in the English Midlands.
DVS Injectable packing solves leakage problem at Scottish plant
A pulp and paper company in southern Scotland was having problems with a side entry agitator shaft, which was running out of concentricity under heavy loads.
AESSEAL packing puts an end to costly leaks
Defective rope style packing on a fan pump at a pulp and paper company in Derbyshire was allowing the constant leakage of paper product, creating a slip hazard in a large area surrounding the agitator and resulting in damage to the shaft.
AESSEAL cleans up the brown lagoon
A sugar company in the English Midlands has saved more than £40,000 following a decision to upgrade its packing system to the AESSEAL® trapezoidal cross-section packing AESSEAL® 380TP.
LabTecta puts a stop to eight-year oil leaks
Excessive shaft wear from the lip seals on the input and output shafts on an extruder was causing problems at a Japanese chemical plant.
CURC solves leakage problem for Saudi company
A petrochemical company in Saudi Arabia was experiencing persistent leakage during startup on a cooling water pump, the result of installation errors and the improper setting of the component seals.
Reliability restored at Egyptian sugar refinery
A major sugar refinery in Egypt was experiencing critical failures in its seal systems, resulting in significant operational challenges.
DMSF seal saves thousands for Australian company
An Australian mining company saved more than AU$20k (US$12,700) in just five months after replacing inefficient gland packing with the AESSEAL DMSF double cartridge mechanical seal.
Savings for US company with AESSEAL DMSF
A US corn processing company has saved thousands of dollars in less than a year following the installation of an AESSEAL DMSF double cartridge mechanical seal.
DVS saves thousands for UK firm
A pulp and paper company has saved almost £20,000 following the installation of an AESSEAL DVS sealing compound system.
Superior AESSEAL product and service seals the deal
A company in Ireland specializing in the production of innovative coats, paints, and specialty materials requested the assistance of AESSEAL Ireland to repurpose a stainless steel Chemineer GTN agitator and wet double seal to accommodate a new product.
Unique utilization of the cooling coil solves pump problems.
The installation of the AESSEAL DMSF double cartridge mechanical seal was the answer to recurring seal failures at a chemical storage facility in the north-east of England.
Company reports huge savings with use of AESSEAL system
The use of an AESSEAL CDPH double mechanical seal is saving more than €280,000 (almost $300,000) a year in energy costs for an alumina producer in the Republic of Ireland.
DMSF solves reliability issues for Swedish company
Elastomer degradation was causing the seals on three of the boiler feed pumps at a Swedish energy plant to fail around every 12 months.
CDSA provides major savings for German company
A German paper and packaging plant has reported significant savings and improved reliability following the installation of CDSA double cartridge mechanical seals.
Seal still giving perfect service after more than ten years
An AESSEAL RDS split seal installed at a US paper mill in January 2014 is still in full operation more than ten years later.
STS seal and LabTecta ST ends steam leak hazard
Steam leakage and spare part availability were causing problems for an oil and gas company in Belgium.
FIDC cleans up at salt plant
Outdated and inefficient gland packing on a slurry pump at a UK salt processing facility was using water at the rate of nearly ten litres a minute.
LabTecta saves €360,000 for Spanish company each year
A lip seal which was leaking oil from an extruder gearbox was causing persistent problems for a Spanish petrochemical company.
Dangerous oil leak problem solved by LabTecta FS
A silicon lip seal fitted to a rubber lumps reactor at a chemical plant in northern Spain failed after just ten days, resulting in the serious leakage of oil from the gearbox.
DMSF ends leakage problem for Saudi firm
The split seal on a transfer pump at a wastewater plant in Saudi Arabia was leaking so badly that sewage was flooding the pumping room.
AESSEAL CURC stops leaks at sewage treatment plant
The installation in December 2022 of an AESSEAL® CURC™ single seal proved to be the remedy for serious issues at a sewage treatment facility in the Middle East.
CDM ends seal failures for German company
A German paper company has reported savings of more than €10,000 following the installation of the AESSEAL CDM double mechanical seal.
Major savings with CKD double seal
The single seals being used by Swedish water treatment company were unsuitable for the job they were being asked to do, allowing limescale to enter between the seal faces and leak out on to the floor of the plant.
FIDC ends costly leaks at US firm
The installation of an FIDC seal to replace single seals with no flush or API Plan has dramatically improved pump reliability at a pulp and paper company in New England.
AESSEAL product removes risk of HFC emissions
A specially designed double seal from AESSEAL has enabled an Italian drinks company to avoid the risk of major financial penalties which could have resulted from the release into the atmosphere of highly damaging HFC (hydrofluorocarbon) gases.
Major US food producer opts for AES-Elast
One of the world’s leading producers of human and animal nutrition has chosen AES-Elast as the elastomer of choice for its North American operations.
CDSA makes for safer workplace
The repeated failure of a component bellows seal was causing hazardous materials to leak into the work area at an Irish company supplying materials to the construction industry.
AESSEAL solves reliability problems for paper company
Persistent leaks from gland packing were causing constant interruptions to the production process at a paper company in south-eastern France. The failure of the packing every few weeks was resulting in damage to the shaft of the pump and causing product to leak into the work area.
AESSEAL packing guarantees highest food quality
Replacement of gland packing with AESSEAL’s precut food grade packing is saving a Portuguese food company around €6,000 a year in repair and maintenance.
CSSN guarantees water supply for Spanish town
Leaking seals were causing major problems for a Spanish water distribution company. The seals were fitted to a pump which was responsible for the delivery of water to a small town in the north-east of the country.
Spanish company cuts costs with CURC
An automotive manufacturing company in north-western Spain was unhappy with the service from its seals supplier, whose products were failing after less than six months, causing chemicals to leak into the work environment.
EasyClean cuts water usage at French milk plant
Installation of the EasyClean™ water management system helped French milk production company to improve its hygiene standards and reduce water usage.
AESSEAL mixer seal solves reliability problem
A locally-made double mixer seal being used by the Ela Kimya chemical company in Istanbul was failing every few months because its elastomers and inner seal design were not suitable for the application.
DMSC is worth its salt
A poorly-designed seal was causing problems for a major salt producer in eastern France.
AESSEAL product eliminates serious health hazard
Leakage of product from a faulty pump was causing problems for a petrochemical company in the south of Spain.
AES-Elast the answer to seal selection problem
Employees at William Grant’s Scottish whisky distillery in Girvan, Ayshire, were having difficulty selecting the correct mechanical seals for specific applications.
CURC solves leakage problem at US plant
Persistent failure of pumps at a chemical plant in Illinois was resulting in unacceptably high loss of product.
EasyClean the answer to excessive water use
Unacceptably high water consumption was a concern for a confectionery company in northern France.
Warman conversion the answer for Spanish company
A seal conversion kit for the Warman® AH Range of Ultra Heavy Duty Slurry Pumps helped to solve a variety of problems being experienced by a Spanish aluminium producer.
LabTecta the remedy for lip seal failures
The lip seals in use at a north of England glass manufacturer were wearing out after just a few weeks
Safety and reliability with AESSEAL heavy duty seal
A mining company in Australia was facing persistent problems from seal failures on one of its slurry pumps.
Bitumen pump upgrade saves over £23,000 a year
Asphalt producer pump for road surfaces was gland packed and losing over 15 tonnes of bitumen.
DMSF seals end contamination problem for Spanish firm
A metalworking company in northern Spain had equipped its pumps with component mechanical seals, parallel spring-mounted back-to-back, with an API Plan 54 circulation system.
AESSEAL upgrade removes safety risk
A sealant being used on an Sulzer APP3 pump by a Spanish biofuel company was leaking each time the pump was stopped.
AESSEAL system fixes sewage problems for US township
A municipality in Pennsylvania was having issues with major inefficiencies in its sewage treatment system.
AVT sensors save thousands for US company
Excessive vibrations in a vertical pump in a slurry pit application was leading to failure every month for the North Carolina company Befesa
AESSEAL cuts water usage by 75 percent at US company
A US mining company was concerned that its large end suction pumps were using excessive amounts of water.
Double seals solve reliability problem for US company
A New England pulp and paper company was reporting the persistent failure of its single seals
Improved reliability using dual seal and system
A corn wet milling plant in the USA had a problem with leaking seals on the centrifugal pumps.
Standard of service makes AESSEAL a clear winner
The seal on a pump at a chemical plant in the east of England was burning out on average every two weeks due to dry running, resulting in some four hours of downtime each time it failed.
Major savings follow installation of AESSEAL product
A petrochemical company based in the Middle East was having problems with persistent and costly seal failures.
LabTecta FS the answer for gearbox problem
A repair and maintenance company in West Virginia says that its customers in the local coal mining industry have recorded major savings following a decision to upgrade to AESSEAL LabTecta FS.
Upgrade solves contamination problem
A pulp and paper mill in South Wales was having problems with contamination in its oscillator unit gearbox.
Leakage problem solved with STS
A global energy company was facing significant losses as a result of damage to the steam turbine housing at one of its ethylene plants.
AESSEAL seals the deal
A US oil seed producer was finding that the single seals used in the production process were inadequate, and were failing on average every three to six months.
DMSF seal the answer for US company
An oil seed producer in the US was reporting that in spite of trying a variety of possible solutions, single seals in the production process were only lasting a few months before failing.
STS steam seal updates UK Ethylene plant
AESSEAL stepped in when a mission critical general purpose steam turbine at a UK Ethylene production facility developed leaks and the original OEM seal housing was no longer available. We updated the 40-year-old turbine with a modern non contacting STS mechanical seal within two weeks.
AESSEAL lowers the temperature in Montana
A company in Montana was having trouble with an unreliable seal on a debutanizer reboiler pump. The problems were being caused by an inner seal cooler.
AESSEAL system eliminates danger of hydrogen sulfide release
A system installed at a US refinery has helped to eliminate a risk to personnel caused by the periodic release of hydrogen sulfide
AESSEAL system aids clean-up at US feed mill
A US feed additives company reported loss of significant amounts of water due to leakage from double component seals.
LabTecta saving time and money at US plant
An oil seal, which had worn a deep fret mark in the output shaft of its Philadelphia Mixer Gearbox, which then leaked oil down through the worn-out mark.
Mining company saves $8 million AUD with AESSEAL system
A coal mine in Australia was having seal failures roughly every two weeks on two disposal pumps.
Full steam ahead for refinery after change to STS seals
An oil and gas refinery in northern England was experiencing poor reliability of its steam turbine.
AESSEAL helps significantly reduce downtime
A US corn milling and food additives company was reporting problems resulting from incorrectly cut bulk packing.
Improved reliability for new process
A refinery in Canada were commissioning a new lipids coprocessing initiative where renewable feedstock is injected into the cracker.
Seal upgrade improves reliability and saves over US$81k
A major oil and gas customer in Oman was experiencing continuous leakage from the gland packing used on their export booster pumps.
Reliability upgrade reduces water consumption
Kraft pulp mills with recovery boilers have multiple effect evaporators and concentrators to reheat and remove water from the returning Weak Black Liquor from the cooking process.
MagTecta improves gearbox reliability
A gas processing facility in the USA was experiencing water ingress and oil leakage into one of its gearboxes.
Seal upgrade improves pump availability
On a molten sulphur pumping operation, at one of the world’s leading producers of liquefied natural gas (LNG) in Qatar, there was the need for continuous availability on three pumps.
Improving reliability and reducing product loss for sugar Refinery
A South African based sugar refining plant was using gland packing on two screened juice pumps and two mixed juice pumps with a quench to drain seal support system.
Lip seal upgrade for US petrochemical plant
A petrochemical plant in the USA was experiencing problems with oil leaking from the vertical input shafts of their pumps and called upon AESSEAL to help out with a solution.
FDA compliant elastomer increases reliability
AES-Elast has found success in the Food & Beverage industries not just because of its FDA compliance but also because of its wide chemical compatibility and its hot water and steam performance.
AES-Elast™ successfully replaces leading brand
A leading global chemical company uses AES-Elast in their Terephthalic Acid (T.P.A) processing facility to seal acetic acid applications.
Cleaner plant with AESSEAL gland packing
Gland Packing Style 745TP has resulted in a cleaner environment for a South African chemical company.
Eliminating over 61 million gallons of water from 26 evaporator pumps
Evaporator steam use reduced by 103,000klbs a year by eliminating over 61 million gallons of water from 26 evaporator pumps
Reliability problems solved at mill
A Canadian paper mill was having issues with the reliability of its Chlorine Dioxide Generator Circulation Pump.
LabTecta seals halt costly oil leaks
A South African company specialising in the production of animal feed was having constant problems with a leaking gearbox
LabTecta reduces quality issues and improves reliability
A paper manufacturer in the USA was experiencing oil leakage from the journals in the dryer section of its paper machine.
MagTecta eliminates gearbox oil leakage
Twin Rivers Paper at its Maine USA plant were dissatisfied with the sealing arrangement on the gear boxes that are the main drive for the paper machine rolls.
New orders follow success of AESSEAL installation
A competitor seal at the petrochemicals company SI Group India in Mumbai was giving trouble.
AESSEAL SW system solves water pressure problem
A US paper company to use the advantages provided by the SW Seal Water Management systems.
The AESSEAL DMSF helps cut water usage for US company
DMSF™ mechanical seal and system has helped to reduce water usage and maintenance costs.
A place of greater safety with AESSEAL SCMS
Shaft fretting and product leakage into the atmosphere were causing safety issues and problems of product contamination.
Reliability upgrade saves $24k per year
A speciality chemical company in the USA was experiencing problems with the mechanical seal fitted on a venturi scrubber.
Preventing toxic leakage and improving reliability
Having tried mechanical seals from other manufacturers without success, the customer had resorted to using gland packing and a ‘Pack-Ryt’ bushing for their Chlorine Dioxide Generator recirculation pump.
ZAR84,000 Saving with reliability upgrade from packing
A vertically integrated chemical and mining company had a poor mean time between failure (MTBF) on a water pump on one of its mining facilities in South Africa.
Reliability upgrade improves reliability 700%
A major steel producer in South Africa were experiencing unacceptable leakage and reliability with one of their lime slurry pumps.
Reliability upgrade improves MTBF 2900%
A speciality chemical company in the USA was experiencing problems with the mechanical seal fitted on a phenol pump.
Seal upgrade improves mixer reliability 5200%
A corn milling facility in the UK had lip seals fitted to the shaft of a dough mixer.
Reliability Improved For Waste Energy Company
Enfinium were disappointed with the support provided by their pump OEM
Gas seal gives 14 years trouble free operation
A chemical production plant in Tennessee was experiencing problems withleakage of the mechanical seals on their Xylene pumps.
Reliability upgrade eliminates unscheduled downtime
An oil refinery in the USA was experiencing excessive seal failures with some even leaking straight from start up.
Reduced downtime, improved safety
Using gland packing to seal an Armstrong – Chemtec crystalliser.
Specialist paper producer saves almost 6.4 million litres of water per year
The main purpose of refining in the pulp and paper industry is to improve the strength and density of the paper produced.
Trapeziodal Packing improves reliability 3-fold
A phosphates and phosphoric acid producer in South Africa was having problems with the packing on its phosphoric acid pumps.
Mean time between failure doubles
The customer was experiencing problems with the main lubrication oil pump which was performing the critical duty of supplying lubricating oil to the carrier’s main engines.
Tailored seal solution cuts costs and operational downtime
A global food and beverage manufacturer in Poland, was experiencing problems with a fan fume pumping toxic fumes as a by-product of the distilling process.
Improved Safety and Reliability
A major manufacturer in the UK were having reliability issues with the seal on a critical Labour chemical pump used to pump caustic solution.
Successful Support System Upgrade Improves Plant Reliability
A chemicals manufacturer in the USA was experiencing ongoing issues with the reliability of the seal support system supplying a double seal.
Unique solution saves $287,000 a year and improves safety
One of the world’s largest nutrition companies was dealing with repeated downtime due to problems with clean condensate pump seals on a corn wet milling application at its plant in Illinois, USA.
MTBF increases by 233%
Seadrift Coke L.P., a Texas based stand-alone coker, was experiencing repeat seal failures on a hot oil pump, leading to unscheduled downtime every six months.
Reduced downtime and health & safety benefits
Cargill Corn Milling Inc was concerned about reduced operational efficiency, the risk of contamination and workforce safety due to ongoing leakage from a fibre press at its Nebraska plant.
Catalogue of issues lead to failures on power station valves
A South African power station were experiencing regular outages leading to expensive downtime along with poor emission control and high energy losses.
Improved safety and production efficiency while reducing water consumption
The slurry tailing pumps at a potash mine were experiencing bearing failure due to ingress of tailings into the bearing frames. The pumps were sealed with Gland Packing and flushed with water.
Zinc Smelting Plant Saves Thousands
Experiencing repeat leakage of a highly abrasive zinc oxide and sulphuric acid solution
Eliminating unplanned maintenance with API Plan 32
A Malaysian geothermal power generation plant had an unreliable mechanical seal on its geothermal brine injection pump. The new solution eliminated the need for frequent maintenance.
Huge cost savings and improved reliability with gland packing upgrade
A mean time between failure (MTBF) of just 2 months meant that costs at over $135,000 AUD for pump maintenance were unacceptably high.
Improving reliability, increasing efficiency
A leading refinery in the UK was having trouble with seal leakage from existing carbon box technology on their 150#, 600# steam turbines.
LabTecta ends dust pollution problem for SA firm
Preventing dust from escaping into the working environment and is saving thousands of dollars a year
£137,830 saving & a 1100% MTBF increase
Increasing MTBF from 6 months to 6 years and saving over £137,000
Replacing gland packing reduces cost, and improves reliability
A coal mine in Australia was using gland packing on 3 coal slurry transfer pumps.
£66,000 savings after upgrading gland packing to an RDS split seal
Old solution costed over £13,000 a year in downtime, maintenance and product loss
Replacing lip seals reduces cost, improves reliability and saves the environment
A soda ash mine in the USA was using lip seals on a vertical turbine pump
$40,000 a year saving with LabTecta
Eliminating steam ingress into the pillow block bearings on a primary air fan, significantly reducing bearing failure.
A 50% MTBF increase whilst sealing a corrosive lime slurry
A coal fired power plant was regular leaking caustic liquid from its Flue Gas Desulphurisation (FGD) pumps causing extensive damage to the pump and surrounding area.
Upgrade eliminates environmental impact and delivers a 833% MTBF improvement
A mining operation in Australia eliminated water leakage to the environment
Mechanical seals upgrade reduces maintenance and will save £5,450 per annum
Increasing plant reliability to reduces maintenance costs
A $30,000 yearly saving for Australian copper mine
Upgrading gland packing to heavy duty slurry seals on a filter press feed pump leads to a $30,000 yearly saving.
$10,500 yearly cost saving for Chemical manufacturer
Eliminating oil leakage from a boiler feed pump with a LabTecta-PB™ that is specifically designed for sealing split bearing blocks.
