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.
Water Savings Case Studies
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 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.
AESSEAL solves reliability problem for US paper company
The installation of the AESSEAL DMSC double mechanical seal, a close clearance bushing, a FLOWTRUE flowmeter, and a 25 litre SW2 water management system, has solved a problem of repeated seal failure for a US paper company.
CURC puts an end to leakage problem
Persistent leakage from a sodium hydroxide pump was causing ongoing problems at a desalination plant in the Middle East.
CDSA seals brings huge savings for US company
A US paper company has saved $1.5 million over the past seven years after replacing inefficient gland packing on two of its pumps with the AESSEAL CDSA double mechanical seal and tank systems.
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.
Major savings for SA company
The South African confectionery manufacturer Premier Foods was having problems with a seal on its licorice mixing machine.
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.
Huge reduction in water usage follows AESSEAL audit
The US petrochemical company Westlake is saving millions of gallons of water each year following advice from AESSEAL on how the company might reduce its overall consumption.
CDPH brings big savings for Botswana company
The replacement of a graphite packing system on a cyclone feed pump with the more efficient AESSEAL CDPH double mechanical seal.
DMSF makes its mark in Japanese paper industry
The installation of an AESSEAL® DMSF™ seal at a Japanese paper plant has increased the MTBF from just six months to seven years.
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.
Reliability the key with DISP seals and FLOWTRUE
Persistent leakage from seals was causing problems for a milk products company in northern France.
SW2 brings huge water savings for French brewery
Excessive water consumption was a recurring problem for a brewery in northern France. The OEM sealing solution used a quench to drain seal support system whose water consumption was costing €2,800 per pump.
Major water savings at South African paper company
A South African pulp and paper company is saving almost 18,000 litres of water a month following the installation of the AESSEAL DISP seal and SW02 water management system.
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.
Staying cool in Cardiff
The cooling system in a High Profile office building in the Cardiff Bay area was operating with just a single duty pump and no standby.
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 upgrade solves bearing failure problem
A Bottom Entry Packed Gland was allowing water to fall on to the bearing assembly of a pulper at a paper company plant in the west of England. This was resulting in the failure of the bottom bearing, which was happening on average every three months.
CDM the key to greater reliability
A French pulp and paper manufacturer was using gland packing on its pulp tank agitators. This required regular replacement of the packing.
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.
System Sentry proves its worth in INEOS field trial
Engineers at the petrochemicals manufacturer INEOS have given the seal of approval to the AESSEAL® monitoring device System Sentry® following a field trial at the company’s plant in Hull in the east of England.
CDM reliability the answer for seal failures
A corrugated packaging plant in northern France was experiencing persistent seal failures, on average every two months.
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.
Enhanced production reliability
Failing double component seals were causing problems for a specialist food producer in eastern France.
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.
AESSEAL achieves major savings for Middle East oil producer
An oil and gas company in the Middle East is saving more than $600,000 a year following the installation of an AESSEAL product.
Company makes huge savings with AESSEAL system
A water company in the Middle East has saved almost a quarter of a million dollars following the installation of an AESSEAL bearing protector.
AESSEAL system fixes sewage problems for US township
A municipality in Pennsylvania was having issues with major inefficiencies in its sewage treatment system.
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
Seal failures solved at US company
The installation of double cartridge mechanical seals and a water management system has solved a persistent and costly problem at a US paper mill
Sweet solution for sugar producer
The installation of the AESSEAL EasyClean seal support system has led to major savings for a UK sugar company.
AESSEAL product stops hot oil pump leakage
A large oil and gas company in north Africa contacted AESSEAL to look at a sealing issue on its hot oil pumps.
Fantastic seal life for notoriously difficult application
A pulp & paper company in the Canada were dissatisfied with the reliability of the mechanical seal used in its Chlorine Dioxide generator pump.
Over a million US gallons of water saved
A Kentucky pulp and paper company is saving at least $19,000 a year following the replacement of its existing seals with AESSEAL products.
LabTecta seals solve leakage problems
A paper mill in the Northwest United States was experiencing persistent problems due to lubricant contamination in its refiners.
AESSEAL cures reliability issues at US wastewater facility
Damage to seals on the pumps at a large wastewater treatment plant in North Carolina was requiring regular and costly seal changes.
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.
Double seals bring major savings for Michigan firm
A Michigan paper company turned to AESSEAL looking to find a solution caused by an unpressurized packing pump, which allowed product to leak out of the system.
New AESSEAL system brings major savings for US company
High levels of water consumption were causing growing concern at a US recycle paper mill. Water from the local public utility was being used as a flush on single seals at a rate of 720 gallons a day per pump, resulting in high water bills and a heavy cost from evaporation.
Lower costs and greater reliability for US pharma company
Frequent seal changes and heavy water use were causing operational problems and rising costs for a US pharmaceutical company.
New approach for slurry pumps reduces water usage by 95%
A copper mining company in central Africa was encountering problems of excessive water usage
AESSEAL helps significantly reduce downtime
A US corn milling and food additives company was reporting problems resulting from incorrectly cut bulk packing.
AESSEAL system eases cost pressures for African company
A mining company in Namibia was experiencing persistently low pressure in its gland service water system. This was causing excessive wear on the shaft sleeves.
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.
DMSF seals halt water leakage
Premature seal failure was causing barrier water and product leakage in a South African chemical plant. This necessitated a plant shutdown while the seal was changed.
MagTecta improves gearbox reliability
A gas processing facility in the USA was experiencing water ingress and oil leakage into one of its gearboxes.
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.
LabTecta the answer for SA chemical company
Constant motor failures on cooling tower motors were plaguing 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
Massive water savings with new seal
The South African company Sappi Saiccor was having problems with water wastage.
Success with bad actor pump leads to further opportunity
A pulp mill in the USA were experiencing issues with the sealing arrangement on the green liquor transfer pumps.
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.
AESSEAL product aids major cuts to water usage
The French company Norpaper Nantes was having issues with the seal of its mixer’s drain pump.
Trapezoidal Packing Improves Reliability
A paper producer in South Africa was having problems with packing on pumps leaking and damaging the pump shaft sleeve.
Water and cost savings with reliability upgrade
A beer producer in South Africa was being forced by the local government to save water around their facility.
Annual savings of over $2.6 million
A food and beverage customer was experiencing high leakage and contamination in their process fluid on the single pass flow through system they were operating.
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.
Massive water savings with improved reliability
A Bio Products manufacturer was concerned about the water used by the sealing systems at one of its manufacturing facility in the USA.
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.
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.
Over 20 million litres of water saved in 5 years for just 2 pumps
A latex producer in South Africa was consuming a large quantity of water in API Plan 54 seal support systems (quench to drain) in 2 pumps.
Seal upgrade saves cornmill $280,000 in repairs and downtime
Cargill Corn Milling Inc was experiencing leakage on the seals of a boiler feed pump at its plant in Iowa, USA.
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.
Dual Seal Upgrade saves over 17 million litres of water
A major sugar manufacturer at one of its alcohol manufacturing sites were looking to reduce the amount of water consumed on 19 critical pumps at one of its sites in South Africa.
Counterproductive flush water in an evaporator pump leads to big savings
During an energy audit at a Canadian pulp and paper plant, AESSEAL identified 15 packed evaporator area pumps that needed upgrading to mechanical seals.
Huge water savings for uranium mine
A Namibian uranium mine had 24 Krebbs pumps sealed with gland packing. The packing required regular maintenance and replacement every 2 months.
Upgrade from packing to mechanical seals for reliability
A paper company in Germany were operating the majority of their pumps using mechanical packing. The packing required a lot of water to operate acceptably.
80 million litres of water per year to be saved at Mexican mine
The Grupo Mexico Caridad mine in Mexico was experiencing lengthy downtimes and using high volumes of water for lubricating pump packing.
Improved reliability and reduced water consumption
A cheese dairy in Denmark were having problems with seals only lasting 3 months, and using 1,300 cubic meters of water per year on a quench to drain flush system, for 25 of their CIP pumps.
Improved reliability and reduced water usage
A pulp and paper manufacturer in France was using gland packing to seal the side entry agitator on a stock pulp mixer. The gland packing had a mean time between failure (MTBF) of just 2 months and was using 2.4 million litres of water per year.
Huge Water Savings for Distillery
An alcohol distillation plant had historically used competitor single seals and previous engineers were not keen on the idea of changing to dual seals and systems.
Reduced maintenance and water consumption at Iron Ore Mine
An iron ore mine in Australia was experiencing unacceptably high maintenance costs on its Warman Thickener Underflow pumps. The pumps were sealed with Gland Packing that was flushed with 48litres per minute.
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.
Chemical company saves £9,400 and 17,000m3 of water a year
AESSEAL worked with a major UK Chemical company to improve reliability and reduce the amount of water used by its sealing solution on its nylon production site.
Water Savings for South African Corn Miller
A South African corn miller had an evaportator pump that had poor reliability.
Energy Savings for Italian Corn Miller
An Italian corn miller used Clean In Place (CIP) water to cool and lubricate thier mechanical seals. This water cannot be drained to the plant depuration system but must be recirculated into the system loop with a high cost in energy in order to reheat and evaporate.
Savings all round for South African beer producer
A South African customer had an extremely low MTBF on a top entry mixer where the shaft dealing arrangement was a viton lip seal. The shaft fretting was leading to failures with a MTBF of just 48 hours.
Saving over 1 billion gallons of water
Warman F-frame pumps were sealed with gland packing which required 19 US gallons (71 litres) per minute.
High Pressure Vertical Mixer Processing Starch
(MTBF) of just two months on a vertical mixer processing starch at its starch and sweetener processing plant
Zinc Smelting Plant Saves Thousands
Experiencing repeat leakage of a highly abrasive zinc oxide and sulphuric acid solution
Paper producer saves more than one million Dollars per year
A leading North American producer of Pulp and Paper recognise the importance of operating their business in a sustainable way.
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.
DMSC saves Nestlé Purina £182k in just 10 months
Significant savings with mechanical seal and bearing protection for the pet food manufacturer
Reducing Energy Usage and Improving Reliability
Suiker Unie were using packing to seal juice circulation pumps at their Dinteloord sugar refinery.
Mondi Meets Sustainability Targets
AESSEAL water management systems cutting water usage at the plant by more than 60,000 kilolitres per month.
LabTecta upgrade gives over 12 years of trouble free operation
A paper mill in Maine, USA was having issues with water and stock getting into their Hydropulper gearbox.
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
Upgrading from packing reduces water usage and operating costs
Packed pumps were using 18 million litres of water a year
Helping to keep the water flowing for South Australia
A remote pumping station in South Australia, was having regular failures on their high pressure booster pump used to pump water through a South Australian pipeline.
$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
Saving water, the environment and our customers money
A chemical manufacturer in the UK was using 2,000 cubic meters of water per year in an API Plan 54 system on a reflux pump, at an annual cost of around £1,700.
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.
Saving water, energy and money for a food manufacturer
16 pumps, with a quench to drain seal support system.
