A global aluminum extrusion manufacturer was experiencing premature packing failure in its press side cylinders. Long stroke lengths and rod flex accelerated seal wear well beyond design life, while inconsistent extrusion gaps forced packing material to migrate and leak. The resulting frequent replacements disrupted production schedules and drove up operating costs.
The Challenge:
To resolve premature packing failure caused by rod deflection and seal extrusion, without requiring modifications to existing press hardware
- Rod Deflection: Long stroke and rod flex accelerated seal wear beyond design life
- Seal Extrusion: Inconsistent extrusion gaps forced packing material to migrate and leak
- Unplanned Downtime: Frequent replacements disrupted production schedules and drove up operating cost
The Solution: POM/HPU Hybrid Packing System
System Seals designed a POM/HPU hybrid packing system as a drop-in retrofit. A POM backup ring replaces the bottom V-ring, stopping gap intrusion at the source, and is paired with an Elite HPU top ring built with a special split for leak-free operation and easy installation.
- Anti-Extrusion Profile: Bottom V-ring replaced with POM backup ring — stops gap intrusion at the source
- Elite HPU Top Ring: Low-risk retrofit , with special split to ensure leak-free operation and easy installation.
- Quick Change Solution: New drop-in design decreases the time to replace pacing, improving ROI.
The Result
The retrofit doubled typical packing lifespan and reduced total cost of ownership by approximately 60% through lower labor, leakage, and production losses, all without any press modifications. Replacements shifted from a recurring maintenance disruption to a predictable, planned maintenance interval.
