Adding value to customers by helping them choose right material and save costs
The rubber industry continues to face many challenges regarding polymer allocations, a lack material sourcing, and overengineering. These challenges has made it difficult for the industry to continue producing high-quality rubber seals and gaskets. A rubber product could have various components. This means that even a single scarcity of a sourcing material can result in disruptions. The production of these products also relies heavily on the selection of right material based on their application.
Rubber gaskets fail for a variety of factors. There are certain reasons that helps engineers design better gaskets and explain common causes of gasket failure. If you want better rubber seals, design them with keeping application, temperature, and pressure in mind. Otherwise, you risk sealing failures that can have expensive and inconvenient consequences.
Over engineering for lack of sourcing?
We received an RFQ for silicone gaskets of 40 hardness extruded as chords and joint to make one piece in smaller length.
We asked our prospective customer about the application/end use of the gasket and came to know that it is used as encapsulation gasket for HMI panels. So the first question was why a Silicon cord is being used since the temperature condition required is only 60 deg C. The temperature that EPDM can easily withstand along with the fact that EPDM has a strong electrical resistance. The customer said they faced the challenge in sourcing 40 hardness cords in EPDM.
Solution
Team Saga has now gathered some experience in processing low hardness EPDM compounds for pipe seals and some other products. So offered them some samples in EPDM. The customer was very happy with the feel & bounce. He confirmed the order in EPDM itself. We then went on to make cords of 2.3 mm diameter in EPDM and then molded joint them to make endless gaskets.
A pilot lot of 10 pieces was submitted to customer and he was totally satisfied with the product. The customer got a cost reduction of approx. 60-70% without compromising on final properties. This happened simply by proper selection of polymer and our expertise in processing low hardness compounds.
Team Saga always makes sure that our valued customers are provided with the best of what we can offer. And to achieve that, one of the crucial aspect is to inform your rubber suppliers of the production forecast. This will facilitate the delivery of your orders to the material suppliers and ensure appropriate allocations. In these circumstances, being “on time” is useless. Allocations may still prevent you from receiving materials even if it is ordered “just in time.” Therefore, material orders must be placed months in advance.
Conclusion
Rubber gasket failure can be attributed to different factors that may offer simple rules for better seal design. A gasket project might fail for a variety of reasons in addition to those related to application, temperature, and pressure. Overengineering a gasket is also a kind of failure because it results in manufacturing waste since you pay too much for a material that you don’t actually need.
From the case above, it was evident that the customer was aware & wanted an EPDM gasket for their HMI panel but faced a challenge in sourcing 40 hardness cords in EPDM. Also, it was the experience and confidence of Team Saga that delivered the product of their choice with the right measurements. This eventually lead to a very satisfied & happy customer, and increased their trust in Saga Elastomer.
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