Custom Wiper Seal Becomes Essential Solution

After an in-depth review and meticulous design process, we presented a custom wiper seal that fits into the mixer with no modifications. Made from a soft 70-durometer polyurethane compound, the seal was not only Food and Drug Administration (FDA) compliant but also metal and X-ray detectable with 3-A® standard commercial tolerances. The soft polyurethane material provided flexibility, allowing it to stretch and seal effectively on uneven areas of the mixer surfaces. Additionally, the seal’s metal and X-ray detectability gave the manufacturer peace of mind. If a seal were to fail and enter the final product, the detection systems consisting of metal detectors and X-ray machines would immediately identify the contamination, enabling efficient corrective action and minimizing waste. Finally, being FDA compliant is critical as any material that can possibly be encountered in food must meet specific purity and hygienic standards set forth by the FDA.

The custom seal checked every box on the manufacturer’s wish list on paper, and they were thrilled to put it to the test. To kick off testing, we facilitated an initial order of thirty seals to be manufactured through our trusted third-party supplier. After reviewing the application requirements, the need for metal detectability, and the price point, the customer was confident that the best solution came from our Dichtomatik brand portfolio. While we often recommend our premium Freudenberg brand for its specialized design, reliable performance, and long service life, the Dichtomatik seal offered an ideal balance for their application. Despite minor challenges with longer lead times still affected by lingering COVID-19 supply chain issues, we expedited the tooling process to ensure testing could begin as quickly as possible.

The Results

Once the seals arrived, the manufacturer eagerly began testing them in their mixers, and the results spoke volumes. Our polyurethane seals proved to be far more robust than the OEM versions, offering an impressive service life that was double that of the originals. These custom wipers not only provided exceptional durability but also delivered significant cost savings compared to the OEM replacements. Fewer replacements extended maintenance cycles and reduced seal costs, ensuring smoother, more cost-effective operations. Everyone from maintenance to production planners was thrilled with the confidence the dependable seals were able to provide allowing them to hit their productivity targets.

The new seal’s combination of economicalness and efficiency has resulted in $30,000 in annual sales for the distributor, with the potential to grow beyond $60,000 as other facilities transition to this superior solution. This custom solution did not just save money - it transformed operations, proving that innovative engineering can solve even the toughest challenges. If downtime is holding you back, we are ready to craft a solution that delivers results.