HOW TO

EXTEND THE LIFE

of older wood-based panel
HYDRAULIC PRESSES
Upgrading cylinder sealing
can pay off in reliability
and longer asset life.
Learn how

A.W. Chesterton Company

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ABOUT THE AUTHOR

INTRODUCTION
Istvan R. Hajzer
Istvan R. Hajzer is the Global
Product Line Manager for
Engineered Polymer Solutions
of A.W. Chesterton Company.
He holds an MSc degree in
Marine Engineering (with special
studies in hydraulic driving
and control systems) and an
MBA. He has over 18 years’
experience in the area of heavy
hydraulic/pneumatic and press
machine applications. Istvan has
helped customers from diverse
industries upgrade critical fluid
power equipment.
The sealing systems used for hydraulic press cylinders have a
substantial impact on the operation of single- and multi-daylight
hydraulic presses in the wood-based panel industry. This impact can
be seen across the plant in forming, lamination and post-forming
areas. The quality and reliability of cylinder sealing systems affects
many aspects of operation, including productivity, production
accuracy, press cycle repeatability/quality, and safety.
This e-book will help maintenance, operation, production, and EHS
managers learn how high-performance sealing solutions/upgrades
can cost effectively extend the life of older presses while still
delivering in the desired level of service/production.
Learn About
1 The special sealing challenges of press
operations and of wood-based paneling
manufacturing conditions
2  hat to look for in high-performance
W
polymer seal systems

3 A
 checklist for optimal hydraulic press sealing

4  ress applications for high-performance polymer

P
seals in the wood-based panel industry

DISCLAIMER: This document is for informational and educational purposes only. It is intended to be a general guide. It should not
be considered advice or a replacement for addressing equipment concerns with a qualified professional. Chesterton assumes no
responsibility for any action or inaction you take based on or made in reliance on the information contained in this document.

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UPGRADES VS. NEW PRESSES
In recent years, state-of-the-art continuous press lines have been handling a larger share of the total
manufacturing capacities in panel production. These press lines offer high capacity rates and a high
degree of reliability from a hydraulic system point of view. They also involve a high level of investment
and considerable maintenance expense for their flying carpets, chains, pins, and rolls to keep
running efficiently.
At the same time, there remains a large population of traditional hydraulic presses in panel-forming
processes (single- and multi-daylight presses). These aging presses continue to dominate the lamination
and post forming technologies of wood-based panel plants. For most wood-based panel
manufacturers, the challenge is keeping this older equipment running as long as possible with
minimal downtime.
Through well-considered sealing upgrades that use the right seal materials, design, and solutions,
wood-based panel plant teams can achieve their asset management goals at a fraction of the cost of
equipment replacement and still benefit from:
n Enhanced reliability (MTBR and MTBF)
n Improved maintainability (MTTR)
n Reduced press cycle time
n Increased equipment availability/capacity and higher production
n Lowered operational and maintenance costs
n Improved efficiency and profitability

High-speed, short stroke

laminating press being rebuilt

The Domino Effect of Poor Cylinder Sealing

One of the main challenges of the aging hydraulic press population is the linear nature of the
manufacturing process for wood panels. If one hydraulic press goes down, the entire production line
is often impacted with significant financial implications. Ultimately, this puts production behind which
can then result in even more capacity demands on aging equipment not built for those demands.
The reliability of the hydraulic press itself is very much dependent on the reliability of the press cylinders
and their seal components/sealing systems.

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Leaking hydraulic oil collected in tray Scored plunger surface causing leakage

High Demands for Seal and Cylinder Performance

The special operating conditions and physical demands placed on press cylinders also create a more
arduous working environment for the seal components. These include:
n Increased press capacity which results in higher hydraulic fluid pressure and sliding speed
(shorter press cycle time)
n Scored/scratched, damaged rod and plunger surfaces
n Worn bushings and metal components
n Contaminated hydraulic fluid (solid particles from outside and inside of the hydraulic system)
that impacts seal surfaces
n High stroke rate (mileage performance of the cylinders)
Poor cylinder sealing systems result in:
n Short life-time (MTBF) of seals; frequent seal replacement (MTBR)
n  ydraulic fluid leakage: causing environmental concerns in combination with high disposal costs,
H
further contamination of the product, and the risk of potential fire
n Complicated, difficult seal replacement work
These compromised seals can result in longer cylinder repair times (MTTR) and unexpected/
unscheduled shutdowns of the presses. As noted above, the outcome can cost hundreds of
thousands of dollars in maintenance and lost production time.

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What are High-Performance Polymer Seal Systems?
State-of-the-art hydraulic sealing systems and solutions bring measurable advantages to hydraulic
press owners/operators. High-performance seal solutions provide the following benefits in
hydraulic press applications:
n  ade with durable sealing materials that last longer under high pressure and high sliding speed
M
(velocity) caused mechanical and thermal load
n Designed to provide tight sealing even with rough/damaged/scored dynamic and static
cylinder surface conditions
n Designed to compensate for excessive clearance (worn metallic components) and
related extrusion
n Reduce high friction and possibility of “stick-slip” effect
n Keep up the functionality of the press
n Help block contaminants from entering the sealing system
n  esigned to be installed and repair quickly – reducing downtime caused by long
D
seal replacements
n  rovide longer seal performance as measured by the overall life-time of the sealing component,
P
condition of the hydraulic fluid, and level of contamination

A CHECK LIST FOR OPTIMAL HYDRAULIC PRESS SEALING

1. Choose Seal Materials Based on Condition of the Press Cylinders
The physical conditions of each press cylinder should determine the optimum seal profile(s) and seal
materials. Take into consideration:
n Worn bushings
n Metallic components
n Scored, damaged surfaces
The seal elements must compensate for the radial motion of the plungers and conform to any surface
irregularities. This is essential for leak-free operation. (In case of heavily damaged surfaces, this might
substantially reduce the leak rate but not eliminate it completely.) In addition, a flexible lip design can
extend the sealing capability in certain seal groove space variations.

Aging equipment population:

old single-daylight forming
press in operation

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Seal Material
n  void Extrusion: High extrusion-resistant sealing materials (such as AWC800) will help avoid
A
extrusion-type failures.
n Seal Support: In case of excessive clearance (an extrusion gap) between the ram and the
gland/bushing, use an anti-extrusion ring made of engineered plastic to provide support
to the seal. This will also reduce the risk of extrusion of the seal material into the gap.
n  aterial Combinations: The proper seal material combination lets the seal conform to surface
M
irregularities. A softer (low durometer) seal material can conform easier to worn surfaces than a high
durometer material. But to withstand operation pressures, a soft material cannot be used alone.
It often requires a combination of soft and hard materials such as used in the Chesterton 11K
(below) for best reliability.

The Chesterton 11K combines

a softer low durometer seal that
will adjust to shaft issues and
a high durometer material that
withstands high pressure.

2. Protect Seals Against Radial Mechanical Forces

The radial support and linear guide of the moving metallic cylinder components (such as piston
rods or ram and piston heads) can be improved by non-metallic bearing bands. These bands can help:
n Achieve a concentric alignment
n Reduced radial clearance
n Eliminate metal-to-metal contact between the cylinder components
n Extend seal life
Non-metallic, split bearing bands minimize the repair time (thanks to a split design) and reduce the
repair budget of the press cylinders. By eliminating metal-to-metal contact among the moving parts
of the cylinders, these bands prolong the life of the equipment. The newest, high-performance bearing
materials have a higher carrying load than standard hydraulic bushing material SEA 660 graded
bronze. These newer products help stand against higher radial force and protect the seal elements
against excessive deformation and possible extrusion.

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Damaged bushing from a single-daylight Worn bushing from a multi-daylight
particle board press HDF press

Bearing bands are made with self-lubricated materials; this improves the sliding property of the
bearing components and greatly reduces friction. The ultra-tight tolerance of the bands helps maintain
the proper concentricity of the press cylinder’s moving components.

Upgraded bushing of a single-daylight Repaired bushing of a single-daylight

laminating press particle board press

3. Reduce Friction by Selecting the Right Seal Design/Material

Both seal materials and seal design have the ability to impact frictional forces that can impair equipment.
Different seal materials (elastomers and polyurethanes) have a different coefficient of friction values:
n  s a general guide, polyurethanes have a lower coefficient of friction than elastomeric
A
seal materials/rubbers.
n S ome sealing types (types/materials) have a significant impact on the frictional force, which can
cause excessive contact heat generation (thermal load and material degradation) and
accelerated wearout.
n For example, fabric-reinforced rubber V packing (one of the most commonly used types
of sealing in single- and multi-daylight press cylinders) generates very high friction.

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The seal design has the biggest impact on dealing with frictional forces. A lip seal is designed with
an automatic sealing effect, optimizing the sealing force according to pressure condition in the press
cylinder. Combine a lip seal with a polyurethane sealing material (with a lower coefficient of friction),
and you have the optimum sealing force. It reduces the friction of seal lips and counter-face metal parts
(plungers and cylinder bores). In the end the wear will be reduced while the service lifetime of the seal
systems will be increased (increased MTBF and MTBR). Using this method, time consuming press
shutdowns, and repair of press cylinders can be avoided in most cases.

4. Functionality (Speed of Installation/Repair and Maintainability)

Given that a broken down hydraulic cylinder has a tremendous impact on an entire production line,
shorter seal installation and repair times are an important consideration.
n Investment in a split seal design is an important return on investment as it will reduce installation
and repair to a fraction of the time involved with a standard seal that requires complete equipment
disassembly. Split seal design can help to reduce seal replacement time to 30-40% of endless
v-ring seals.
n Equipment accessibility is another consideration. Where press cylinder stuffing boxes are difficult to
access, maintenance staff benefit greatly from a split seal solution. The bottom line is that the press
being worked on can get back online in the shortest possible time.
n  odern, high-performance seals are also designed to provide leak- and maintenance- free operation.
M
They benefit the plant in terms of both maintenance and safety.
n  odern seals are also designed to eliminate future shimming and require less adjustment than
M
traditional v-ring sets. Overall, they reduce maintenance labor and reduce the load on existing,
often smaller, maintenance staffs.

Installation of a split seal in Installation of a split seal in Installation of a split seal in

multi-daylight press single-daylight laminating press single-daylight laminating press

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5. Use High-Performance Wiper Seals to Keep Contaminants
out of Hydraulic Fluid
One of the most important components of every hydraulic system is the media/fluid itself. The
condition of the hydraulic fluid will determine the operation, efficiency, and lifetime of the other moving
components in the entire system. If the hydraulic fluid is contaminated and solid particles are moving/
flowing with the fluid through the system, this is a critical situation. To avoid this, there should be
continuous monitoring and maintenance of the hydraulic fluid.
There are external and internal sources of fluid contamination. Typical external sources are the reservoir
breather, cylinder rods/rams, and plumbing. Internal contamination can be caused by wear, tear, or any
other mechanical damage of components in the system.
The Value of Wiper Seals
High-performance wiper seals are an organic part of modern hydraulic sealing. Wipers protect the whole
hydraulic system and, in doing so, greatly extend its life.
With a focus on the press cylinders, fluid can become contaminated through the rod extension and
retraction allowing dust/dirt/solid particles to enter the cylinders. It is an important aspect of the sealing
solution to effectively dislodge such particles.
The basic requirement of wiper seals is a positive rake lip design that can effectively wipe contaminants
away from plunger/rod surfaces. This prevents the scoring of seal elements and the metallic
components of the cylinder in addition to reducing system and hydraulic fluid contamination.
You can measure effective wiper seal performance by the extended life cycle of seal elements and by
the increased reliability of the cylinders and presses as well. They are well worth the investment over the
entire life cycle of your equipment.

Wiper seal is installed in the gland High-performance wiper seal design

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Which Applications Can Use High-Performance Seal Solutions?
Review sealing systems in the following areas to improve reliability of the entire line, and extend the life
of existing presses.
Forming Area:
n Single-Daylight Downstroke Hydraulic Pre-Presses
n Single-Daylight Downstroke Hydraulic Heat-Presses
n Single-Daylight Downstroke Forming Hydraulic Presses
n Single-Daylight Upstroke Hydraulic Presses
n Multi-Daylight Upstroke Hydraulic Presses
Lamination Area:
n Single-Daylight Upstroke Hydraulic Presses
n Single-Daylight High Speed Downstroke Hydraulic Presses
Post-Forming Area:
n Single-Daylight High Speed Downstroke Hydraulic Presses

SUMMARY
High-performance seals and properly selected seal systems will help to manage your press machine/
press line assets resulting in:
n Reduced maintenance demand
n Less possibility of unplanned shutdowns
n Higher production
n More predictive maintenance of the press cylinders
At the same time, the cylinder upgrade will prolong the lifetime and extend the total life cycle of your
press line. Altogether, you will be that much closer to achieving your asset management goals and
optimizing the service/performance level of your plant.

Want to Learn More?

n Read about Chesterton’s sealing solutions for the Wood-Based Panel Industry
n Ask an Expert: Contact one of our Application Engineers
n Find a local Chesterton Sales/Service Office

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© 2017 A.W. Chesterton Company.
® Rin egistered trademark owned by A.W. Chesterton Company
USA and other countries, unless otherwise noted.

A.W. Chesterton Company Telephone: 781-438-7000 Form No. EN36534

860 Salem Street Fax: 978-469-6528 Asset Management eBook – English
Groveland, MA 01834 USA chesterton.com 12/17