Case Study: Rotary Seal Solution Increases Compressor Efficiency and Seal Life

Rotary screw compressors rely on continuous, high-volume air compression, and even minor leakage in the sealing system can lead to significant energy loss, pressure drops, and increased maintenance.

For many compressor OEMs, it's typically the VAVE teams that drive sealing decisions — seeking efficiencies, longer component life, and reduced field maintenance. Seal replacement in the field is difficult and costly, so increasing longevity was a major priority.

The client was evaluating new strategies for minimizing leakage, comparing traditional sealing options such as PTFE, labyrinth, and mechanical face seals. They also sought to reduce downtime, enhance efficiency, and ensure long-term reliability in demanding industrial environments.

The implementation of the custom rotary seal led to measurable improvements in compressor efficiency and reliability:

• Reduced leakage and energy loss

• Improved oil retention in oil-flooded models

• Extended seal lifespan, reducing downtime and maintenance costs

• Enhanced overall system reliability in continuous-use industrial environments

Most notably, the solution helped increase the expected seal life from approximately 15,000 hours to over 40,000 hours — a dramatic improvement that directly supports the VAVE team's long-term goals.