John Crane’s Seal Upgrade Cuts Water Use, Boosts Reliability at U.S. Pulp Mill

John Crane helped a pulp and paper mill in the United States significantly improve reliability and sustainability performance by upgrading its mechanical sealing system in a cellulose fiber production process. The project reduced water consumption by 90% and lowered total cost of ownership by $75,000, while extending seal life from weeks to more than a year.

The mill had experienced persistent seal failures and excessive water use, which affected reliability, operating costs, and sustainability goals. Mechanical seal failures occurred frequently, with mean time between repairs averaging about three weeks. The failures caused repeated production interruptions, increased maintenance workload, and higher operating costs. The previous sealing arrangement also consumed approximately three gallons of water per minute and lacked conservation measures, creating both financial and environmental challenges.

After conducting a technical review, John Crane engineers recommended deploying the Type SB2 upstream pumping (USP) heavy-duty dual cartridge mechanical seal, designed for demanding slurry and abrasive pulp applications. The seal incorporates USP seal face technology, which enables stable, non-contacting operation to reduce barrier fluid requirements while improving reliability and energy efficiency.

“This case study highlights how advanced sealing technology can deliver measurable reliability improvements while supporting responsible water management in demanding pulp and paper applications,” said Mike Eason, Chief Technology Officer, John Crane. “By extending seal life and cutting water use by 90%, we helped the mill reduce costs, improve uptime, and align operations with long-term sustainability goals.”

The seals were installed along with a John Crane seal reservoir and a 5-micron filtration system, creating a controlled sealing environment designed to support long-term operation in abrasive conditions. According to the company, the system was prepared within two weeks and installed in one week with support from John Crane’s field service team. Performance was validated during operation, drawing on the company’s experience in pulp and paper applications.

Since installation, the mill has increased mean time between repairs from three weeks to more than 12 months, effectively eliminating unplanned stoppages associated with seal failures. Water consumption has also been reduced from three gallons per minute to 0.3 gallons per minute, a 90% reduction. The improved sealing arrangement has also lowered total cost of ownership by approximately $75,000 through reduced maintenance requirements and lower operating costs.

The project has strengthened the mill’s confidence in the Type SB2 USP seal and created opportunities for broader deployment across additional slurry pump applications as part of the facility’s ongoing reliability and sustainability initiatives.

Gas Imaging Survey

In early March, John Crane executed a quantitative optical gas imaging (QOGI) survey for a top food-industry producer, focusing on a critical extractor used in vegetable oil production. The company’s imaging technology helped engineers identify 22 potential leak points across numerous fittings, seals, inspection points, and flanges. Nine leaks were quantified at a combined rate of approximately 16 kg/hr, providing the customer with data-driven insights for maintenance and repair work.

The QOGI survey resulted in opportunities to reduce fugitive emissions, improve reliability, and strengthen operational efficiency upon implementing corrective maintenance actions. Based on the customer’s value for hydrocarbon solvent use, the quantified leaks represented an estimated annual material loss of over $194,000 if left unmitigated. The survey was completed at a fraction of the potential material savings, demonstrating strong ROI and the value of early detection and targeted maintenance.