John Crane has delivered a significant reduction in water consumption and maintenance costs at a pulp and paper mill in the southern United States through the deployment of an upgraded mechanical seal system. The project reduced water use by 90% and extended seal life from weeks to more than a year, while lowering total cost of ownership by $75,000.

The upgrade was carried out as part of efforts to address recurring equipment failures and high resource consumption within the mill’s cellulose fibre production process. Mechanical seals are a critical component in rotating equipment, particularly in industries such as pulp and paper where abrasive materials and continuous operation place systems under strain.

Addressing Reliability and Water Consumption Challenges

Prior to the upgrade, the mill experienced frequent seal failures, with mean time between repairs averaging just three weeks. These failures led to repeated production interruptions, increased maintenance demands and higher operating costs.

The existing sealing system also required a continuous flow of water at approximately three gallons per minute, with no measures in place to reduce consumption. This created both environmental and financial pressures, particularly as industrial water use comes under increasing scrutiny.

To resolve these issues, John Crane conducted a technical review and recommended the installation of its Type SB2 USP heavy duty dual cartridge mechanical seal. The solution is designed for challenging slurry and abrasive applications commonly found in pulp processing.

Deployment of Advanced Sealing Technology

The Type SB2 USP seal incorporates Upstream Pumping seal face technology, which allows for stable, non contacting operation. This reduces the need for barrier fluid while improving reliability and energy efficiency.

The seals were installed alongside a dedicated seal reservoir and a 5 micron filtration system. Together, these components create a controlled sealing environment that helps maintain consistent performance under demanding operating conditions.

The system was prepared within two weeks and installed over the course of one week, with support from John Crane’s field service team. Performance was quickly validated during operation.

Operational and Environmental Gains

Following installation, the mill increased its mean time between repairs from three weeks to more than 12 months. This has effectively eliminated unplanned stoppages linked to seal failure and reduced the burden on maintenance teams.

Water consumption was reduced from three gallons per minute to 0.3 gallons per minute, representing a 90% decrease. This reduction contributes to lower operating costs and supports more efficient use of water resources within the facility.

The project also delivered a $75,000 reduction in total cost of ownership. Savings were achieved through a combination of reduced maintenance activity, fewer production interruptions and lower water usage.

Water efficiency is an increasing focus for industrial operators, particularly in sectors such as pulp and paper where processes are water intensive. Technologies that reduce consumption while maintaining operational performance are becoming more widely adopted as companies respond to regulatory requirements and resource constraints.

Scope for Wider Deployment

The results of the upgrade have led the mill to consider broader deployment of the technology across other slurry pump applications. Expanding the use of the sealing system could deliver similar gains in reliability and resource efficiency across additional parts of the operation.

Mike Eason, Chief Technology Officer at John Crane, said the project demonstrates the role of sealing technology in improving both operational performance and water management.

“This case study highlights how advanced sealing technology can deliver measurable reliability improvements while supporting responsible water management in demanding pulp and paper applications. 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.”

As industrial operators look to balance performance with resource efficiency, equipment upgrades such as mechanical seals are playing a role in reducing environmental impact while maintaining production reliability.