Look beyond the cost of the seal and consider the overall system cost!
The total system cost in use is the sum of several components: The cost of seals + installation cost + downtime cost (which includes loss of productivity, cost of manhours, emergency call out charges, lost material, clean-up costs and setting up cost). The sum of these costs far outweighs the seals initial purchase price. By selecting and installing Kalrez® high performance seals, |
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the mean time between repair (MTBR) can be extended, and unscheduled down time and associated costs avoided, resulting in significant cost reductions as shown in the example below!
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Find out if you
can save costs!
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See example data below |
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| The replacement and downtime costs associated with repeated, multiple replacements of existing seals can far outweigh the initial higher costs of Kalrez® perfluoroelastomer parts. |
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Example data for calculating total system cost for O-rings in coupling:
(amount in US$ can also stand for Euros)
| Cost of Elastomeric Seals |
1 |
50 |
| Installation Cost |
100 |
100 |
| Number of Seals |
1 |
1 |
| Downtime Cost of Seal Failure (Avg*) |
1000 |
1000 |
| Mean Time Between Repairs (in months) |
18 |
36 |
| Timeframe / Expected Equipment Lifetime (in years) |
3 |
3 |
| Expected Number of Repairs over Timeframe |
1 |
0 |
| Total Cost for Installed Seals |
202 |
150 |
| Total Downtime Cost Over Timeframe |
1000 |
0 |
| Total Cost Over Timeframe |
1202 |
150 |
| Cost Savings Over Timeframe |
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1052 |
| Cost Savings Over Timeframe (%) |
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87% |
*Downtime cost generally ranges between US$ 1000 and 3000. The above example was kept rather conservative. With higher downtime cost, total system cost savings could be even higher. The example covers 15-30 minutes to replace O-ring and rebuild coupling, or to install a spare coupling. Of course, each plant has its unique replacement rate and downtime cost to be considered for this cost calculation.
Explanations to above chart:
- The initial seal price of the Kalrez® O-ring is estimated at 50 times higher than the current elastomer O-ring. This is an indicative number, if you would like to get a quote for a Kalrez® part, please contact us
- The installation (100.-) and the downtime cost (1000.-) related to seal failure are the same for both O-rings.
- The lifetime of the Kalrez® O-ring is twice as long (36 months) as the lifetime of the current O-ring (18 months). Thus, for a timeframe of 3 years, the current O-ring will need to be replaced once, whereas the Kalrez® part does not need replacing. The resulting total cost (total downtime cost and cost for installations) related to the number of seal replacements is also higher for the current O-ring material used.
- Conclusion: The lifetime of the O-ring has a dramatic impact on total system cost. In this example, even for only one O-ring installed, savings of 87% could be realized from using a Kalrez® O-ring.
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