Intalox Saddle Packing Manufacturing Methods, Ceramic/Metal/Plastic Production Processes

2025-07-25

Intalox saddle packing manufacturing involves a series of precision processes tailored to different materials (ceramic, metal, plastic), each designed to ensure structural integrity, dimensional accuracy, and performance consistency. The production methods vary based on material properties but share core goals of achieving the characteristic saddle shape and functional efficiency.


陶瓷矩鞍环填料 ceramic saddle ring packing (5).jpg

Ceramic Intalox Saddle Manufacturing

Ceramic production begins with raw material preparation. Alumina powder (with purity ranging from 70% to 99% based on grade) is mixed with binders (e.g., clay, organic adhesives) and water to form a homogeneous paste. This mixture is then shaped using isostatic pressing or extrusion molding: isostatic pressing uses uniform pressure (100–200 MPa) in a flexible mold to form the saddle shape, ensuring dense and uniform structure; extrusion molding pushes the paste through a die with the saddle profile, suitable for mass production of small to medium sizes. After shaping, the green bodies undergo drying at 80–120°C to remove moisture, preventing cracks during sintering. The critical sintering step occurs in high-temperature kilns at 1500–1700°C, where particles bond tightly, and the ceramic achieves its final hardness and strength. Post-sintering, edges are smoothed via tumbling to remove burrs, and dimensional inspections ensure compliance with specifications.


Metal Intalox Saddle Manufacturing

Metal variants start with material selection, typically sheets or coils of carbon steel, stainless steel, or nickel alloys. The manufacturing process involves stamping or press forming: flat metal sheets are cut into blanks, then shaped using precision dies in stamping machines to form the saddle’s curved profile and reinforcing tabs. For complex designs, progressive stamping may be used, where blanks undergo multiple forming steps to create the final shape. Welding is rarely needed due to the one-piece design, but some large-sized packings may require spot welding for structural reinforcement. After forming, metal saddles undergo surface treatment: carbon steel is often painted or galvanized for corrosion resistance, while stainless steel and nickel alloys may undergo passivation to enhance their natural oxide layer. Quality checks include dimensional measurements, hardness testing, and visual inspections for defects like cracks or deformation.

Plastic Intalox Saddle Manufacturing

Plastic saddles are primarily produced via injection molding, a cost-effective method for mass production. The process starts with melting thermoplastic resins (PP, PVC, PVDF) in an injection molding machine, where the molten material is injected into a precision mold cavity shaped like the saddle. The mold is cooled to solidify the plastic, then opened to eject the part. For materials like PVDF with high melting points, specialized machines with higher temperature controls are used. Secondary processes may include trimming excess flash (plastic protrusions) and deburring edges. Some manufacturers use blow molding for larger plastic saddles, though injection molding remains dominant for its precision. Quality control focuses on ensuring uniform wall thickness, absence of voids, and dimensional consistency across batches.

Common Quality Control Steps Across Materials

Regardless of material, production includes critical quality checks. Dimensional inspection uses calipers and coordinate measuring machines to verify size tolerances (typically ±0.5mm for key dimensions). For ceramics, density and porosity tests ensure the sintered product meets strength requirements. metal packings undergo pressure testing or load-bearing checks to confirm mechanical stability. Plastic variants are tested for chemical resistance via immersion in target media. All materials undergo sampling for performance validation, such as measuring specific surface area and void fraction to ensure they meet design specifications for mass transfer efficiency.

Process Optimization for Performance

Manufacturing methods are continuously optimized to enhance performance. Ceramic producers adjust sintering temperatures and holding times to control grain growth, balancing hardness and toughness. Metal fabricators refine die designs to minimize material waste while improving structural integrity. Plastic manufacturers optimize injection molding parameters (temperature, pressure, cooling time) to reduce internal stresses, preventing warping in service. These refinements ensure the final product maintains the saddle shape’s key advantages: uniform fluid distribution, high voidage, and efficient gas-liquid contact.


We use cookie to improve your online experience. By continuing to browse this website, you agree to our use of cookie.

Cookies

Please read our Terms and Conditions and this Policy before accessing or using our Services. If you cannot agree with this Policy or the Terms and Conditions, please do not access or use our Services. If you are located in a jurisdiction outside the European Economic Area, by using our Services, you accept the Terms and Conditions and accept our privacy practices described in this Policy.
We may modify this Policy at any time, without prior notice, and changes may apply to any Personal Information we already hold about you, as well as any new Personal Information collected after the Policy is modified. If we make changes, we will notify you by revising the date at the top of this Policy. We will provide you with advanced notice if we make any material changes to how we collect, use or disclose your Personal Information that impact your rights under this Policy. If you are located in a jurisdiction other than the European Economic Area, the United Kingdom or Switzerland (collectively “European Countries”), your continued access or use of our Services after receiving the notice of changes, constitutes your acknowledgement that you accept the updated Policy. In addition, we may provide you with real time disclosures or additional information about the Personal Information handling practices of specific parts of our Services. Such notices may supplement this Policy or provide you with additional choices about how we process your Personal Information.


Cookies

Cookies are small text files stored on your device when you access most Websites on the internet or open certain emails. Among other things, Cookies allow a Website to recognize your device and remember if you've been to the Website before. Examples of information collected by Cookies include your browser type and the address of the Website from which you arrived at our Website as well as IP address and clickstream behavior (that is the pages you view and the links you click).We use the term cookie to refer to Cookies and technologies that perform a similar function to Cookies (e.g., tags, pixels, web beacons, etc.). Cookies can be read by the originating Website on each subsequent visit and by any other Website that recognizes the cookie. The Website uses Cookies in order to make the Website easier to use, to support a better user experience, including the provision of information and functionality to you, as well as to provide us with information about how the Website is used so that we can make sure it is as up to date, relevant, and error free as we can. Cookies on the Website We use Cookies to personalize your experience when you visit the Site, uniquely identify your computer for security purposes, and enable us and our third-party service providers to serve ads on our behalf across the internet.

We classify Cookies in the following categories:
 ●  Strictly Necessary Cookies
 ●  Performance Cookies
 ●  Functional Cookies
 ●  Targeting Cookies


Cookie List
A cookie is a small piece of data (text file) that a website – when visited by a user – asks your browser to store on your device in order to remember information about you, such as your language preference or login information. Those cookies are set by us and called first-party cookies. We also use third-party cookies – which are cookies from a domain different than the domain of the website you are visiting – for our advertising and marketing efforts. More specifically, we use cookies and other tracking technologies for the following purposes:

Strictly Necessary Cookies
These cookies are necessary for the website to function and cannot be switched off in our systems. They are usually only set in response to actions made by you which amount to a request for services, such as setting your privacy preferences, logging in or filling in forms. You can set your browser to block or alert you about these cookies, but some parts of the site will not then work. These cookies do not store any personally identifiable information.

Functional Cookies
These cookies enable the website to provide enhanced functionality and personalisation. They may be set by us or by third party providers whose services we have added to our pages. If you do not allow these cookies then some or all of these services may not function properly.

Performance Cookies
These cookies allow us to count visits and traffic sources so we can measure and improve the performance of our site. They help us to know which pages are the most and least popular and see how visitors move around the site. All information these cookies collect is aggregated and therefore anonymous. If you do not allow these cookies we will not know when you have visited our site, and will not be able to monitor its performance.

Targeting Cookies
These cookies may be set through our site by our advertising partners. They may be used by those companies to build a profile of your interests and show you relevant adverts on other sites. They do not store directly personal information, but are based on uniquely identifying your browser and internet device. If you do not allow these cookies, you will experience less targeted advertising.

How To Turn Off Cookies
You can choose to restrict or block Cookies through your browser settings at any time. Please note that certain Cookies may be set as soon as you visit the Website, but you can remove them using your browser settings. However, please be aware that restricting or blocking Cookies set on the Website may impact the functionality or performance of the Website or prevent you from using certain services provided through the Website. It will also affect our ability to update the Website to cater for user preferences and improve performance. Cookies within Mobile Applications

We only use Strictly Necessary Cookies on our mobile applications. These Cookies are critical to the functionality of our applications, so if you block or delete these Cookies you may not be able to use the application. These Cookies are not shared with any other application on your mobile device. We never use the Cookies from the mobile application to store personal information about you.

If you have questions or concerns regarding any information in this Privacy Policy, please contact us by email at . You can also contact us via our customer service at our Site.