In this Voices interview, Plant Engineering spoke with Brad Allen, regional sales manager for End Users at TEADIT®, about the role of industrial sealing in emissions control and reliability. Allen shared insights on how real-world application conditions, installation practices and material selection have a long-term influence on sealing performance.
 
 

 
 
Plant Engineering: Over the course of your career, what types of field exposure, application challenges or long-term problem-solving efforts have most influenced how you approach sealing reliability today, and why do those experiences matter when advising engineers and operators?
 
Brad Allen: Over the course of my career, I’ve run into several application challenges and issues in the field. These range from working under time constraints during plant outages and the assessment of older technologies to the implementation of advanced sealing solutions in a variety of environments. Some of the problem-solving opportunities we encounter involve determining if a gasket has been installed correctly, offering training for technicians and ensuring the right equipment is used during installation.
 
One example that comes to mind involves API 650 tank flanges and manways, which are designed with relatively low clamping loads. What often happens with these assets is that the end user tries to compensate for leakage by over-tightening the flange. Over time, this tends to warp or damage the flange.  I worked with a customer on a tank farm that had this exact problem. They were experiencing leakage because the flanges had become warped from over-tightening. We recommend using TEADIT® 24SH expanded PTFE, which requires much lower gasket stress and conforms well to irregular flange surfaces.
 
By switching to our material, the customer achieved proper gasket stress and an effective seal, even with flange damage. That saved them significant downtime as they no longer needed to cut out and replace the flanges. Beyond solving the immediate problem, it helped them rethink their approach to sealing for new installations, so they could avoid the same issue in the future.
 
Industrial sealing performance is increasingly tied to reliability, emissions compliance and asset integrity. From your perspective, how has the role of sealing evolved within modern industrial operations, and what factors are driving this shift?
 
Industrial sealing technology has moved from a maintenance concern into a critical component of emission control and asset reliability. The ultimate goal for every industrial organization is to employ sealing solutions that prevent leaks, keep product inside the system and meet emissions requirements.
 
The shift towards more sustainable operations is being driven by increasingly stringent regulatory frameworks.  Mandates from agencies like the EPA, as well as internal reliability targets tied to uptime and safety, have been major contributors to this movement. This has resulted in new evaluation practices in which sealing solutions are assessed for their ability to maintain stress, resist creep relaxation and perform under thermal and mechanical cycling.
 
Another factor is the increasing focus on proper training for bolted flange assembly. The sealing solution is not just the gasket itself; how the gasket is installed and how the flange is assembled are very relevant factors. Training can have a big impact on reliability. We often work with end users and provide training on bolted flange assembly during outages or turnarounds. After implementing that training, the facilities have reported substantially lower leakage rates when the systems come back online.
 
For example, I worked with a facility experiencing issues with a valve that constantly leaked. The customer kept tightening the gland in an attempt to stop the leak, but they could never get it sealed properly. After reviewing the application, we recommended our TEADIT® 2848 low-emissions packing, which seals below 10 parts per million. We also guided them through the proper installation process. Once they installed that packing correctly, the leakage issue was completely resolved, and they have not had problems with that valve since.
 
Many sealing failures are not the result of material limitations alone, but of how those materials interact with real operating conditions. What are the most common gaps you see between theoretical selection and real-world application demands?
 
The most common gaps come down to knowledge, specifically understanding what technologies are available and how they should be applied.
 
One mistake sealing suppliers sometimes make is assuming that customers know as much about sealing technology as we do. In reality, customers rely on us to be experts and guide them through the selection process. That knowledge gap can affect everything from gasket stress calculations to bolting selection.
 
Selecting the wrong bolt material can significantly impact sealing performance. For example, B8 or B8M Class 1 stainless steel bolts have lower yield strength than Class 2 bolts. As a result, they can be over-tightened more easily, causing the bolt to yield and potentially compromising the seal’s integrity.
 
When theoretical assumptions do not match real operating conditions, the consequences are usually leakage. In more severe cases, you can see catastrophic failures such as flange blowouts or explosions. For instance, using compressed fiber sheet gaskets in pressure classes where they aren’t appropriate, above certain pressure ratings, can lead to failures. In those cases, a semi-metallic gasket would be the better choice.
 
Standards, regulations and environmental requirements continue to place greater scrutiny on sealing performance. How do these evolving requirements influence how engineers and maintenance teams approach gasket and packing selection today?
 
Standards and regulations are constantly changing, so it is important for engineers to implement solutions that do not need to be replaced every time requirements change. That is why it is valuable to work with sealing technologies that already exceed current regulatory requirements.
 
Our products are designed to perform well beyond the leakage limits required by many EPA regulations. By installing solutions that exceed minimum requirements, companies can avoid constantly replacing seals as requirements evolve.
 
Another important consideration is the economic impact of leakage. When a product escapes into the atmosphere, it results in lost revenue for the company.
 
Environmental conditions also play a key role. Industrial facilities operating in harsh conditions require sealing technologies to be selected with safety, environmental protection and community impact in mind.
 
What typically causes an end user to move away from an incumbent sealing supplier and try TEADIT products?
 
One of the biggest reasons customers seek out TEADIT® is our commitment to service. Availability and product quality are important, but service is what sets suppliers apart.  When a customer has a problem that another supplier cannot solve, or is not willing to solve, we position ourselves as partners who will work closely with them to find a solution.
 
We work directly with customers to understand their applications and provide practical solutions, often drawing on our innovation team and SEMs to devise a customized approach. Our willingness to engage and solve difficult problems leads customers to try our products.
 
For engineers and reliability professionals looking to improve sealing performance across their facilities, what guidance would you offer on selecting both the right sealing technologies and the right technical partner?
 
It starts with finding the right technical partner. You need someone you trust, someone who listens and understands your application before recommending a product. If a supplier immediately pushes a product without first understanding the problem, they probably do not have the right solution for your situation.
 
A good partner will work with you on projects both large and small, integrate with your team, and focus on providing value rather than simply selling a product. In our case, when a customer comes to us with a problem, we start by reviewing the application in detail. That might involve phone calls, site visits or working directly with our engineering team.
 
We analyze previous case studies and application databases to see what solutions have worked in similar situations. Our engineering team can run calculations and evaluate material options before recommending a solution. In many cases, we also present customers with multiple options. For example, a short-term fix and a longer-term solution, along with timelines and cost considerations. That allows them to make an informed decision about the best path forward.
 
For engineers, reliability professionals, and maintenance leaders seeking to improve sealing performance, reduce emissions risk, and extend equipment life, expert guidance can make a measurable difference.
 
Learn how application-driven sealing strategies, backed by decades of field experience and engineering support, can help address your most demanding operating challenges. To explore how TEADIT® supports informed sealing decisions through technical expertise, testing, and real-world validation, visit teadit.com or connect with a TEADIT® technical specialist to discuss your application requirements.