How proactive seal reliability strategies boost pharmaceutical uptime (Part Two)

Successful pharmaceutical processing must mitigate well-established and more recent challenges to reduce the risk of failed batches, quality deviations and compromised sterility.  

Selecting the right mechanical seal must be part of a wider, more integrated approach. This blog examines additional support options for operators to prevent unscheduled downtime.  

Support systems that safeguard uptime and product quality 

Seal support systems in the pharmaceutical industry must maximise seal life by controlling the cooling and pressure environments around the mechanical seal and contend with Clean-in-Place (CIP) or Sterilise-in-Place (SIP) cycles. 

Working together, the seal and support system must prevent product contamination. Support systems that provide an inert gas barrier are becoming favoured over liquid equivalents. 

Maintaining uptime is a single challenge with multiple potential solutions. There is no single answer, but many options and pharmaceutical customers can leverage them all to create a package that reduces downtime risk.  

Innovative technology is a solid start, but proactive, reliability-first seal management represents a more strategic, sustainable and long-term solution. And John Crane can offer bespoke technical support packages, supported by the world’s largest mechanical seal service network, through the John Crane John Crane Performance Plus™ modular service framework.  

For example, our Seal Reliability Management Contracts can help improve production dry gas seal reliability while reducing safety incidents, fugitive emissions and total cost of ownership through two platforms.  

Reliability Support Programme (RSP)

The RSP service contract supports operations dependent on wet seals to maintain uptime. Customers using the RSP benefit from 

The support of this programme helps reduce unplanned downtime, extends the life of mechanical seals and rotating equipment and addresses recurring failures as needed. The RSP also offers technical training to strengthen in-house capability, enabling faster issue resolution and minimising downtime.  

Managed Reliability Programme (MRP) 

Pharmaceutical industry customers looking for full reliability support for their mechanical seals, support systems and rotating equipment health should consider the MRP. It shifts the emphasis from reactive maintenance to predictive reliability.  

The MRP is a fully managed solution for wet seal reliability, designed for customers who want deeper, hands-on involvement from John Crane. 

With dedicated on-site engineers or technicians, the programme offers customised service agreements with agreed KPIs and fixed fees. 

By combining proactive maintenance strategies with continuous field presence and deeper operational integration, the MRP ensures consistent and dependable performance across critical rotating equipment while freeing customers from the day-to-day burden of seal management. 

For pharmaceutical companies and others involved in intensive processing operations, establishing a proactive maintenance strategy is synonymous with maximising uptime. 

Deploying monitoring technology that provides near real-time functionality insights and enables live data feeds that provide real-time alerts, performance trends and predictive analytics supports early interventions that minimise unplanned maintenance and production pauses.  

Digital monitoring to support pharma uptime 

John Crane Sense® Monitor is the ideal solution for monitoring in unpredictable, potentially hazardous environments. Engineers use this wireless digital technology to support remote surveillance and data analysis from anywhere and conduct essential maintenance without risking contact with the volatile materials common in pharmaceutical processing.  

Steps towards a seal reliability strategy in pharmaceuticals 

In pharmaceutical processing, no two businesses are identical. Variables include site size and location, technology profile and process materials. But in terms of maintaining uptime, certain principles are consistent. 

The story starts with selecting a reliable mechanical seal. The right seal resolves three key issues in pharmaceutical production by protecting product integrity, maintaining regulatory compliance and ensuring high production availability. 

Our mechanical pump seal product range is broad and underpins every successful processing operation.  

The next stage is to proactively maintain seal uptime. An interventionist strategy moves manufacturers from firefighting and issue resolution to supporting continuous, predictable performance through proactive monitoring and support.  

Deploying digital sensors within the seal itself using the John Crane Sense® Monitor solution enables the data-driven insights that prevent unexpected issues and support scheduled maintenance. Contractual support through the RSP and MRP, available through the John Crane John Crane Performance Plus™ modular service framework, puts the world’s largest engineering support network within reach.  

In short, pharmaceutical processing is demanding on people, processes and the technologies that support them. While maintenance is inevitable, unscheduled stoppages are not, and taking an integrated approach that includes products, support systems, services and digital tools can reduce failures and maximise uptime. 

Contact us if you are unsure whether your operation is using the correct sealing technology. 

Further reading