Case Studies
Improving Large Hydraulic Cylinder Performance with Dust Wipers and Rod Packing
Challenge
Background
An automotive parts manufacturer was using a large press with a cylinder rod diameter of ~800 mm and experienced frequent hydraulic oil leakage from the main cylinder.
Root Cause
Dust Wiper: The nitrile rubber wiper had high friction, causing rapid seal lip wear. This reduced contaminant removal and led to internal cylinder deterioration.
Rod Packing: An oversized ring was cut and reused instead of a proper fit, resulting in poor sealing and oil leakage.
Low-flexibility packing resized to a smaller diameter can form inner wrinkles, causing uneven pressure and rod surface striping.
Solution
Product
Dust Wiper: Chesterton W21KF
- Made from a thermoset polymer containing molybdenum disulfide, offering self-lubrication
- Reduces seal lip wear and prevents contaminants from entering the cylinder
Rod Packing: Chesterton 27K
- Machined using CNC technology, allowing precise sizing without modification
- Can be manufactured to match the exact groove dimensions
- Maintains sealing performance even in split configuration, which was required due to difficult cylinder disassembly
Dust Wiper: Chesterton W21KF.
Results
Before Improvement
Frequent hydraulic oil leakage required packing replacement about once per year.
After Improvement
After installing Chesterton 27K and W21KF, no leakage has occurred over ~3 years, with zero packing replacements.
Results
MTBR (Mean Time Between Repairs) improved by approximately 3×, reducing maintenance workload and improving equipment reliability.
Stacked Rod Packing: Chesterton 27K.
About Us
Chesterton® is a world leader in helping process industry companies and manufacturers improve the reliability and efficiency of their rotating, stationary, and fluid power equipment platforms. We are known across a wide range of industries for our award-winning pump and valve sealing solutions, applications expertise, equipment maintenance and wear-prevention products, and knowledgeable hands-on local service. Chesterton product range includes mechanical seals, packing and gaskets, industrial lubricants and coatings.
® Registered trademark owned by A.W. Chesterton Company
APAC0118. Issued 03/2026
Technical data reflects results of laboratory tests and is intended to indicate general characteristics only. A.W. Chesterton Company disclaims all warranties expressed or implied, including warranties of merchantability and fitness for a particular purpose. Liability, if any, is limited to product replacement only. Any images contained herein are for general illustrative or aesthetic purposes only and are not intended to convey any instructional, safety, handling, or usage information or advice respecting any product or equipment. Please refer to relevant Safety Data Sheets, Product Data Sheets, and/or Product Labels for safe use, storage, handling, and disposal of products, or consult with your local Chesterton sales representative.