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Dobson Gaskets is a leading UK manufacturer of gaskets and sealing products

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+44 (0) 1535 607257
 

Address

E Dobson and Co [Gaskets] Ltd
Unit 1
Holme Mill Ind Estate
Fell Lane
Keighley
West Yorkshire
BD22 6BN

Call Us Now

+44 (0) 1535 607257

Call Us Now

+44 (0) 1535 607257
 

Opening times

Mon - Thur 8.00 - 17.00
Fri 8.00 - 16.00
Sustainable Gasket Production using a Laser Jet Cutter

In industrial applications, gaskets are often overlooked despite their critical role in maintaining safety, efficiency, and sustainability. These small yet vital components prevent leaks and emissions, ensuring that machinery and systems run smoothly and reliably. Over time, advancements in gasket materials and design have shifted the industry away from hazardous materials like asbestos to safer, eco-friendly options. 

 

Quality Gaskets: Essential for Preventing Leaks and Emissions

Gaskets are designed to create a seal between two surfaces, preventing the escape of liquids, gases, and other substances. When poorly constructed or damaged gaskets fail, they can cause severe safety risks, environmental harm, and costly operational disruptions. Here’s how quality gaskets make a difference.

Leak Prevention for Safety and Efficiency

Leaks in industrial systems can lead to malfunctions, reduced equipment life, and hazardous work environments. High-quality gaskets are engineered to withstand pressure fluctuations and temperature extremes, ensuring a reliable seal. This reduces the likelihood of breakdowns and maintains operational efficiency.

Reducing Emissions for a Greener Environment

Fugitive emissions, such as volatile organic compounds (VOCs) or greenhouse gases like methane, contribute significantly to air pollution and climate change. By minimising emissions through superior sealing performance, gaskets help industries adhere to environmental regulations and play a role in global sustainability efforts.

Cost-Effective Solutions Through Longevity

While premium gaskets may seem expensive initially, their durability minimises frequent replacements and maintenance. Over time, these long-lasting gaskets provide cost savings by reducing unplanned downtime and improving system reliability.


DG BLOG STRIP asbestos car gaskets

Old-style asbestos gaskets for a car exhaust system

Lessons From The Past: The Legacy of Asbestos in Gaskets

The need for eco-friendly sealing technologies becomes even clearer when juxtaposed with the historical use of asbestos, a material that, for decades, was a cornerstone of industrial sealing applications.

Why Asbestos Was Once the Go-To Material

Asbestos is a naturally occurring mineral that became widely used in the 20th century due to its remarkable sealing properties:

  • Heat Resistance: Asbestos could endure extremely high temperatures without degrading, making it ideal for industrial and automotive gaskets.
  • Chemical Stability: Resistant to corrosive substances, asbestos-based gaskets performed well in chemical processing and refining operations.
  • Durability and Cost-Effectiveness: It was abundant, inexpensive, and easy to process into various gasket forms.

Because of these traits, asbestos-based gaskets were considered irreplaceable in demanding applications, such as steam systems, boiler seals, and engine head gaskets.

The Hidden Cost: Health and Environmental Impacts

Despite its industrial advantages, asbestos came with significant and devastating health risks. When asbestos gaskets are cut, handled, or subjected to wear and tear, microscopic fibres can become airborne and inhaled. This exposure can lead to:

  • Asbestosis: A chronic lung condition caused by scarring of lung tissue.
  • Mesothelioma: A rare, aggressive cancer primarily affecting the lining of the lungs or abdomen.
  • Lung Cancer: Prolonged exposure increases the risk of developing lung cancer.

The environmental risks of asbestos are equally severe. Improper disposal of asbestos-based gaskets can lead to soil and water contamination, posing long-term risks to ecosystems. As awareness of these dangers grew, asbestos became heavily regulated or banned in many countries by the late 20th century.


 non asbestos gasket materials

Examples of non-asbestos sheet materials available at Dobson Gaskets

 

Transitioning to Safer, Eco-Friendly Gasket Materials

The ban on asbestos drove the development of modern gasket materials that provide the same level of performance without the associated health and environmental risks.

Non-Asbestos Gaskets

Today, synthetic fibres, aramid, and elastomers have replaced asbestos in most applications. These materials offer excellent heat resistance and durability, serving as a direct and safer replacement.

Modern Materials with Environmental Benefits

  1. Polytetrafluoroethylene (PTFE): Chemically inert and non-toxic, PTFE gaskets are widely used in food processing, pharmaceuticals, and chemical industries.
  2. Graphite and Mica: These materials excel in high-temperature environments, providing flexibility and strength without relying on hazardous substances.
  3. Recycled and Biodegradable Polymers: Gaskets made from recycled rubber or biodegradable materials reduce waste and lower the environmental footprint of production.

 

Advancements in Gasket Design

Material innovation is only part of the equation—modern gasket designs also enhance performance and sustainability.

  • Profiled Gaskets: Custom shapes that conform to uneven surfaces, improving compression and preventing leaks in extreme conditions.
  • Multi-Layered Gaskets: Combine materials with varied properties depending on the application, to maximise sealing capability with minimal material use.
  • Self-Sealing Gaskets: Engineered to expand, swell, or conform when exposed to certain fluids, creating an even tighter seal without requiring additional force.
  • Low-Stress Gaskets: Strong seals with minimal compression for applications using delicate components such as electronics.
  • Envelope Gaskets: Designed with an inner core for structural strength and an outer "envelope" layer of chemically resistant material like PTFE.
  • Spiral Wound Gaskets: A combination of metal and filler material for outstanding performance under extreme temperatures and pressures.
  • Inflatable Gaskets: Uses air or fluid pressure to inflate and create a tight seal, ideal for applications requiring dynamic or temporary sealing solutions.
  • Soft Gaskets with Hard Inserts: Hybrid gaskets enhance mechanical stability while retaining the ability to conform to surfaces.

DG BLOG STRIP Rubber Crumb

Manufacturing Rubber Gaskets with an automated press (left) and rubber crumb recycled from the waste rubber (right)

Gaskets and Sustainability: A Path Forward

The evolution from asbestos-based gaskets to modern, eco-friendly alternatives is a testament to the industry's commitment to sustainability and safety. By prioritising non-toxic materials and innovative designs, gasket manufacturers are helping industries reduce emissions, prevent leaks, and minimise environmental impacts.

Sustainability in gasket manufacturing requires a multi-faceted approach. Material and design choices are a key part, but so too are energy consumption, manufacturing methods and waste management. At Dobson Gaskets, we have a deep commitment to sustainable practices in gasket fabrication.

Waste Management

Our factory uses various recycling streams for waste, especially for excess gasket materials. Rubber sheets are a key material in our gasket manufacturing process, but their extensive use generates significant waste. To address this, we invested in a rubber crumb machine that recycles all our rubber waste into clean, uncontaminated rubber crumbs. These crumbs are repurposed for use in horse arenas, playgrounds, gardens, pathways, and animal runs. Unlike rubber crumb sourced from vehicle tyres, our product is guaranteed to be free from contaminants like dust, glass, or rocks.

Energy Production

The use of Laser Cutters in our manufacturing processes allows us to precision-engineer complex metal gasket designs at high volume, quickly and efficiently. The cutters require nitrogen to prevent oxidisation of the metal during the cutting process, which can create a carbon layer on the cut edge, causing problems like a rough product finish and issues with coatings. Previously reliant on an external supply of nitrogen, we brought a nitrogen generator in-house that has helped us manage our supply and optimise our processes.

Across the facility, we are also upgrading our energy supply to incorporate solar panels this year, allowing us to generate our own energy which, along with nitrogen generation, will significantly reduce our carbon footprint.

Investing in energy efficiency, waste management and high-quality, environmentally safe gasket materials isn’t just a compliance measure—it’s a strategic choice that ensures reliable operations and a greener future.

 

NEED ADVICE ABOUT SUSTAINABLE GASKETS?
Talk to Our Experienced Technical Team

At Dobson Gaskets, our highly experienced technicians can guide you through the buying process, create designs from your specifications and precision-engineer sustainable, energy-efficient gaskets for your application.