Equipment reliability is paramount in the mining industry, where operations face constant wear and extreme conditions. From gold extraction in Zimbabwe to copper mining in Zambia and diamond operations in Botswana, the challenges are consistent: abrasive slurries, chemical exposure, fluctuating pressures and remote sites with limited access to maintenance. Despite the tough demands, pump packing provides a practical sealing option that balances reliability, performance and sustainability.

Although pump packing – a flexible braided sealing ring compressed into a stuffing box – may seem like a legacy technology, it continues to provide significant value in today’s mining operations, says mission-critical solutions provider John Crane.

Packing helps prevent leakage around rotating or reciprocating shafts and is used to seal pumps, valves, compressors and agitators. Unlike more complex systems, packing is straightforward to install, relatively low-cost and tolerant of misalignment and vibration. This makes it an attractive option in high-impact environments where simplicity and durability are non-negotiable, adds the company.

Pump packing is especially well-suited for slurry pumps moving abrasive materials, valve stems in corrosive process lines, crushers and grinders that handle solids-laden fluids and chemical dosing systems requiring compatibility with aggressive agents.

Meeting Harsh Conditions Head-On
Mining involves more than just transporting water or slurry, it requires sealing technology that can endure everything from high acidity to coarse solids, explains John Crane, noting that the evolution of packing materials has helped extend operational lifespans and reduce unplanned downtime.

Material innovations have made a difference. Today’s packing is made from Kevlar, graphite, carbon and advanced synthetic fibres, chosen for their abrasion resistance, chemical stability and ability to handle elevated temperatures and pressures. These properties are fundamental in mining environments where conditions vary drastically from one process to another, states the company.

Some standard material configurations include synthetic fibres with or without polytetrafluoroethylene (PTFE) for general services and a range of fluids; polyamides with PTFE, expanded PTFE and lubricating oil for abrasive services with enhanced wear resistance; PTFE, carbon filaments with lubricating oil for chemical exposure, offering high resistance and stability; and graphite filaments for high-speed, high-temperature environments, owing to strong thermal conductivity.

Installation and Maintenance Best Practices
Despite its relatively simple design, pump packing’s performance depends heavily on correct selection, installation and ongoing maintenance, advises John Crane.

Choosing packing that matches the chemical and physical nature of the media handled is essential, while over-tightening or under-tightening can lead to leakage, excessive wear or overheating.

In addition, packing should be regularly checked for wear, leakage rates and proper gland pressure to ensure consistent performance. Maintenance personnel must also be familiar with packing procedures and adjustment techniques to optimise uptime.

When properly installed and maintained, pump packing offers reliable sealing that competes with complex solutions while keeping costs down.

Key Benefits in Mining Applications
Across Africa’s mining sites, where cost pressures and logistical constraints shape decision-making, pump packing offers several strategic advantages.

In isolated areas with limited access to specialised support systems, packing can be serviced on-site with minimal tools. Pump packing is also typically more economical to install and maintain, providing a practical solution in operations looking to improve return on investment without compromising reliability.

Further, with the proper setup, modern packing can be configured to control leakage, helping reduce unnecessary water loss in dry or drought-prone regions.

The shift from natural to synthetic fibres has allowed packing to meet more demanding service conditions. Braided composites can now withstand high-pressure, abrasive media and fluctuating temperatures – an everyday occurrence in modern mining.

As a result, mining operations have started to view packing not as a legacy product but as a strategic asset, states John Crane.

By tailoring material selection to specific pump types and process conditions, engineers can extend packing life, reduce maintenance intervals and limit unscheduled shutdowns.

The Role of Packing in Sustainability
Sealing technologies must also contribute to sustainability goals in a region where environmental regulations are tightening and community expectations are rising. Packing that reduces leakage helps to prevent contamination of groundwater and surrounding ecosystems; lowers water and chemicals use, and extends the life of critical equipment, reducing waste and emissions from frequent replacements.

This aligns with many African mining companies’ broader environmental, social and governance targets – particularly in water management and operational safety, shares John Crane.

Pump packing’s strength lies in its adaptability. With the proper materials and design, it can reliably perform across a range of mining environments, from abrasive slurries to chemically aggressive processes and remote locations where simplicity and serviceability are key.

Choosing the right pump packing solution is essential for balancing performance, cost and sustainability in a mine. With a legacy built on reliability, John Crane provides the mining sector with field-proven sealing solutions and the technical expertise to support optimal material selection and long-term performance.