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PCHE vs Shell-and-Tube Heat Exchanger: Which Is Right for Your Application?
Compare PCHE and shell-and-tube heat exchangers to see which compact heat exchanger fits your application’s efficiency, space, and cost requirements.
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Regasketing is the process of removing worn gaskets from heat exchanger plates and bonding new ones in their place. It is a standard maintenance procedure for gasketed plate heat exchangers, typically performed every 3–7 years depending on operating temperature, fluid chemistry, and duty cycle. A proper regasketing job restores the compression seal between plates, preventing internal leakage and maintaining design heat transfer coefficients.
For process engineers and purchasing managers, regasketing is far more cost-effective than buying a new plate pack. It also allows you to upgrade gasket materials—for example, switching from EPDM to NBR or Viton—when process conditions change. SHPHE, a Shanghai-based manufacturer founded in 2005, offers regasketing services and replacement gaskets compatible with most major brands, including Alfa Laval and GEA units.
Look for these signs that indicate your unit needs regasketing:
If you operate in demanding applications like chemical processing or district heating, schedule regasketing proactively based on operating hours rather than waiting for failure. Our gasketed plate heat exchangers page provides typical service intervals for different gasket materials.
Follow these steps to ensure a reliable regasketing outcome. Always refer to your unit's service manual for torque values and plate handling instructions.
Shut down the unit, isolate it from the process, and drain both circuits. Carefully remove the tightening bolts in a crisscross pattern to avoid warping the frame. Slide the movable frame back and separate the plates one by one. Inspect each plate for pitting, cracks, or deformation—damaged plates should be replaced, not regasketed.
Use a blunt scraper or a plastic pry tool to lift the old gasket from the groove. Avoid scratching the plate surface. For stubborn adhesive residue, apply a commercial gasket remover or heat the area gently with a hot air gun (below 150°C). Remove all adhesive traces—any leftover compound prevents proper bonding of the new gasket.
Clean the gasket groove with a solvent like acetone or isopropyl alcohol to remove oil, grease, and dust. Use a lint-free cloth. Ensure the groove is completely dry before applying adhesive. If the plate has a clip-on gasket design, verify that the groove edges are free of burrs.
Apply a thin, even layer of gasket adhesive (typically a cyanoacrylate or contact cement) into the groove. Press the new gasket into place starting from one corner, ensuring it seats fully without twisting. For clip-on gaskets, no adhesive is needed—just snap the gasket into the groove. Allow the adhesive to cure per the manufacturer's instructions, usually 2–4 hours at room temperature.
Stack the plates in the correct order, matching the gasket orientation marks. Slide the movable frame back and install the tightening bolts. Tighten in a crisscross sequence to the torque value specified in the manual—typically 40–80 Nm for M16 bolts, depending on plate size and design pressure. Over-torquing can damage plates or gaskets.
Perform a hydrostatic test at 1.3 times the design pressure on both circuits. Hold for 30 minutes and check for leaks at the plate pack edges and nozzle connections. If no pressure drop is observed, the unit is ready for service. If leaks appear, retorque the bolts slightly or replace the affected gasket.
Choosing the right gasket material is critical for long service life. Below are typical options:
| Material | Max Temperature (°C) | Typical Fluids |
|---|---|---|
| EPDM | 150 | Water, steam, dilute acids, caustic solutions |
| NBR (Nitrile) | 130 | Oils, fuels, hydraulic fluids |
| Viton (FKM) | 200 | Strong acids, solvents, high-temperature applications |
| HNBR | 160 | Oil and gas, high-pressure steam |
SHPHE stocks gaskets in all these materials and can supply pre-cut sets for most plate patterns. For extreme temperatures or aggressive media, consider our HT-Bloc welded plate heat exchangers which eliminate gaskets entirely.
With proper installation and compatible gasket material, a regasketed plate pack should deliver 3–5 years of leak-free operation under normal conditions. Factors that shorten gasket life include:
Regular inspection every 12 months helps catch early signs of wear. If your process involves high fouling or abrasive particles, a wide gap welded plate heat exchanger may be a better long-term solution.
SHPHE has been manufacturing plate heat exchangers in Shanghai since 2005, with ISO9001 and ASME U certifications. We export to over 20 countries and offer free thermal design and selection support. Our regasketing service covers:
We also manufacture our own line of gasketed plate heat exchangers, so we understand the engineering behind the seal. For applications where gaskets are not ideal, explore our PCHE (printed circuit heat exchangers) for high-pressure, high-temperature duties.
Yes, if you have the correct gaskets, adhesive, torque wrench, and a clean workspace. However, for large plate packs (over 100 plates) or critical processes, professional service is recommended to avoid assembly errors that cause leaks.
Regasketing typically costs 20–35% of a new plate pack. For example, regasketing a 50-plate unit might run $800–$1,500, while a new pack could be $3,000–$6,000. The exact price depends on plate size, gasket material, and labor.
Use a high-temperature cyanoacrylate or a two-part epoxy designed for elastomer-to-metal bonding. Avoid general-purpose glues that soften at process temperatures. SHPHE supplies adhesive matched to each gasket compound.
Plates are reusable if they have no cracks, deep scratches, or corrosion pits deeper than 0.5 mm. Measure plate thickness with a micrometer—if it has worn more than 10% from original, replace the plate. SHPHE offers plate thickness gauging during inspection.
No, all gaskets in a plate pack must be the same material and hardness to ensure uniform compression. Mixing materials leads to uneven sealing and early failure. Always use a matched set from the same manufacturer.
If performed by the original manufacturer or an authorized service center, the warranty remains valid. Third-party regasketing may void the warranty—check your unit's terms. SHPHE provides warranty on our regasketing work for 12 months.
To get an accurate quote for your plate heat exchanger regasketing project, please provide the following details:
Our team will provide a free thermal design check and recommend the optimal gasket material for your process. Contact SHPHE today to keep your plate heat exchanger running at peak efficiency with a complete regasketing process that meets industry best practices.
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User Comments
Service Experience Sharing from Real Customers
Marcus
Maintenance SupervisorWe had three of our old GEA plates start leaking last month. I was dreading the downtime, but these regasketing kits fit perfectly and the adhesive held up under pressure test. Saved us a week of waiting for a new unit. Solid product.
Lena
Process EngineerNot gonna lie, I was skeptical about regasketing vs buying new plates. But the material quality is impressive—no cracking after 3 months of brine service. Only dropped a star because the instructions could be clearer for first-timers. Still, would buy again.
Tommy
Facility ManagerI run a small dairy plant and we can't afford to have our pasteurizer down for long. These regaskets arrived quick, clamped on easy, and we were back running in under 4 hours. The seal is holding up great with our daily CIP cycles. Highly recommend for anyone on a tight budget.
Priya
HVAC TechnicianUsed this on a plate heat exchanger in a hospital HVAC loop. Old gaskets were brittle and leaking glycol. New ones fit like a glove on the Alfa Laval plates. No leaks after 2 months of constant 180°F water. My boss was impressed I didn't have to order a whole new unit.