Filter Bag Needle Hole Sealing Machine | RapidSeal Double Seal

Filter Bag Needle Hole Sealing Machine | RapidSeal Double-Seal System

RapidSeal 5–8s Double-Seal System – Embedded + Surface Sealing for True Zero Leakage

A high-speed machine designed specifically for industrial filter bag needle-hole sealing, providing true fiber-level double-seal performance using a two-component silicone system.

In industrial filter bag manufacturing, needle holes are the primary source of leakage and long-term performance decline. Traditional methods such as PTFE tape or surface-only gluing cannot form a structural seal. They only attach mechanically to the surface, which leads to peeling, seam failure, and leakage—especially on aramid and other high-temperature filter bags.

Even worse, PTFE tape must be heated to extremely high temperatures, releasing harmful fumes that pose operator health risks and raise serious concerns regarding environmental and regulatory compliance.

KABORY’s patented RapidSeal 5–8s Double-Seal System delivers a true fiber-level sealing solution powered by a 2-component high-temperature fast-cure silicone formulation:

🔸 Inner Columnar Seal – The 2-component liquid silicone penetrates the stitch holes and reacts instantly to form a flexible, fiber-bonded columnar seal that eliminates leakage from within.

🔸 Outer Seam Coating – A controlled outer layer of the same high-temperature silicone reinforces the seam zone, providing additional protection against abrasion, thermal cycling, and chemical corrosion.

This dual-action sealing approach ensures not just surface adhesion but true three-dimensional embedding—achieving structural integrity, chemical resistance, and high-temperature durability up to 250°C.

✅ Seamless integration with high-speed sewing lines
✅ Real-time curing (5–8s) — no downtime, no bag sticking
✅ Non-adhesive to PTFE membranes or bag surfaces
✅ Uniform silicone distribution — consistent and controlled bead filling
✅ Proven stability on Polyester, Acrylic ,PPS, Aramid, PTFE-impregnated felt, P84, fiberglass
✅ High temperature & chemical resistance — up to 250°C, acid/alkali safe
✅ Safe & eco-friendly — no toxic fumes, no irritation, operator-safe

How Filter Bag Needle Hole Sealing Works

–Synchronized Dual-Component High-Temperature Silicone Needle-Hole Sealing with 5-Second Full Curing

The automatic sealing system operates in full synchronization with the three-thread sewing machine. As the stitches are being formed, the 1:1 auto-metering and dynamic mixing system delivers freshly mixed dual-component high-temperature silicone through a precision nozzle, accurately coating each needle hole in real time.
This ensures true in-line, perfectly aligned sealing without any secondary positioning.

Once applied, the silicone exhibits excellent flow and penetration characteristics. It naturally settles into the needle holes, filling the puncture and the surrounding fiber micro-gaps, and forms adhesion and structural interlocking with the internal fiber network. After curing, it becomes a stable pillar-shaped embedded structure, sealing the needle hole from the inside.

At the same time, the silicone on the surface spreads into a uniform, continuous protective layer over the stitch line and seam area, improving abrasion resistance and enhancing the overall sealing performance.

Thanks to its rapid 5-second full curing, the sealed seam becomes completely dry and stable almost instantly.
After the tubing line is cut, the filter bag can be folded, stacked, or transferred immediately, with no waiting time, no smearing, and no secondary handling.

The final result is a dual-layer sealing structure — an internal pillar-shaped plug combined with an external protective coating.
This synchronized and fast-curing sealing method greatly improves durability, resistance to pulse-jet cleaning, and long-term leak-tight performance, far surpassing traditional PTFE tape hot-sealing methods.

Result
This Double-Seal Structure maintains long-term leak integrity under:

• Pulse-jet cleaning impact

• Continuous vibration

• Mechanical flexing

• Thermal cycling at 180–250°C

Achieving stable low emissions performance where PTFE tape sealing commonly fails over time.

🟠 Unique Tw0- component Silicone Sealant Developed Specifically for Filter Bag Needle-Hole Sealing

This machine uses a unique, purpose-built Two-component silicone adhesive that was specifically developed for filter bag needle-hole sealing.
Unlike generic adhesives or PTFE seam tape, this formulation is engineered to:

• Penetrate deep into the needled felt

• Fill the needle hole completely

• Mechanically lock with internal fibers

• Create a flexible, long-lasting sealing layer

• Cure within 5–8 seconds during continuous sewing

Because the adhesive was designed exclusively for industrial filter bags, it delivers a sealing performance that conventional PTFE tape cannot achieve, especially under thermal cycling, pulse-jet shock, and long-term vibration.

Performance Comparison: Double-Seal vs. PTFE Tape Sealing

Feature	RapidSeal 5–8s Technology	Traditional PTFE Tape
Production Speed	10–12 meters/min (fully synchronized with sewing)	3–5 meters/min (slower and less consistent)
Cost	Lower total cost due to reduced labor, waste, and glue usage	Higher cost from manual labor and excessive material use
Curing Time	Fast 5–8 seconds	Requires longer heating or curing time
Working temperature	250°C continuous operation	Max 200°C
Safety	Non-toxic, odorless silicone adhesive	PTFE emits harmful fumes during heat application
Emissions Compliance	Supports ultra-low emissions (≤3 mg/m³) when paired with fine-fiber media	Inconsistent sealing may lead to emission issues

Advantages of RapidSeal Double-Seal in Filter Bag Needle Hole Sealing

Seal Layer	Action	Result
Inner Embedded Pillar Seal for Filter Bag Needle Hole Sealing	Silicone penetrates & solidifies inside needle holes	Forms a pillar-shaped internal leak barrier
Outer Seam Coating	Flexible film covers stitches & seam area	Prevents peeling, cracking, and wear under pulse-jet cleaning

🔸This advanced sealing method is ideal for modern industrial filtration applications demanding durability, safety, and productivity.

PTFE Tape vs. Filter Bag Needle Hole Sealing on Different Media

Quick reference comparing how common filter media respond to silicone/adhesive sealing, needle-hole penetration, and columnar seal formation in filter bag production.

Material Type	Surface Characteristics	Adhesion Strength	Needle Hole Penetration	Columnar Seal Formation	Application Notes
Polyester	Smooth surface, mild polarity	⭐⭐⭐⭐	✅ Moderate	✅ Achievable	Common in low-to-mid temp filtration; use moderate-viscosity silicone
Acrylic	Moderate polarity, dense fiber structure	⭐⭐⭐⭐	✅ Moderate	✅ Easy to form	For 80–120°C environments; stable bonding
Aramid (Nomex)	High polarity, consistent texture	⭐⭐⭐⭐⭐	✅ Strong	✅ Easy to form	Outstanding adhesion and shear strength
PPS	Moderate surface energy, thermally stable	⭐⭐⭐⭐☆	✅ Strong	✅ Easy to form	Excellent performance at high temps
P84	Low surface energy	⭐⭐⭐☆☆	✅ Moderate	✅ Achievable	⚠ Surface roughening (e.g., fine sanding) improves bonding performance
Fiberglass	Rough surface, open weave	⭐⭐⭐⭐☆	✅ Excellent	✅ Very easy to form	High-temp compatibility; ideal for mechanical locking
PTFE- Felt	PTFE Dipping	⭐⭐⭐⭐	✅ Strong	✅ Easy to form	More adhesive than PTFE film; widely used in hot gas filtration

🔒 Seal It Right, Run It Longer

In high-demand filtration, a bag is only as reliable as its seal.
Even the best fiber or scrim fails if needle holes leak, coatings peel, or seams weaken.

That’s why at KABORY, we go beyond conventional felts:
✔️ Proprietary needle-eye sealing technology (RapidSeal 5–8s) eliminates leakage at stitch points
✔️ Strong adhesion between fiber and silicone ensures columnar seal formation deep inside the felt
✔️ Proven performance in incineration, metallurgy, and chemical tail gas filtration, where emissions standards are toughest

👉 Secure your production, protect your emissions compliance, and extend filter bag life — all with KABORY’s sealing expertise.

Boost your filter performance. Cut your downtime. Protect your bottom line.

The KABORY Alternative: Needle Hole Sealing Machine

Inline System for Filter Bag Needle Hole Sealing

KABORY introduces the world’s first Needle Hole Sealing Machine for Filter Bags, using dual-component high-temperature silicone instead of PTFE tape.

This system applies sealant inline with sewing, cures in just 5–8 seconds, and forms a pillar-shaped embedded structure inside every needle hole.

Key Features of Filter Bag Needle Hole Sealing

• Dual-Component Silicone Application — penetrates fibers and locks inside the needle holes.

• Rapid Curing (5–8s) — synchronized with sewing speed, no production delays.

• Fully Integrated — mounted directly onto automatic sewing machines.

• Safe & Clean — zero toxic smoke, no carcinogenic risk for operators.

• Durable — becomes part of the fabric structure, resistant to heat, abrasion, and humidity.

Double-Seal vs PTFE for Filter Bag Needle Hole Sealing

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PTFE Tape Sealing Behavior on Different Filter Media

📌 Conclusion: Regardless of the filter media, PTFE tape can only provide surface-level mechanical locking without true fiber-level integration, leading to poor long-term stability.
👉 This highlights the superiority of dual-component silicone sealing technology: it penetrates into needle holes and creates chemical + mechanical dual anchoring, ensuring reliable long-term sealing.

⚙️ Process Mechanism of Filter Bag Needle Hole Sealing

Inner Embedded Pillar Seal for Filter Bag Needle Hole Sealing

🔸 High-temp silicone forms a comprehensive sealing layer both on the surface and inside the needle hole
🔸 Cylindrical internal bonding enhances leak prevention and filter bag durability under demanding conditions

🔧 High-Precision Automatic Gluing Machine

To fully realize the potential of RapidSeal 5–8s Technology, a matching high-precision automatic gluing machine is required.

This purpose-built system ensures the accurate application of high-temperature dual-component quick-curing adhesive directly onto the needle hole area during the sewing process.

This advanced glue application system offers:

✔ Intelligent Temperature Control System – One-touch heating with precise, automatic temperature regulation for stable glue performance
✔ Smart Linkage Control – Enables real-time synchronization of sewing, gluing, and curing processes, boosting throughput and reducing delays
✔ Automatic Precision Glue Mixing – Maintains an accurate 1:1 mixing ratio for consistent adhesive quality with simple one-touch activation
✔ Leak-Proof Dispensing System – Utilizes anti-drip nozzles and back-suction mechanisms to prevent overflow and ensure clean, precise glue lines
✔ Optimized for Dual-Component Silicone – Specifically designed for fast-curing, high-temperature adhesives that remain flowable for extended periods even during machine stoppages

Why Needle Hole Sealing Matters

Filter bag seams are the most common leakage point in industrial dust collection.
Unsealed needle holes lead to:

• Increased emissions

• Shorter filter life

• Baghouse instability

• Higher operating cost

Seams determine bag performance — not just fabric quality.

By combining these features, the gluing machine ensures seamless operation, reduced waste, lower maintenance, and maximum compatibility with high-speed sewing lines using RapidSeal Technology.

Achieving ≤3 mg/m³ through Filter Bag Needle Hole Sealing

When paired with ultra-fine fiber filter media, RapidSeal 5–8s helps Achieving ≤3 mg/m³ Emissions with Needle Hole Sealing

⚠ Health & Safety Risks of Heated PTFE Tape

Traditional sealing methods using PTFE tape and heat may seem simple, but they come with hidden dangers.

When heated during the sealing process, PTFE tape can release toxic fumes, especially at high temperatures. These emissions may cause:

• Throat irritation and coughing

• Watery or burning eyes

• Headache, nausea, or dizziness

• Long-term respiratory discomfort from prolonged exposure

Operators working close to the sealing area have reported symptoms such as scratchy throat, persistent coughing, and eye irritation, especially in enclosed work environments with insufficient ventilation.

✅ Our Safer Alternative: Cold-Applied, Fiber-Bonded Sealing

Unlike heated tape systems, our two-component silicone sealant:

• Is applied cold, with no fumes or harmful vapors

• Penetrates deeply into needle holes and bonds with the base fiber

• Cures in seconds and remains stable under 250°C without breakdown

• Is odorless, non-toxic, and safe for factory operators

This not only improves long-term sealing integrity — it also protects your workers and helps your facility meet modern environmental and occupational safety standards.

🔁 Make the Switch

If you’re still relying on heated PTFE tape sealing, it’s time to upgrade.
Our needle-hole sealing system delivers:

• Cleaner air for your workers

• Stronger seams for your filter bags

• Faster throughput with less waste

📩 Contact us for technical consultation or a trial demonstration.

This technology enables compliance with the most stringent global emission regulations, making it the go-to solution for high-performance industrial dust collection systems.

✅ Key Benefits of Needle Hole Sealing Technology

1. Effective Leakage Prevention – Seals needle holes to prevent dust/gas leaks
2. Enhanced Filtration Efficiency – Meets ultra-low emission standards when combined with fine-fiber media
3. Improved Durability – Reduces damage risk from heat, corrosion, or abrasion
4. High Temp & Chemical Resistance – Withstands up to 250°C, suitable for corrosive or acidic environments
5. Lower Maintenance Costs – Extends filter bag lifespan and reduces replacement frequency
6. Safe & Eco-Friendly – No toxic fumes during application, safer for workers
7. Boosted Production Efficiency – RapidSeal 5–8s synchronizes with high-speed sewing for real-time sealing

🏭 Applications

✔ Steel Plants – Withstands high heat and extends filter life
✔ Power Plants – Performs in acidic gas environments
✔ Cement Plants – Effective in high-dust, high-temp operations
✔ Aluminum Oxide Production – Excellent alkaline resistance
✔ Asphalt Plants – Quick curing ensures high throughput
✔ Municipal Waste Incineration – Resists heat and corrosion

Performance is based on extensive field testing. Actual results may vary based on operational parameters.

Next Step: Evaluate the Seam, Not the Description

We provide:

• Sealed seam sample section (for microscope & tensile testing)

• Material-to-silicone matching recommendations

• Line integration & ROI projection based on your actual production conditions

Your production conditions → Our sealing solution.

→ Request Sealed Seam Sample
→ Upload Media Specs to Match Silicone Grade