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The Essentials Guide: Caps And Plugs Application

clock 5 minutes | 12 Feb 2020

The Essentials Guide: Caps And Plugs Application

We’ve created this guide to outline specific protection solutions for your project, in a number of key industrial manufacturing applications.

Many products that you manufacture are likely shipped to another location or customer, or simply moved along an assembly line as part of your production process. During these transits and end uses, it’s important to protect vital parts to ensure efficient processes, safe use and reduced downtime. We strongly recommend that you request free samples so that you can try before you buy. This will ensure you get the solution that works best for your application

EQUIPMENT MANUFACTURING

Ensure smooth assembly and transit to your customers by protecting critical internal and external profiles from damage, maintaining quality and a timely delivery. Key equipment to protect includes electric cable enclosures, HVAC components, industrial generator parts, indoor and outdoor cabinets, such as a data cabinet or an outdoor utility cabinet.

Essentra recommends protecting with these solutions:

Many products that you manufacture are likely shipped to another location or customer, or simply moved along an assembly line as part of your production process. During these transits and end uses, it’s important to protect vital parts to ensure efficient processes, safe use and reduced downtime.

Explore our guide to see what we recommend when protecting your products.

Blanking Plug

Recommended:

Blanking Plug

Why?

  • Ideal for closing panel cavities for clean finish
  • Available in a large offering to suit hole diameter and panel thickness
  • Available in nylon or copolyester for rigidity and durability
Body Plugs

Recommended:

Body Plugs

Why?

  • Quick solution for closing panel cavities
  • Large selection to suit hole diameter and panel thickness
  • These push in plugs for panels come in silicone or TPR for flexibility, covering multiple diameters

VEHICLES

In applications where precision is everything, it’s essential to guard fuel lines from potential debris contamination and protect vital threads from damage during shipment and masking. Key vehicle parts to protect are diesel/petrol pumps, engines, specialist vehicle fittings, powertrains and brake systems.

Essentra recommends protecting with these solutions:

AUTOMOTIVE
Tapered Cap and Tapered Plug

Recommended:

Tapered Cap and Tapered Plug

Best for:

Powertrain

Why?

  • Plugs multiple inner diameters
  • Caps multiple outside diameters
  • Tapered caps and plugs made of Low Density Polyethylene (LDPE), a rigid, yet soft material
Pull Tab Caps

Recommended:

Pull Tab Caps

Best for:

HVAC

Why?

  • PVC does not shred on sharp edges like polymers do
  • No residue left during installation or removal
  • Pull tab for easy removal
Flanged Caps

Recommended:

Flanged Caps

Best for:

Fuel System

Why?

  • Ease of assembly and removal on high-volume applications
  • Clear colour shows integrity of adapters’ o-ring and thread
  • Internal seal prevents paint ingress
Blanking Plug

Recommended:

Blanking Plug

Best for:

Body & Chassis

Why?

  • Close off holes for clean, finished look
  • Prevents injury from sharp edges
Threaded Sealing Plugs

Recommended:

Threaded Sealing Plugs

Best for:

Brake System

Why?

  • Nylon threaded plug with sealing o-ring
  • Tighter, more secure fit, o-ring acts as a seal
  • Wide flange prevents paint ingress during removal
SPECIALIST VEHICLES
Threaded Sealing Caps - UNF Threads

Recommended:

Threaded Sealing Caps - UNF Threads

Best for:

Construction

Why?

  • Protects and limits fluid leakage
  • HDPE material resistant to solvents and reduces potential shearing
  • Hexagonal head can be tightened by a wrench or socket at low torque, but hand tightening is recommended
O-ring threaded plugs

Recommended:

O-ring threaded plugs

Best for:

Agriculture

Why?

  • Protects threads on fuel pumps and engine equipment from dirt and debris
Hydraulic Caps

Recommended:

Hydraulic Caps

Best for:

Agriculture

Why?

  • Protect couplings from dirt, moisture and corrosion
  • Quick Release Dust Caps made of TPE withstand temperatures -40°F to 203°F (-40°C to 95°C)
Threaded Protection Plugs – Easy Pull

Recommended:

Threaded Protection Plugs – Easy Pull

Best for:

Freight

Why?

  • Made from LDPE, seals both threaded and non-threaded holes
  • Simple push fit and convenient pull-tab for easy unlocking

ELECTRIC VEHICLE CHARGING STATIONS

Electric vehicle charging stations have to meet strict design and manufacturing requirements. That includes protecting critical profiles from contamination while providing an overall aesthetic solution that performs the way you need it to.

Liquid tight plugs

Recommended:

Liquid tight plugs

Why?

  • Protects from dust and withstands water immersion (IP67)
  • Silicone rubber; UL94 V-0
Push-fit Vinyl Round End Caps

Recommended:

Push-fit Vinyl Round End Caps

Why?

  • Flexible PVC allows easy fitting - can stretch onto larger dimensions for a snug fit without tearing, splitting, or shredding
  • Glossy finish is ideal as a decorative end cap

METAL FABRICATION

Guarantee a professional finish every time by masking holes, studs and contact points during painting, blasting, and finishing processes. By protecting important areas of fabricated metal with easy-to-fit caps and plugs, you can successfully increase customer satisfaction and minimise recall of finished products. Key areas to guard include electrical contact points, threaded holes or studs and welding areas.

Essentra recommends protecting with these solutions:

High-Temperature Silicone Tapered Plugs

Recommended:

High-Temperature Silicone Tapered Plugs

Why?

  • Available as a solid plug or with a hollow core to aid in compression
  • Excellent chemical resistance
  • Reusable
  • Also available in EPDM
Masking Pull Plugs

Recommended:

Masking Pull Plugs

Why?

  • Masks threaded or non-threaded through holes
  • Fast, easy removal
  • Available in silicone and EPDM
Masking Flangeless Plugs

Recommended:

Masking Flangeless Plugs

Why?

  • Masks holes without masking surrounding areas
  • Protects multiple diameters
  • Masking pull plug with tab for easy installation and removal
  • Available in TPR and EPDM
Masking Washer Caps

Recommended:

Masking Washer Caps

Why?

  • Protects threaded and non-threaded end tips
  • Washer seals the edge to protect from contaminant
  • Available in silicone and EPDM

HOSES & HYDRAULICS

Safe operation of devices using hydraulic fluid calls for specialist hose-fitting protection and coverage. The right cap or plug can help mitigate fluid spills and maintain hose integrity when looking to ensure constant machinery uptime and user safety. Key hydraulic parts that need safeguarding include grease nipples, DKO-compression fittings, fuel lines and banjo unions.

Essentra recommends protecting with these solutions:

Hexagonal Caps

Recommended:

Hexagonal Caps

Why?

  • Rigid design allows easy application and removal
  • Available in all common hydraulic coupling sizes
  • Also suitable for protecting round components
Driveshaft Protection Caps

Recommended:

Driveshaft Protection Caps

Why?

  • Available in flexible PVC and LDPE to protect driveshaft and surrounding bearings
Banjo Union Plugs

Recommended:

Banjo Union Plugs

Why?

  • Prevents dirt and moisture ingress
  • Made of Low Density Polyethylene (LDPE), a rigid, yet soft material
Quick Release Plugs

Recommended:

Quick Release Plugs

Why?

  • Designed to remain attached to the hose
  • Offer excellent protection from dirt, moisture and corrosion
  • Male fitting suitable to plug ISO A and ISO B Series

Download free CADs and try before you buy

Free CADs are available for most solutions, which you can download for free. You can also request free samples to ensure the solutions you’ve chosen are exactly what you need. If you’re not quite sure which product will work best for your application, our experts are always happy to advise you.

Request your free samples or download free CADs now.

For more advice please call us on 0845 758 5070 or email sales@essentracomponents.co.uk

The Essentials Guide: Caps & Plugs Applications PDF Download
Caps & Plugs - The Design Engineer's Guide