Project Highlight: Specialty Washer for an HVAC Player

New Process engineers and technicians received a call from a company in Texas with whom we had never worked. This company was in a tight spot and asked if we could deliver 100,000 specialized non-metallic washers – by the next morning.

The company manufactures compressors used in all of the major HVAC industry players’ products. They usually manufacture their washers in-house, but in this case they needed very tight tolerances that their equipment could not meet. The company asked us to manufacture PTFE washers with a 0.022” thickness and a +/- .002 tolerance.Specialty Washers

Meeting the client’s request under such a tight deadline was a challenge, but was possible because of New Process’ material inventory and state-of-the-art machining capabilities. We had the right PTFE material on hand, but did not have the right die to meet the company’s dimensional requirements. We gathered our tooling department experts together and asked if they could stay late that night to build a new die based on the client’s specific needs.

Our experts rallied together to produce a new die in record time. With the right tooling in place, we were able to start the manufacturing process right away. As soon as the job was  finished, we shipped them to the client and they received their custom-made washers the next day. Upon receiving the parts, we received a phone call from the client, telling us that they had not seen such a clean machining of washers in years, and they needed 10 million more!

Years later, New Process continues to work with this client, making 3 to 4 million parts for them annually.

New Process is here to help with your next project

New Process is a leading manufacturer of non-metallic stamped parts, specifically PTFE and Nylon washers. As this project demonstrates, our team goes above and beyond to get every job done no matter the product specifications or deadline requirements. Our clients value our expertise and work ethic, and consistently rely on us for follow-up projects.


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Click here to contact us and to discuss how we can help you with your next project.

New Process – An Important Player in HVACR Manufacturing

The HVACR industry is a vast and complex one, affecting many people and businesses alike.  Issues like energy efficiency and power sources, the function and future of the energy grid, and many more are some of the fundamental areas of attention and growth within the industry.  Every year at the AHR Expo, the players in the industry gather to exchange ideas, information, and business to promote and advance the ever expanding goals of the industry.  We’re attending, and we couldn’t be more excited to do so.

In an industry concerned with getting the most efficiency out of each system as possible, the quality and characteristics of each part of the system become paramount.  Every piece of the HVAC puzzle that the engineer specifies needs to perform in the specific way it is intended, and to the expectations of the designer.  Whether it’s the compressibility and sealing capability of a gasket, the insulating properties of an assembly housing, or the flammability or operating temperature of a specified material, each part has a unique design and characteristics to accomplish specific tasks.  These tasks may be as simple as protecting the outside unit of an HVAC installation, or as important as ensuring the safety of the technicians who repair and retrofit systems after installation – either way, the knowledge of the proper materials and characteristics for each application is incredibly important.

These considerations can be cost-saving as well, in the event that more than one material can effectively accomplish its intended purpose, one of them will likely be a better fit.  This is why we at New Process consider ourselves quite valuable to the industry; our long history and expertise combined with our variety of materials and custom processes allow us to come up with the perfect solutions that are economic and effective for our customers.

If you’re at the AHR EXPO this year, stop by Booth #8173 and say hello – we’d be more than happy to connect with you.  We’ll also be keeping an eye on our Twitter and Facebook during the show, so shout out to us on social media, and have a great time at the show!


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