When you are sealing a pipe, tank or equipment in a corrosive environment, choosing the right gasket material is very important. Using the wrong material can cause leakage, breakdown, contamination or even create a dangerous situation for the factory or plant. A corrosive environment comes with strong chemicals, acids and solvents. Hence, it is important to choose wisely between PTFE vs rubber gaskets.
PTFE is Polytetrafluoroethylene, and rubber is various elastomers. Today, we bring you a blog that will guide you to choose the best chemical-resistant gasket or material for your corrosive environment, with its strengths and weaknesses.
What Makes the Environment Corrosive?
The corrosive environment is one where material will slowly break down and be destroyed by the chemical reactions. A corrosive environment combines aggressive temperature, pressure, high and low pH, solvent, oxidiser, flow, etc. So in certain environments, the gasket fails due to the reaction and leads to leakage, maintenance downtime, and safety hazards. Common corrosive substances include:
- Strong acids (like sulfuric acid or hydrochloric acid)
- Strong bases or alkalis (like sodium hydroxide, also known as caustic soda)
- Aggressive solvents (like chlorine or bromine)
- Saltwater
In these conditions, a gasket isn’t just a simple seal. It is a critical barrier against destruction.
What are PTFE and Rubber Material?
Let’s understand PTFE vs Rubber gasket.
What is PTFE?
PTFE is a solid, high-pressure synthetic fluoro polymer. It is also known as Teflon. It comes with non-reactive material with a unique set of properties. It is not rubber. It behaves more like a high-performance plastic. Its key features are high temperature tolerance, extreme chemical resistance, low surface friction, nonstick, and non-reactive.
To understand PTFE in detail, including its structure and resistance capabilities, you can read our complete guide on What is a PTFE Gasket.
What is Rubber?
Rubber is a sealing material. There are various types of rubber used for rubber gasket manufacturing. The most common types of rubbers are natural rubber, nitrile rubber, neoprene, EPDM, fluoro elastomer, Viton and many more. Every type of rubber works for different kinds of applications and holds different kinds of properties. For corrosive cases, their suitability varies according to the condition.
Key Comparison of PTFE Vs. Rubber (Gasket Material Comparison)
| Property | PTFE | Rubber (General) |
| Chemical Resistance | Excellent resistance to most acids, bases, and solvents | Varies by type; requires careful material selection |
| Temperature Range | Very wide range from cryogenic to high temperatures | Limited to moderate temperatures |
| Elasticity/Conformability | Low elasticity but dimensionally stable | High elasticity for easy compression and sealing |
| Creep/Cold Flow | Can slowly deform under constant pressure | Generally resists cold flow better than PTFE |
| Cost | Higher initial material cost | Lower cost option for standard applications |
| Ease of Installation | Requires smooth flanges and careful installation | Forgiving on imperfect surfaces due to flexibility |
When to Use PTFE Gasket
- When you are handling strong acids, bases or solvents. PTFE is “universal” in chemical resistance.
- When there is a wide temperature swing. PTFE can withstand high temperatures, rather than rubber.
- When you require extreme purity and non-contamination, like in the food and pharmaceutical industries.
- When the chemical is unknown or a mixture. PTFE goes with every kind of material and can withstand all situations.
- When you need a nonstick surface. PTFE is easy to clean and gives a coating to the surface.
- When you need a lifelong solution with low maintenance. PTFE materials are durable.
For industrial-grade, high-purity PTFE gaskets, explore our full range designed for corrosive environments.
Common Application of PTFE Gasket
PTFE gaskets are suitable for use in chemical processing plants, pharmaceutical reactors, semiconductor, food & plants project, oil, and gas, chemical systems and many more.
When to Use a Rubber Gasket?
Choosing the rubber gasket is also an option, but it is not ideal to use in a corrosive environment. Still, if you want a rubber gasket, make sure to use it in these cases.
- When the environment involves mild chemicals, steam, or air.
- When the plant’s surface finish is poor and gaps are regular.
- When your initial budget is limited.
- When you need flexibility and vibration dumping.
Common application for a rubber gasket
Rubber gaskets are suitable for use in water pipelines, HVAC systems, hydraulic systems, automated engines, etc.
Conclusion
If we talk about PTFE vs rubber gaskets for corrosive environments, the clear answer is to use PTFE gaskets only. PTFE gaskets are unmatched in chemical resistance, wide temperature tolerance, inertness behaviour and effective material. Rubber gaskets can be used for everyday applications. It does not withstand harsh chemical environments, even make your plant or factory risky. Do not opt for a rubber gasket in a corrosive environment.
In many real scenarios, engineers and professionals always opt for PTFE gaskets only. In addition, for a corrosive environment, you should only go with a high-grade PTFE gasket. Goa Polymers provide high-quality PTFE gaskets that withstand corrosive environments and give you extreme safety, reliability and peace of mind.
FAQs (Frequently Asked Questions)
Viton is one of the most chemically resistant rubbers, but it also comes with a major limitation. If you are using a Viton, make sure where you are using it. If you are still in doubt and not aware of the material, then opt for PTFE gaskets only. Because they can withstand all the extreme temperatures and environments.
Yes, PTFE gaskets are always the better choice for chemical applications. PTFE material is superior for aggressive acids, bases and solvents. It does not raise a health concern.
PTFE is a high-pressure engineered polymer and is prepared with a complex manufacturing process. Rubber is a simpler and moldable component, which is easy to manufacture.
Rubber is a better option when you need a highly flexible, compressible sealing for an uneven surface, but for a corrosive environment, strictly no to rubber sealing.
