Plastic Super Saddles

MACH Engineering offers a polymer version of the well-known Super INTALOX® product to complement our lineup of ceramic Super Saddles. Our plastic Super Saddles feature a similar design, as well as an accessible price point and our exclusive material quality guarantee. Choose MACH Engineering plastic Super Saddles for a wide range of applications and processes — keep reading to learn more.

Product Overview
Nominal Size (IN) 1 (25 mm) 2 (50 mm) 3 (76mm)
Void Fraction (%) 90 93 94
Geometric Surface Area (ft2/ft3) 73 33 27
Weigth – PP (lb/ft3) 5.85 3.75 3
Packing Factor (1/ft) 33 21 16


MACH Engineering plastic Super Saddles feature a curved, saddle-like shape with a series of small openings in the arc surface and corrugations on the outer ridge. These openings promote the free passage of fluid, minimizing pressure drop. They also neatly solve the problem of nesting. Traditional saddles often nestle into one another once they settle to the bottom of a tank, reducing the surface area they are designed to provide. The scallops on Super Saddles inhibit this tendency to help the packing retain its high performance.

Our design differs slightly from the plastic INTALOX® saddle — the MACH Engineering product permits enlarged voids between packing for increased capacity, lower pressure drop and better gas-liquid distribution. Overall, this is a highly versatile packing option and an excellent alternative to both INTALOX® plastic Super Saddles and our own Plastic Ring product.


Materials & Sizes

Our plastic Super Saddles come in three sizes — 1 inch, 2 inches and 3 inches. Larger saddles have a larger void fraction, lower weight, smaller geometric surface area and a smaller packing factor. Six material options are available:

  • Polypropylene (PP)
  • Polyethylene (PE)
  • Polyvinyl chloride (PVC)
  • Corzan® (CPVC)
  • Kynar® (PVDF)
  • Teflon® (PFA)

More-dense plastics such as PVDF operate at higher temperatures, whereas less-dense PP and PE are better for low-temperature use. All offer exceptional corrosion resistance and resistance to many harsh solvents and other chemicals. Plastic saddle rings are lightweight and extremely durable, making them easy to load into and remove from a tower.


Choosing a plastic saddle ring for your tower packing application brings the benefits of several unique features. Here are the top features of plastic Super Saddle rings from MACH Engineering that can benefit your application:

  • High void ratio: MACH plastic Super Saddles enable increased voids between packing, which creates a higher void ratio within the tower. A high void ratio indicates that the vapor will move quickly through the system. These plastic saddle rings provide void ratios reaching as high as 95%.
  • Efficient mass transfer: Adequate mass transfer is vital for plastic Super Saddle ring performance. Fortunately, plastic Super Saddles from MACH Engineering have efficient mass transfer because of their low liquid residence time and increased surface area.
  • Uniform contact between gas and liquid: The scalloped edges of a plastic Super Saddle prevent settling and enable uniform surface area. Maintaining this consistent contact and even distribution between the gas and liquid within the column is essential for maximized capacity and productivity.
  • Low pressure drop: The corrugated outer edge of a plastic Super Saddle allows fluid to pass freely within the tower, increasing the surface area of the plastic Super Saddle ring. This structure contributes to low pressure drop, which improves chemical separation efficiency and performance.
Main Benefits

Compared to a Raschig ring, MACH Engineering plastic Super Saddles offer improved strength and better mass transfer performance. Other advantages of choosing this product include:

  • Higher liquid hold-up: Greater liquid hold-up volume enables increased absorption efficiency with slow chemical reactions. With slow-moving gases that can damage the tower, a plastic Super Saddle ring also offers low residence time that minimizes potential damage.
  • Excellent versatility: With less sensitivity to liquid and vapor distribution than a ceramic alternative, plastic Super Saddles offer greater versatility for use in many applications.
  • Affordable pricing: Because plastic Super Saddles are the most cost-effective to produce, these plastic saddle rings come in multiple sizes and material options that allow for use in a range of chemical and industrial processes.

Compared to plastic INTALOX® saddles, plastic Super Saddles also offer the benefit of higher capacity and lower pressure drop and improved gas-liquid distribution.

See the difference for yourself by purchasing MACH Engineering plastic saddle rings today.

Applications & Compatible Chemicals

Use MACH Engineering plastic Super Saddles for:

  • Desulfurization and decarbonization: Desulfurization of fuels like natural gas minimizes corrosion by reducing sulfur levels in the fuel. The decarbonization process decreases the carbon content of metal. Both of these processes require the separation of gases from liquids, which a plastic Super Saddle can accomplish effectively.
  • The chemical processing industry: Sulphuric acid production is essential in the chemical processing industry. Whether in fertilizer manufacturing, chemical synthesis or mineral processing, many industries use plastic Super Saddles to produce sulphuric acid.
  • The pulp and paper processing industry: Paper processing plants use bleach plant absorbers to remove color-causing fibers like lignin. This chemical process uses plastic Super Saddles to separate liquids and gases.
  • The crude oil industry: Crude oil processing is a prime example of an industry that frequently uses plastic Super Saddle rings. A plastic Super Saddle will effectively remove other liquids and particulates from the crude oil during processing.
  • Liquid separation processes: Manufacturers use plastic Super Saddle rings in various applications involving drying, scrubbing and stripping towers.
  • General absorption, extraction and heat transfer: There are many applications for plastic Super Saddle rings besides the ones listed above. A plastic saddle ring is efficient in many applications requiring extraction, heat transfer or absorption.

While a ceramic saddle would be ideal for use in extremely high temperatures, a plastic Super Saddle is optimal for use in applications involving corrosive surfaces.

Contact MACH Engineering for information about whether or not plastic Super Saddles are right for your application. Drawing from our extensive engineering expertise, we can run a variety of process simulations to help you make an informed decision.

When to Choose Plastic Super Saddles Over Other Designs

The type of tower packing you select depends on several factors, including your application’s needs and environment. You might need to choose plastic Super Saddles if you experience any or all of the following circumstances:

  • You handle corrosive surfaces: Using a plastic Super Saddle ring can provide excellent corrosion resistance in several extractions and absorption applications.
  • You need mass transfer: Plastic Super Saddle packing media enables mass transfer through the force of gravity. The uneven surfaces of the grooved, saddle-shaped ring facilitate better mass transfer than a plastic INTALOX® saddle.
  • You want better gas-liquid distribution: The improved efficiency, mass transfer and contact area make a plastic Super Saddle ring more effective at gas-liquid distribution.
  • You need to minimize pressure drop: A plastic Super Saddle distributes pressure more evenly, ideal for certain situations requiring lower pressure drops.

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When to Choose Plastic Super Saddles

Why MACH Engineering?

MACH Engineering offers unparalleled material quality and a one-on-one approach to service that promotes the mutual success of our business and our customers. We specialize almost exclusively in tower packing and related products — drawing from our in-depth industry expertise, we are well-positioned to help our clients solve the unique or complicated challenges that are impacting their productivity.

To request a quote for plastic Super Saddle rings or learn more about any of our products, contact us via our online form or call us at (281) 550-3232 today.

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