Plastic Raschig Ring vs Plastic Intalox Saddle: Which Random Packing Should You Select?

Plastic Raschig Ring and Plastic Intalox Saddle are both corrosion-resistant random packings, but their geometry creates very different relationships between surface area, void fraction, packed-bed weight and dry packing factor. DAIER's catalog-confirmed data show that Plastic Intalox Saddle provides substantially more geometric surface area at comparable 25, 38 and 50 mm sizes, but it does not consistently provide a lower dry packing factor or even a higher void fraction at every size. 

The correct selection question is:

Does the tower benefit more from the simple cylindrical geometry and lower packing-factor position of Plastic Raschig Ring, or from the much greater geometric surface area of Plastic Intalox Saddle?

There is no universal winner.

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1. Direct Answer

Choose Plastic Raschig Ring more readily when:

• simple open cylindrical geometry is preferred;
• the existing tower already uses Raschig Rings successfully;
• lower catalog dry packing factor is important;
• like-for-like replacement minimizes project risk;
• very high geometric surface-area density is not required.

Evaluate Plastic Intalox Saddle more strongly when:

• much higher geometric surface area is valuable;
• the selected size offers suitable void fraction;
• gas-liquid contacting is a strong priority;
• the tower is a new design or an intentional retrofit;
• the process can accept the higher packing-factor position shown in the supplier data.

The main lesson is:

Plastic Intalox Saddle provides more area, but “more area” does not automatically mean “lower pressure drop” or “more open bed.”

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2. Same-Size Catalog Comparison

DAIER's verified datasets provide exact comparisons at 25, 38 and 50 mm. 

The data reveal two separate effects:

1. Intalox Saddle strongly increases geometric area.
2. Its hydraulic descriptors do not move in one universally favorable direction.

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3. The Biggest Difference Is Specific Surface Area

At every directly matched size, Plastic Intalox Saddle provides much more surface area.

25 mm

Raschig Ring:

205 m²/m³

Intalox Saddle:

288 m²/m³

38 mm

130 vs 265 m²/m³

50 mm

93 vs 250 m²/m³. 

The difference becomes particularly large at 38 and 50 mm.

At 50 mm, the Intalox Saddle provides more than:

2.6 times the geometric surface area

of the same-nominal-size Plastic Raschig Ring.

That is a genuine product distinction.

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4. Why More Surface Area Matters

Higher geometric area creates more potential surface for:

• liquid wetting;
• gas-liquid contact;
• mass transfer.

That can make Intalox Saddle attractive when:

• contacting intensity is important;
• the process is reasonably clean;
• liquid distribution is good.

However:

geometric surface area is not automatically effective mass-transfer area.

Real performance also depends on:

• liquid load;
• gas velocity;
• wetting behavior;
• fluid properties;
• distributor performance.

Therefore a 2.6× geometric-area difference does not mean 2.6× process performance.

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5. 25 mm Gives a Surprising Result

At 25 mm:

Plastic Raschig Ring

• 205 m²/m³;
• 90% void;
• 112 kg/m³;
• 50,000 pcs/m³;
• 400 m⁻¹ packing factor.

Plastic Intalox Saddle

• 288 m²/m³;
• 85% void;
• 102 kg/m³;
• 97,680 pcs/m³;
• 473 m⁻¹ packing factor. 

The Intalox Saddle has:

• much more area;
• slightly lower bed weight;

but also:

• lower void fraction;
• almost twice as many elements;
• higher dry packing factor.

This is a very important trade-off.

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6. Why the 25 mm Comparison Matters

It directly disproves the simple claim:

“Saddle packing is always more open than Raschig Ring.”

At this supplier-confirmed 25 mm size:

• Raschig Ring = 90% void;
• Intalox Saddle = 85%.

So if hydraulic openness is the primary concern:

25 mm Intalox Saddle should not automatically be preferred simply because the geometry is more sophisticated.

Exact size data matter.

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7. 25 mm Intalox Saddle Has Almost Twice as Many Pieces

The packing populations are:

• Raschig Ring — 50,000 pcs/m³;
• Intalox Saddle — 97,680 pcs/m³. 

That creates a much finer element population.

This helps explain why selecting packing from nominal size alone is misleading.

Both are called:

25 mm

but their individual element proportions and bed structures are very different.

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8. 38 mm Completely Changes the Voidage Ranking

At 38 mm:

Raschig Ring

• 130 m²/m³ surface area;
• 89% void;
• 70 kg/m³;
• 19,000 pcs/m³;
• 305 m⁻¹.

Intalox Saddle

• 265 m²/m³;
• 95% void;
• 63 kg/m³;
• 25,200 pcs/m³;
• 405 m⁻¹. 

Now Intalox Saddle provides both:

• more than twice the geometric surface area;
• substantially higher void fraction.

But its packing factor is still higher.

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9. Higher Voidage Can Coexist with Higher Packing Factor

The 38 mm comparison is particularly important:

Raschig Ring

89% void305 m⁻¹ packing factor

Intalox Saddle

95% void405 m⁻¹ packing factor.

The packing with more open bed volume has the higher dry packing factor.

This proves:

Void fraction and packing factor describe different aspects of random-packing geometry.

You cannot use one as a substitute for the other.

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10. Why This Matters for Pressure-Drop Claims

It would be incorrect to say:

“38 mm Intalox Saddle has 95% void, therefore it must have lower pressure drop.”

The verified dry packing factor points in the opposite direction.

But it would also be incorrect to say:

“Its pressure drop must be higher because its packing factor is higher.”

Actual tower pressure drop still depends on:

• gas velocity;
• liquid flow;
• gas density;
• fluid properties;
• packed height.

The correct conclusion is:

38 mm Intalox Saddle and Raschig Ring require actual hydraulic evaluation; void fraction alone cannot decide the result.

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11. 50 mm Makes the Contact-Area Advantage Even Stronger

At 50 mm:

Raschig Ring

• 93 m²/m³;
• 90% void;
• 68 kg/m³;
• 6,500 pcs/m³;
• 177 m⁻¹.

Intalox Saddle

• 250 m²/m³;
• 96% void;
• 75 kg/m³;
• 9,400 pcs/m³;
• 323 m⁻¹. 

Intalox Saddle now combines:

• much higher geometric area;
• higher void fraction.

But it is also:

• heavier;
• higher in packing factor;
• more densely populated by elements.

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12. 50 mm Is the Strongest Mass-Transfer Screening Case

The geometric-area difference is:

250 vs 93 m²/m³.

That is approximately:

157 m²/m³ additional geometric area

for Intalox Saddle.

If a project needs:

• high contacting area;
• plastic chemical resistance;
• 50 mm-class random packing;

then Intalox Saddle deserves serious evaluation.

But that higher area comes with an important hydraulic trade-off.

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13. The 50 mm Packing-Factor Difference Is Also Large

At 50 mm:

• Raschig Ring = 177 m⁻¹;
• Intalox Saddle = 323 m⁻¹. 

So Intalox Saddle has:

about 82% higher dry packing factor

as a catalog geometric parameter.

That does not mean 82% more pressure drop.

But it clearly means:

the two products occupy very different hydraulic geometry positions.

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14. Which Has Lower Packed-Bed Weight?

The answer changes with size.

25 mm

Intalox Saddle is lighter:

• 102 vs 112 kg/m³.

38 mm

Intalox Saddle is again lighter:

• 63 vs 70 kg/m³.

50 mm

Raschig Ring becomes lighter:

• 68 vs 75 kg/m³. 

So neither family is universally lighter.

Another reason to avoid family-level assumptions.

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15. Which Has More Elements per Cubic Meter?

Intalox Saddle has more pieces at every exact matched size:

 

But despite its larger packing population, Intalox Saddle has:

• higher void fraction at 38 and 50 mm.

Again:

packing population alone does not define bed openness.

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16. Which Is Better for Contact-Intensive Service?

Plastic Intalox Saddle has the stronger geometric-area position.

This becomes particularly strong in the larger matched sizes.

38 mm

265 vs 130 m²/m³.

50 mm

250 vs 93 m²/m³.

This makes Intalox Saddle a strong preliminary candidate where:

• high potential wetted area;
• gas-liquid contacting

are priorities.

Actual mass transfer still needs process data.

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17. Which Is Better When Lower Packing Factor Matters?

Plastic Raschig Ring has the lower catalog dry packing factor at every matched size.

25 mm

400 vs 473 m⁻¹.

38 mm

305 vs 405.

50 mm

177 vs 323. 

Therefore Raschig Ring deserves stronger screening when:

• simpler hydraulic geometry;
• lower packing-factor position

are major priorities.

This is not the same as guaranteeing lower operating ΔP.

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18. Which Is Better for High Gas Throughput?

There is no universal answer from these physical data alone.

Intalox Saddle has:

• much higher void fraction at 38 and 50 mm.

Raschig Ring has:

• lower dry packing factor.

These parameters point in different directions.

Therefore:

high-throughput selection requires actual hydraulic evaluation rather than selecting from product reputation.

This is one of the strongest reasons this comparison page deserves to exist.

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19. Which Is Better for Fouling?

Raschig Ring has the simpler geometry:

• one basic cylindrical flow passage.

Intalox Saddle creates:

• curved surfaces;
• more complex element-to-element geometry;
• more pieces per cubic meter.

Where fouling includes:

• crystals;
• suspended solids;
• sticky deposits;

simple geometry can become valuable.

However, the higher void fraction of larger Intalox Saddle sizes can also be favorable.

Therefore fouling selection should consider:

• deposit type;
• size;
• cleaning strategy.

Neither packing should be called non-clogging.

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20. Existing Raschig Ring Tower: Should You Upgrade to Intalox Saddle?

Only if there is a real process reason.

Potential reasons include:

• insufficient mass-transfer contacting;
• new operating duty;
• changed throughput;
• intentional packed-bed optimization.

For example, changing:

50 mm Raschig Ring → 50 mm Intalox Saddle

changes surface area:

93 → 250 m²/m³

but also changes dry packing factor:

177 → 323 m⁻¹.

That is not a routine replacement.

It is an engineering retrofit.

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21. Existing Intalox Saddle Tower: Should You Change to Raschig Ring?

Possible reasons include:

• desire for simpler geometry;
• fouling problems;
• hydraulic operating concerns;
• reduced need for very high surface area.

But switching back to Raschig Ring may dramatically reduce geometric contact area.

Therefore the process duty must be reviewed before conversion.

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22. Do Not Automatically Keep the Same Packed Height

The surface-area difference can be enormous.

At 50 mm:

• Raschig Ring — 93 m²/m³;
• Intalox Saddle — 250 m²/m³.

Changing geometry while keeping:

• the same nominal size;
• the same bed height

does not guarantee equivalent process performance.

A retrofit should review:

• mass-transfer duty;
• hydraulic operating point;
• bed height.

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23. 76–80 mm Shows the Families Continue to Diverge

The largest verified products are not exactly the same nominal size:

Plastic Intalox Saddle 76 mm

• 200 m²/m³;
• 97% void;
• 60 kg/m³;
• 3,700 pcs/m³;
• 289 m⁻¹. 

Plastic Raschig Ring 80 mm

• 90 m²/m³;
• 95% void;
• 66 kg/m³;
• 1,820 pcs/m³;
• 130 m⁻¹. 

These are near-size-class, not exact same-size products.

But the pattern remains striking:

Intalox keeps much more area while Raschig retains a much lower packing-factor position.

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24. Tower Diameter Still Matters

Large random packing needs enough elements across the tower cross-section.

Even if 76 mm Intalox Saddle offers:

• high surface area;
• high voidage;

it may not be appropriate for a narrow tower.

Likewise, a small Raschig Ring may create an unnecessarily fine bed in a large tower.

Therefore:

first identify an appropriate size class from tower geometry, then compare packing families.

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25. Plastic Material Selection Is Separate

This article compares packing geometry.

It does not establish that every polymer is suitable for the actual process.

Plastic random packing can be manufactured from different polymers depending on product and supplier capability.

Material compatibility must consider:

• exact chemical;
• concentration;
• temperature;
• oxidizers;
• solvents.

Do not choose polymer from pH alone.

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26. Support Grid Compatibility

Raschig Ring and Intalox Saddle have very different element proportions.

For example, a nominal 50 mm Intalox Saddle is catalog-listed with an approximate geometry of:

50 × 25 × 1.5 mm

whereas a 50 mm Raschig Ring is a different cylindrical geometry.

Changing packing family should therefore include review of:

• support openings;
• retention;
• open area;
• mechanical loading.

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Decision Table

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27. Quick Selection Guide

Favor Plastic Raschig Ring more readily when:

• simple geometry is important;
• existing Raschig operation is proven;
• lower catalog packing factor is a priority;
• fouling risk makes simple passages attractive;
• high surface-area density is unnecessary.

Evaluate Plastic Intalox Saddle more strongly when:

• greater geometric contact area is important;
• 38–76 mm open saddle geometry fits the tower;
• mass-transfer duty is demanding;
• project hydraulics can support the selected model.

Do not decide only from:

• void fraction;
• surface area;
• packing factor;
• nominal size.

All four can tell different parts of the engineering story.

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Common Selection Mistakes

Assuming Intalox Saddle Always Has Higher Void Fraction

False at 25 mm: 85% vs 90% for Raschig Ring.

Assuming Higher Void Fraction Means Lower Packing Factor

False at 38 and 50 mm in the verified data.

Assuming More Surface Area Guarantees Better Tower Performance

Effective wetted area and operating conditions matter.

Assuming Lower Packing Factor Guarantees Lower Actual ΔP

Real flow conditions are required.

Ignoring Packing Population

The same nominal size can contain radically different numbers of elements.

Treating 76 mm Intalox and 80 mm Raschig as Exact Equivalents

They are only near-size comparisons.

Changing Geometry Without Reviewing Bed Height

Mass-transfer and hydraulic performance may change materially.

Ignoring Support-Grid Retention

Saddle and cylindrical elements have different characteristic dimensions.

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Frequently Asked Questions

Which has more surface area: Plastic Raschig Ring or Plastic Intalox Saddle?

Plastic Intalox Saddle has significantly higher verified surface area at matched 25, 38 and 50 mm sizes. 

What is the 25 mm comparison?

Raschig Ring:

• 205 m²/m³;
• 90% void;
• 112 kg/m³;
• 400 m⁻¹.

Intalox Saddle:

• 288 m²/m³;
• 85% void;
• 102 kg/m³;
• 473 m⁻¹.

Why does 25 mm Intalox Saddle have lower voidage?

Because nominal size does not determine bed voidage. Element proportions and saddle geometry differ substantially from a cylindrical ring.

What is the 38 mm comparison?

Raschig:

• 130 m²/m³;
• 89% void;
• 305 m⁻¹.

Intalox:

• 265 m²/m³;
• 95% void;
• 405 m⁻¹.

What is the 50 mm comparison?

Raschig:

• 93 m²/m³;
• 90% void;
• 177 m⁻¹.

Intalox:

• 250 m²/m³;
• 96% void;
• 323 m⁻¹.

Which has lower packing factor?

Plastic Raschig Ring at all directly matched sizes in the DAIER catalog data.

Does that mean Raschig Ring always has lower pressure drop?

No. Actual pressure drop requires gas and liquid operating data.

Which is better for mass-transfer contact?

Plastic Intalox Saddle provides much more geometric surface area, but actual effective performance depends on wetting and operating conditions.

Which is better for fouling?

Raschig Ring's simple geometry may be attractive in dirty service, but final selection depends on fouling mechanism and packing size.

Can one directly replace the other at the same nominal size?

No. Treat the change as a retrofit because surface area, voidage, packing factor and bed geometry differ substantially.

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Selection Takeaway

Plastic Raschig Ring vs Plastic Intalox Saddle is not a simple “old cylinder vs better saddle” comparison. The supplier-specific data reveal a much more useful trade-off.

At 25 mm:

Raschig → 205 m²/m³ / 90% void / 400 m⁻¹

versus:

Intalox → 288 m²/m³ / 85% void / 473 m⁻¹.

At 38 mm:

Raschig → 130 m²/m³ / 89% void / 305 m⁻¹

versus:

Intalox → 265 m²/m³ / 95% void / 405 m⁻¹.

At 50 mm:

Raschig → 93 m²/m³ / 90% void / 177 m⁻¹

versus:

Intalox → 250 m²/m³ / 96% void / 323 m⁻¹. 

The consistent lesson is:

Plastic Intalox Saddle strongly increases geometric surface area.

But the hydraulic story is more complicated:

• 25 mm Intalox has lower voidage;
• 38–50 mm Intalox has higher voidage;
• Intalox has higher dry packing factor at all three matched sizes.

Therefore the correct selection sequence is:

Process Duty → Required Contacting Area → Tower Diameter → Hydraulic Constraint → Fouling → Compare Exact Size Data → Polymer Compatibility → Retrofit / Internals Review

The key principle is:

Never use “saddle geometry is more advanced” as the selection rule. Compare the exact supplier model and decide whether the process truly needs the additional surface area enough to justify its different hydraulic geometry.