5 Benefits of Custom Valves for Industrial Systems

Custom valves have a number of advantages over standard versions when used in industrial systems. They are specifically made for particular applications and so are designed to meet the challenges that those applications present. 

Because of this, they provide greater operational efficiency, improved safety and a reduction in costs over the long-term.

The Role of Valves

A valve has three main functions:

• to control the flow rate of fluid or gas through a system by adjusting the extent of the valve’s opening, which is important where precise measurement is needed
• to shut off sections of a system so that repair and maintenance work can be carried out safely without having to disrupt the entire operation
• to ensure a safe pressure is maintained, preventing failures and harmful conditions due to excess pressure.

Custom valves are better able to carry out these functions because they are specifically designed for the conditions and will fit perfectly. Standard valves, on the other hand, sometimes have to be made to fit so there is a greater potential for failures.

Benefit 1: Precision Tailoring for Specific Applications

Custom valves can cope with problems for which standard valves are not designed. They are therefore perfect for niche applications and will deal with process requirements and operating conditions that are unique to those applications. Standard valves may not be available to address particular challenges presented by certain materials, flow rates and processing needs, but custom versions can be developed to deal with them perfectly.

Custom valves can be made with materials that resist high temperatures, corrosive substances, variable flow rates and extreme pressure. By meeting these challenges, they deliver high performance with minimal risk of failure. They can also incorporate advanced control mechanism and smart features to enable precise control and real-time monitoring, and can easily adapt to changing requirements as situations evolve.

Benefit 2: Enhanced Durability and Longevity in Harsh Environments

Because they are designed for specific applications and to withstand particular conditions, and are made using suitable materials, custom valves have great durability. As a result, they have improved reliability and are much less likely to fail and cause downtime, so that repairs and replacements are minimised.

Custom valves can be specifically made to withstand harsh environments and so will not be prone to corrosion or to degrade in other ways. So they can be relied on to work for long periods and provide uninterrupted processing that will improve productivity.

Benefit 3: Improved Safety and Compliance

Custom valves are often used in manufacturing processes where harsh chemicals or other hazardous liquids are used, sometimes under extreme pressure. They are therefore designed to handle these materials safely without leaking, thereby helping to maintain worker safety by preventing those materials coming into contact with employees.

By eliminating leaks and preventing overflows, custom valves stop materials coming into contact with each other and causing chemical reactions. They are able to handle materials at different temperatures without becoming corroded or damaged in other ways, and are also used in pharmaceuticals and food processing where they prevent contamination and ensure strict hygiene standards are met.

Many industries are governed by various regulations that relate specifically to safe operation. A failure to comply can result in severe financial penalties in addition to the cost of disruptions to production. To ensure worker safety and compliance with regulations, custom valves may be the obvious choice.

Benefit 4: Space Optimisation and Simplified Installation

Since custom valves are specifically designed and manufactured for a particular application, they can often incorporate a number of functions in one unit. As a result, they require less space than separate components would, reduce the number of points where leaks can occur and make the whole system much more simple.

Fewer components mean that assembly and installation are made much easier and quicker. So the combination of easy installation and reduced space requirements means that custom valves offer great flexibility in how and where they are used.

Benefit 5: Cost-Efficiency and Return on Investment (ROI)

Custom valves are able to contribute to improved cost-efficiency in a number of ways:

• they are designed to fit in with existing plant layouts rather than the layout having to be adapted to accommodate standard valves, so the operation is streamlined and energy consumption may be reduced
• by minimising leaks and spills, custom valves reduce wastage and so save money as well as lowering impacts on the environment
• since they are designed to withstand changes in temperature and pressure for various materials, these materials are transferred quickly and more efficiently.

Although custom valves have a higher initial cost than standard valves due to necessary design and tooling expenses, they will repay that initial investment through cost savings and increased efficiency. Reduced downtime and lower maintenance costs combined with increased reliability and service life will ensure the total cost of ownership is often less than for standard valves and so the return on investment is much higher.

Conclusion: Investing in Performance and Reliability

Although custom valves are undeniably more costly to buy and may take longer to supply due to the need for design and development, they are undoubtedly worth the time and effort. They are vital components when dealing with gas, oil and various chemicals and liquids. Being specifically made for an application, they do the job perfectly, preventing backflows, spills and leaks.

By reducing downtime and accidents, they ensure continuous production, which increases productivity and profitability. Reliability is one of the main factors that makes custom valves worth the investment and the perfect fit that customisation brings means risks are minimised and workers are protected.

Paying a premium price for a custom valve that is designed to do a particular job well will always pay dividends over the long term. Unlike standard valves that often require compromises to make them work reasonably well, custom versions will always work effectively, reliably and at peak efficiency because that is exactly what they are designed to do.