Mismatched Flanges & Failing Valves? See How JRVAL Solved It.

In complex industrial environments, seemingly simple components like valves can become major points of failure if not specified correctly. This case study highlights how JRVAL, a leading china butterfly valve manufacturer, addressed critical issues for a major food processing client by providing a tailored double flanged butterfly valve solution, moving beyond the pitfalls of "universal" products.

⊙ Part I: The Challenge: Mixed Standards and Operational Failures

› Client Background: A large food processing company in Henan ("Xianmei Foods") required a batch of DN100 and DN150 manual carbon steel butterfly valve units for their steam network and cooling water systems. Their aging facility presented a significant challenge: a mix of older German-standard (DIN valve) pipelines and newer national-standard (GB) pipelines.

› The Problem & Losses: Xianmei Foods initially sourced "universal" handle-operated butterfly valves from Supplier B. This led to two disastrous outcomes:

•  Flange Mismatch & Severe Leakage: The "universal" valves failed to properly align with the DIN-standard flanges. Bolt hole misalignment and poor gasket contact resulted in steam and water leaks after pressurization. This caused daily energy losses, created a high-humidity environment damaging food production, and posed a significant slip hazard. The ensuing production shutdown for repairs led to direct economic losses exceeding ¥10,000.

•  Inadequate Handle Design: The competitor's butterfly valve with handle featured a flimsy, stamped steel lever that rusted in the humid plant and bent under the torque required for operation. Loose fixing screws caused the valves to fail, disrupting process control and wasting valuable operator time.

⊙ Part II: The JRVAL Solution: Precision, Durability, and Reliability

Facing this crisis, Xianmei Foods discovered JRVAL. Our technical team proposed a solution that addressed every point of failure.

› Precision-Matched Flanges: Eradicating Leaks at the Source

•  JRVAL's Approach: We rejected the "one-size-fits-all" concept. For Xianmei Foods, we supplied two distinct valve types within the same order: valves with flanges precision-machined to strict DIN valve standards for the older pipelines, and valves with flanges compliant with GB standards for the new ones. This precise butterfly valve flange connection ensured a perfect, leak-proof seal.

•  The JRVAL Difference: Our commitment to single-standard precision eliminates guesswork and fundamentally resolves leakage risks associated with mixed-standard systems. It’s a core principle of our valve machining and butterfly valve assembly process.

› Optimized Design: Robust Handles and Reinforced Bodies

•  JRVAL's Approach: We supplied a butterfly valve lever operated model designed for industrial reality. The butterfly valve handle was made from more robust materials like ductile iron or thickened steel, ensuring it would not bend or fail. Furthermore, we recommended a valve body with increased wall thickness, providing a higher safety margin and extended service life even in demanding steam applications.

•  The JRVAL Difference: We focus on the entire valve unit's reliability, not just the body. The ergonomic and durable handle butterfly valve, combined with a reinforced body, far exceeds the performance of standard off-the-shelf products.

› Guaranteed Quality: Material Integrity and Craftsmanship

•  JRVAL's Approach: We provided full material certification for the carbon steel butterfly valve. The butterfly valve casting, produced in our ISO9001-certified butterfly valve factory, features clear, as-cast lettering and retains its original foundry finish—a testament to our confidence in quality.

•  The JRVAL Difference: This transparency in materials and manufacturing provides clients with easy verification and long-term traceability, eliminating concerns about substandard components.

⊙ Part III: The Result: Restored Safety, Efficiency, and Confidence

Upon installing JRVAL’s custom double flanged butterfly valve units, Xianmei Foods experienced immediate and total success. Every connection, whether to a DIN or GB flange, was perfectly sealed with zero leakage. The reinforced handles made operation smooth and effortless, and the robust construction gave the client confidence in the long-term stability of their pipeline. JRVAL's solution not only fixed the immediate problems but also significantly upgraded the overall safety and reliability of their system, earning high praise from the client.

⊙ Conclusion: Your Partner for Custom Industrial Valve Solutions