Most of us have bought cheap sneakers and found them falling apart a year later. It feels like a waste to replace them so soon, especially when you realize a higher-quality pair would have lasted several years.
When you’re dealing with processing equipment, the cost of a cheap purchase can hit your business much harder. Some losses are easier to calculate, while others add up in unseen or unexpected ways.
Downtime is a big one. Then there’s shorter lifecycles, added costs for safety features, and the risk of cross-contamination and recalls. It’s even harder to put a price on scalability, service, and optimization, but these are also things you can miss out on when you go for the cheapest option.
You need to weigh all these factors when you evaluate the ROI of a rotary airlock valve.
Does the valve reduce downtime?
For the largest manufacturers, unplanned downtime costs an estimated $260,000 per hour. For smaller shops, hourly losses are more likely to be in the hundreds or thousands — which is still a lot.
If a rotary valve is built with poor materials or designed without your process in mind, it causes more downtime than necessary. It doesn’t hold up to wear-and-tear, so it breaks down more, or it requires more maintenance to keep it running. You could also see frequent jams or leakage, depending on your material.
To deliver better ROI, your vendor should be able to explain how the valve is engineered, built, and tested for quality, as well as why that particular valve’s features are best suited to your application.
Is the valve designed for longer lifecycles?
A cheaply-built rotary valve is not designed for durability or longevity, and the same goes for its parts. If you have to replace rotors, seals, and bearings more often than necessary — all requirements for the safe and efficient operation of a valve — you’re paying more over time.
These costs add up, but it’s worse if you need to frequently replace the valve itself. As such a critical part of your conveying system, valves shouldn’t be designed as disposable commodities. It’s worth seeking out a valve that’s engineered for longevity in your application, especially if you’re working with abrasive or corrosive materials.
Does the valve have built-in safety features?
Sometimes a valve seems cheap because the vendor doesn’t disclose all the costs up front. Unfortunately, we’ve seen this happen often with features required for OSHA or NFPA compliance.
We don’t believe essential safety features should be packaged as an “extra.” At ACS Valves, they’re built in as needed, designed around your specific compliance needs. Your vendor should be able to explain how their equipment’s features help you achieve compliance.
Does the valve reduce contamination risks?
Coming back to the valve’s materials of construction, you can identify a quality valve by its smooth, crevasse-free surfaces. Cheaper builds will have pits and cracks — prime spots for bacteria to grow. Unless you spend extra downtime cleaning them, you could end up with cross-contamination or a recall, which is costly both to your budget and reputation.
Strong materials and coatings add durability to the valve, preventing it from developing crevasses and protecting your investment.
Is the valve scalable?
Let’s say you want to introduce a new material to your conveying line or ramp up production. Can a cheap valve keep up with your plans? You may need a higher temperature or pressure rating, which means throwing out the valve prematurely to buy a new one.
To plan ahead for quick growth or sudden changes in production, you can ask your vendor for a model with more flexibility and customizability, ensuring your valve can tackle whatever the future brings.
Do you have support from valve experts?
Bad service may not cost you money directly, but a frustrating phone call can take a toll on your sanity. Delayed responses waste time, and refusal to help with repairs or troubleshooting can leave you stuck with faulty equipment.
It’s worth finding a vendor that stands behind their product. They should send quotes promptly, offer help when you need it, and take the time to understand your system.
When a vendor gets to know your process, they can recommend ways to optimize performance. For example:
• Options to reduce energy consumption.
• Features to speed up cleaning.
• Designs to improve material release and eliminate dead zones.
• Configurations to meter consistently.
• Coatings to reduce wear and extend the valve’s lifecycle.
• Types of parts that last longer and are easier to maintain.
So, how much?
At the end of the day, price still matters. ACS Valves does its best to deliver on price, quality, and delivery time. Contact us to request a quote for a rotary valve that adds value to your process.
