Does your industry have you changing bulk materials like you change socks? We’re all for clean socks, but in a demanding processing environment, changes can cause friction in your process.
When market demands change rapidly, you may need to keep up by switching ingredients every so often. Since you probably want to avoid buying new equipment every single time you swap, you should ensure your machinery plays well with different types of material.
In the case of rotary airlock valves, certain models are ideal when you need to switch gears quickly. If your goal is to swap materials while spending less time and money on maintenance and replacements, look for these valve types and features.
What are the most versatile valve choices?
For sheer customizability, we usually recommend the CI Series and MD Series rotary valves. They both have a durable yet flexible build that can be sized and configured for a wide range of applications.
Each one also comes in a Quick-Clean model, which is built on a rail system for fast and easy access to the rotor. This design drastically cuts down cleaning time, so they’re often used in industries where regulatory compliance is key, like food and pharmaceuticals. Quick-Cleans are also popular in non-sanitary applications because the speed of maintenance provides a big productivity boost — and makes ingredient swaps so much easier.
If you’re looking to convey multiple ingredients at the same time, the Multi-Port might be for you. Like several valves rolled into one, it features multiple compartments you can use in split feeds, making it much more versatile than a standard valve. It’s also possible to use it for quick material swaps by reserving a compartment or two for later use.
What materials and coatings can help?
Some materials are more abrasive, corrosive, or sticky than others, so your rotary valve’s surfaces should be able to accommodate different types. Materials like stainless-steel with a 180-grit polish can help prevent material buildup, prevent corrosion, and slow the formation of cracks and crevices inside the valve.
Coatings can serve similar purposes, but they’re applied to the internal components of your valve. More abrasive applications like construction may need hard chrome or tungsten, fine powders in food processing may need rotors with Lectrofluor, and chemical manufacturers may need the anti-corrosive XTR-Coat.
Your rotary valve supplier can recommend the best materials and coatings to handle different ranges of material characteristics in your industry.
How does rotor speed affect a valve’s performance?
Unlike those with chain drives, rotary valves with direct-drive motors are generally easier to adjust for different conveying materials. They’re more energy efficient and pose less risk of contamination because they don't have a chain that requires lubrication.
Direct drives can also be equipped with a variable frequency drive (VFD), which comes highly recommended for multiple material types. A VFD lets you increase or decrease the rotor’s speed of rotation by turning a dial.
Why does it matter? Different materials require different levels of airflow. Too much air for certain materials can create a sandblasting effect that damages your equipment, while too little air can cause blockages further down the conveying line. The VFD lets you fine-tune airflow as you swap materials, helping you minimize extra cleanups, damage, and safety risks.
How do I configure a valve for multiple materials?
You’ll need to mix and match these options to find the right combination for your application, but you don’t have to do it alone. The experts at ACS Valves are happy to help you size and configure a rotary valve that keeps up with fast-paced processing requirements. Just give us a call.
