Complete Valve Manufacturing Process

The design process begins with detailed CAD models and 3D pattern drawings that shape the core geometry of each valve. Before moving into physical production, performance and functionality are validated through advanced computer-aided simulations. After the virtual testing phase, CAM data is generated to guide the precise machining of the casting patterns.

Pattern Production

Pattern materials are selected based on casting volume and production requirements. For high-volume manufacturing, aluminium patterns are preferred due to their durability and suitability for automated moulding systems. For smaller batches, prototyping or large-size components, wooden patterns provide flexibility and cost efficiency.

• Aluminium Gate Valve Body Pattern
• Aluminium Pattern Stock
• Wooden Butterfly Valve Body Pattern

Foundry & Casting

Our foundry operates with full, semi-automatic and manual moulding capabilities to accommodate different valve sizes and project needs. Both greensand and resin-sand moulding processes are used, with or without cores, enabling casting weights ranging from 0.1 kg to 8,000 kg.

Automated Casting Lines

High-precision automated systems ensure repeatable casting quality and faster production cycles.

Surface Preparation

After casting, components undergo sand blasting / shot blasting to clean surfaces and prepare them for machining, coating and final assembly.

Machining

Our machining department is equipped with a large number of CNC machines, allowing us to achieve high-precision tolerances and consistent quality across a wide range of valve components.

Using modern CNC lathes and dedicated machining centres, we are able to process valve bodies and parts up to DN3000, ensuring accurate dimensions and reliable performance in demanding applications.

• BFV milling machines for butterfly valve bodies and components
• Ball valve CNC drilling units for precise port and passage machining
• Heavy-duty turning lathes for large-diameter and long-length parts

Coating

Our primary coating method is Electrostatic / Fusion-Bonded Powder Epoxy (FBE), applied across all valve sizes—including the largest diameters—to ensure long-term durability and corrosion protection.

For specific applications, industrial spray epoxy coatings are also used, providing an alternative finish for specialised valve types.

Standard powder epoxy coatings are applied at a minimum thickness of 250 microns, while 300 microns or higher can be provided upon request. When required, WRAS-approved coatings are applied to meet drinking water standards.

After coating, a full Coating Inspection Report is generated to document quality, thickness, and application conformity.

Assembly

Our assembly teams are specialised in each specific valve type, ensuring that every product is built according to its dedicated procedure and technical requirements.

Precision assembly guiding components are used to position parts correctly, minimise errors and maintain consistent product quality.

Regular assembly trainings are conducted to prevent missing components, enhance efficiency and continuously improve workmanship on the production line.

Hydrostatic Testing

After assembly, every valve undergoes a full hydrostatic test without exception, in compliance with EN 12266-1 and EN 12266-2 standards. Rate A is applied as the acceptance criterion to ensure zero leakage and maximum operational safety.

Shell tests are performed at PN × 1.5 pressure levels to verify structural integrity.

Seat tests are carried out at PN × 1.1 to confirm reliable sealing performance under working pressure conditions.