Dispensing valves are vital components in industries that require precise fluid control, such as manufacturing, electronics, and food processing. However, regardless of their dependability, issues may still occur that can jeopardise their effectiveness and the product’s quality.
Discover the causes of the typical dispenser valve problems and learn their corresponding solutions.
1. Inconsistent Flow Rates
Causes
Inconsistent flow rates can result from improper calibration, clogged valve components, or fluctuations in input pressure. This issue often occurs when the dispensing valve is incompatible with the material’s viscosity or when debris obstructs the valve.
Solutions
- Calibration: Regularly calibrate the dispense valve according to the material’s viscosity and application requirements.
- Cleaning: Disassemble the valve and clean it thoroughly to remove clogs. Use manufacturer-recommended cleaning agents.
- Pressure Control: Ensure consistent input pressure by maintaining proper equipment settings and checking for leaks in supply lines.
- Upgrade the Valve: Consider switching to a dispensing valve designed for high-viscosity or specialised materials if the problem persists.
2. Leakage or Dripping
Causes
Leakage usually occurs due to worn-out seals, improper assembly, or using dispensing valves beyond their rated pressure.
Solutions
- Inspect Seals: Replace worn or damaged seals immediately. Always use compatible seal materials for the fluid being dispensed.
- Correct Assembly: Ensure all components are correctly aligned and tightened during installation.
- Pressure Regulation: Avoid exceeding the recommended operating pressure for the dispenser valve. Invest in a heavy-duty valve if higher pressures are required.
- Preventative Maintenance: Regularly inspect valves for early signs of wear or damage.
3. Clogging and Material Build-Up
Causes
Clogging occurs when materials, especially high-viscosity or quick-curing ones, solidify inside the dispensing valve. Poor cleaning practices or incompatible valve designs exacerbate this issue.
Solutions
- Flush After Use: Clean the dispensing valve immediately after each use with appropriate solvents.
- Use Compatible Materials: Ensure the dispense valve can handle the material’s properties, such as viscosity and cure time.
- Install Filters: Use inline filters to prevent debris from reaching the valve.
- Periodic Cleaning: Schedule regular cleaning even during extended operational periods to minimise material build-up.
4. Air Bubbles in the Dispensed Material
Causes
Air bubbles form when air enters the system through faulty connections, improper priming, or using materials prone to air entrapment.
Solutions
- Check Connections: Inspect supply lines for loose fittings and seal any leaks.
- Prime the System: Ensure the dispensing valve and supply lines are free of air pockets before use.
- Material Handling: Degas the material before loading it into the system if air entrapment is a known issue.
- Use Anti-Bubble Valves: Consider using specialised dispensing valves to eliminate air bubbles.
5. Slow or Irregular Response Times
Causes
This issue often stems from worn-out internal components, inadequate maintenance, or incorrect valve selection.
Solutions
- Inspect Components: Regularly inspect internal parts, such as springs and diaphragms, for wear and replace them as needed.
- Upgrade Controls: Use advanced control systems for better response time regulation.
- Choose the Right Valve: Match the dispensing valve to the application’s requirements to avoid operational delays.
- Preventive Maintenance: Conduct regular checks to identify and replace deteriorating parts.
6. Short Valve Lifespan
Causes
A shortened valve lifespan may result from excessive wear due to improper use, incompatible materials, or inadequate maintenance routines.
Solutions
- Follow Manufacturer Guidelines: Operate the dispensing valves within the specified pressure and temperature ranges of the manufacturer.
- Material Compatibility: Use dispensing valves made of materials that resist corrosion or wear from the dispensed fluid.
- Maintenance Schedule: Implement a robust maintenance plan to clean, lubricate, and inspect valves periodically.
- Invest in Durable Valves: Choose dispenser valves designed for extended life cycles for high-demand applications.
7. Over-Dispensing or Under-Dispensing
Causes
This problem often results from improper calibration, fluctuating pressure, or using the wrong dispense valve for the application.
Solutions
- Recalibrate the Valve: Set the dispenser valve to the correct flow rate and dispense duration.
- Stabilise Input Pressure: Use pressure regulators to maintain consistent supply pressure.
- Upgrade Equipment: Opt for advanced dispensing valves with precision flow controls to ensure accurate dispensing.
- Train Operators: Ensure operators are trained to calibrate and use the equipment correctly.
Final Thoughts
Adherence to operating requirements, appropriate valve selection, and routine maintenance are all necessary to address frequent issues with dispense valves. Implementing these solutions ensures consistent performance, reduces downtime, and extends the lifespan of dispensing valves. Industries can maintain high production standards and optimise their dispensing systems by prioritising these practices.
Visit Unicontrols for reliable and high-quality dispensing solutions.
