In industrial operations where fluid control is critical, efficiency can make or break profitability. Among various types of valves used for flow regulation, butterfly valves stand out for their compact design, quick operation, and cost-effectiveness. At Alis Valves, we recently partnered with a leading process plant to optimize their pipeline systems. The results? A dramatic improvement in flow efficiency, reduced pressure loss, and lower energy consumption — all thanks to our engineered butterfly valves.
This case study takes you through the journey of how our valves transformed their operations and why you should consider upgrading your current valve systems.
The Challenge: Inefficient Flow and Pressure Drops
Our client, a large-scale manufacturing plant in the chemical industry, was facing ongoing issues with flow inefficiencies. They were using outdated gate and globe valves that were:
- Bulky and space-consuming
- Slow to operate
- Causing high-pressure drops
- Requiring frequent maintenance
- Leading to increased energy consumption
These issues led to downtime, high operating costs, and fluctuating flow rates — a serious concern in their tightly controlled production environment.
Our Solution: Installing High-Performance Butterfly Valves
After a comprehensive audit of their piping and valve systems, our team recommended replacing the outdated valves with Alis High-Performance Butterfly Valves.
Here’s why:
- Quarter-turn operation – Butterfly valves operate with a simple 90-degree turn, enabling quick shutoff or throttling.
- Compact design – They occupy less space, perfect for tight installations.
- Low-pressure drop – The streamlined disc design ensures minimal obstruction to flow, reducing energy losses.
- Corrosion-resistant materials – For chemical applications, our valves use Teflon or stainless-steel linings.
- Automation ready – Easily integrated with actuators and control systems for remote or automatic operation.
Implementation Process
We followed a step-by-step installation and upgrade strategy:
Step 1: Site Assessment
Our engineering team inspected flow paths, pressure zones, and maintenance history. We identified areas where butterfly valves would create the highest impact.
Step 2: Valve Selection
Based on temperature, fluid type, and pressure ratings, we selected double-offset and triple-offset butterfly valves suitable for aggressive media and high-cycling environments.
Step 3: Installation
Installation was performed during scheduled downtime. Old valves were removed and our butterfly valves were fitted using wafer and lug types, depending on pipe layout.
Step 4: Testing & Calibration
Each valve was tested for leak-tightness, torque requirements, and actuator response time to ensure optimal performance.
The Results: Improved Flow and Efficiency
Post-installation, the plant recorded measurable performance gains in just two months.
30% reduction in pressure drop
Compared to globe valves, butterfly valves offer a less turbulent flow path. This translated to a noticeable reduction in energy required to move fluids across long pipelines.
20% faster flow response time
The quick action of butterfly valves allowed operators to adjust flow with better precision and minimal lag.
25% lower maintenance costs
Our valves feature low-friction seat designs and corrosion-resistant materials. The plant saw fewer leaks, no seizing, and extended service life of critical components.
Enhanced automation integration
Butterfly valves were integrated into the plant’s SCADA system for remote monitoring and control — improving overall plant safety and reducing manual labor.
Real-World Use Case Snapshot
Industry: Chemical Manufacturing
Application: Cooling Water Line
Old System: Cast Iron Gate Valves
New System: Alis Triple-Offset Butterfly Valves
Flow Rate Increase: From 520 m³/hr to 655 m³/hr
Energy Savings: Approximately 18% reduction in pump energy consumption
Downtime Saved: 40 hours annually
Key Takeaways
- Butterfly valves are not just cost-effective — they’re smart. With high efficiency and low-pressure loss, they’re a game-changer for process optimization.
- Upgrading valves leads to long-term savings. You save on energy, maintenance, and labor — all of which affect your bottom line.
- Customization matters. At Alis Valves, we don’t sell one-size-fits-all. We engineer solutions based on your application.
Final Thoughts
Whether you’re running a chemical plant, water treatment facility, or a power generation unit, upgrading to butterfly valves can deliver big returns. The improved efficiency, automation readiness, and durability make them a must-have for modern process systems.
If your plant is still using outdated valve technology, now is the time to upgrade. Talk to our team at Alis Valves and let us help you engineer a solution that cuts costs and boosts performance.
Conclusion
Improving flow efficiency is not just about upgrading components — it’s about making smarter choices that enhance your entire operation. Our butterfly valves have proven to be a reliable and efficient solution for industrial plants looking to reduce energy consumption, lower maintenance costs, and improve process control. By choosing the right valve for the right application, our client experienced noticeable gains in performance, safety, and cost-effectiveness.
At Alis Valves, we don’t just supply valves — we deliver performance-driven solutions tailored to your industry needs. If you’re looking to optimize your plant’s efficiency, it may be time to consider how a well-engineered butterfly valve system can transform your operations.
