An incredible ROI story built on collaboration, testing, and the right valve solution.
When one of our industrial customers came to us a couple of years ago, they were stuck in a frustrating — and costly — maintenance cycle. Their operation, which uses CO₂ in a chemically intensive production process, was burning through standard ball valves every 30 to 90 days.
This wasn’t just inconvenient. It was expensive. They were spending $40,000 every month on valve repairs, and the loss of CO₂ during failures cost them nearly $1 million. With mounting downtime, wasted media, and recurring maintenance, they knew they needed a more reliable solution — and fast.
The Harsh Reality of Their Process Environment
The manufacturing process involves aggressive chemicals like silica precursors, alcohols, acids, and bases, used during various sol-gel phases. These substances are highly corrosive to most standard valve materials, especially at high concentrations or over long durations.
As the media progresses through different stages, it produces fine particulate matter and solid residues that enter the flow stream. These act like abrasives — eroding valve seats, stems, and seals over time. Combine that with high-pressure CO₂ usage, frequent flow control demands, and regular purging, and you’ve got a highly punishing environment for valves
It’s no surprise the standard ball valves couldn’t keep up.
Our Approach: Dig In, Test, Solve
Rather than suggest another off-the-shelf replacement, the Collins team took a more strategic route. We partnered with Conval, a respected valve manufacturer known for producing rugged, high-performance industrial valves. Together, we launched an in-depth testing phase to identify a long-term fix built for this unique challenge.
After careful analysis and field validation, we recommended Conval’s metal-seated ball valve — a robust solution engineered for abrasive, high-temperature, and chemically aggressive service conditions.
The Results: Zero Replacements in Over Two Years
Since installing Conval’s metal-seated ball valves more than two years ago, the customer hasn’t had to replace a single valve. Compare that to a replacement cycle of every 30 to 90 days, and the return on investment is crystal clear.
This level of reliability also gave the customer the green light to take the next step. They now have approval to test additional valves, with the goal of standardizing across the facility and keeping full assemblies or spare components in stock — either at their site or with Collins — to ensure seamless operation going forward.
Beyond the dramatic savings, they’ve experienced:
· Reduced maintenance costs
· Improved uptime
· Tighter process control
· Less stress on operations staff
They’ve even been able to increase production with confidence in their upgraded valve infrastructure.
Why It Worked
What made this project successful wasn’t just the product — it was the partnership. We listened. We tested. We worked side-by-side with the customer and a local manufacturer to develop a durable, purpose-built solution. And the results speak for themselves: a solution still going strong after thousands of cycles in one of the most aggressive operating environments out there.
Let’s Solve the Tough Problems
At Collins, we’re not just here to move boxes. We’re here to solve problems.
If your operation is struggling with valve failure — whether from corrosion, abrasion, cycling, or process complexity — let’s talk. We’re ready to roll up our sleeves and deliver a long-term solution that works.
Contact us to learn more about how Conval’s metal-seated ball valves — and our engineering support — can help your facility run smoother, longer, and smarter.
