Product
Development
Guide

Incorporated in the year
1997

Incorporated By
Mr. Raghunathan Thiagarajan

Mr. Raghunathan Thiagarajan is the visionary behind the Airlock Group Companies, a leading provider of Bulk Solids Handling Components across multiple industries, including Food, Dairy, Pharmaceuticals, Minerals, Chemicals and Petrochemicals. Mr. Raghunathan Thiagarajan has led the way in advancing manufacturing and maintenance solutions, specializing in: Rotary Valves, Diverter Valves, Bin Activators, Powder Samplers, Scale Valves, Relief Valves, By-Pass Valves and various components for Bulk Handling Systems. With decades of experience, Mr. Raghunathan Thiagarajan has built a legacy of trust, quality and global expansion. His leadership continues to drive the Airlock Group towards new heights, ensuring excellence in industrial solutions worldwide.

Message for New Employees & Distributors

Welcome to the Airlock Group Companies! It is a pleasure to have you as part of our growing family. As you get on this exciting journey with us, I want to personally extend my best wishes for your success and growth.
At Airlock Group, we believe that our people are our greatest asset. Over the years, we have built a strong foundation based on innovation, integrity and excellence. As a new member of our team, you are now an integral part of this legacy. Your skills, ideas and dedication will contribute to our continued success and help us achieve even greater milestones.
We are committed to providing you with an environment that encourages learning, collaboration and personal development. I encourage you to embrace challenges, ask questions and take every opportunity to grow. Your journey here will be one of continuous learning and we are here to support you every step of the way.
Together, we will build a future of excellence and innovation. I look forward to seeing your contributions and celebrating your achievements.

Note : Pause the animation when hovered, and play it when the hover is released.

Group Companies

ORGANIZATION HEAD

Mr. Raghunathan Thiagarajan

Group CEO
- Mr. Krishnan
  Thiagarajan
  
  Business Head
  
  NTR ENGINEERS PTY.
  LTD.
- Mr. Bernard
  Shaw Guruswamy
  
  Business Head
  
  RAP ENGINEERS ASIA PACIFIC
  PTE. LTD.
- Mr. Ramesh
  Kannan Govindhan
  
  Business Head
  
  PT. AIRLOCK INDONESIA JAYA
  RAYA
- Mr.
  Subramanian
  
  Business Head
  
  VALVECO
  PTE. LTD.
- Mr.
  Manian
  
  Business Head
  
  AIRLOCK INDIA
  PVT. LTD.
- Mr. Aditya
  Raghunathan
  
  Business Head
  
  AIRLOCK CORPORATION LTD
  P & A CONVEYORS
- Mrs. Padma
  Raghunathan
  
  Business Head
  
  AIRLOCK INDUSTRIAL PLANT EQUIPMENT
  SPARE PARTS TRADING L.L.C

RAP Engineers & Consultants Pte. Ltd.

RAP Engineers Asia Pacific Pte. Ltd.

About :

RAP Engineers & Consultants Pte. Ltd. Incorporated in the year 1997
RAP Engineers Asia Pacific Pte. Ltd. Incorporated in the year 2013
Location: Singapore
Supplier of wide range of components for Bulk Solids Handling Industries

Office :

53, Ubi Avenue 1, #01-22 Paya Industrial Park,
Singapore - 408934.

NTR Engineers Pty. Ltd.

About :

Incorporated in the year 1998
Location: Australia
Supplier of wide range of components for Bulk Solids Handling Industries

Office :

G1, 101 Rookwood Road, Encompass Business Park,
Yagoona NSW 2199, Signi, Australia

Valveco Pte. Ltd.

About :

Incorporated in the year 2008
Location: Singapore
Supplier of wide range of components for Bulk Solids Handling Industries

Office :

53, UBI Avenue 1, #01-22 Paya Industrial Park,
Singapore 408934

Airlock India Pvt Ltd

About :

Incorporated in the year 2009
Location: India
Manufacturer of Airlock brand Rotary valves, Diverter valves and other equipment
Supplier of wide range of components for Bulk Solids Handling Industries

Office :

1/15-8, Ponnandampalayam,
Arasur - Annur Road
Thennampalayam,
Coimbatore - 641659, Tamil Nadu, India

P & A Conveyors Sdn. Bhd.

About :

Incorporated in the year 2022
Location: Malaysia
Supplier of wide range of components for Bulk Solids Handling Industries

Office :

NO. 12, Jalan Teknologi Perintis 1/2,
Taman Teknologi Nusajaya,
Iskandar Puteri, Johor, Malaysia - 79250.

Air-Lock Corporation Ltd.

About :

Incorporated in the year 2015
Location: Thailand
Manufacturer of screw Conveyors, volumetric feeders, bag loaders,big bag unloaders, lump breakers, magnetic separators & bin activators
Supplier of wide range of components for Bulk Solids Handling Industries

Office :

32 SOI Anamai, Srinakarin road
suan Luang, Suan Luang
Bankok - 10250

PT. Airlock Indonesia Jaya Raya

About :

Incorporated in the year 2016
Location: Indonesia
Supplier of wide range of components for Bulk Solids Handling Industries

Head office:

Kawasan industry jababeka tahap vi.
Jl. east park boulevard block c1b no. 7, jatireja
Cikarang Timur, bekasi, Indonesia

Surabaya Office:

Spazio tower 10th floor, suite 1017
Jl. mayjen yono soewoyo no.35
Pradahkalikendal, kec. dukuh pakis, surabaya
Jawa timur 60225, Indonesia

Jakarta Office:

Cyber2 tower, 9th floor
9-9f, thrive colony indonesia
Jl. h. r. rasuna said blok x-5, kav. 13,
Jakarta 12950 - Indonesia

Airlock Inc.

About :

Incorporated in the year 2019
Location: Philippines
Supplier of wide range of components for Bulk Solids Handling Industries

Office :

Unit 26-A 26th Floor, Rufino Pacifi Tower, 6784 Ayala Avenue,
City of Makati, Philippines - 1223.

Airlock Industrial Plant Equipment & Spare Parts Trading L.L.C

About :

Incorporated in the year 2022
Location: Dubai
Supplier of wide range of components for Bulk Solids Handling Industries

Office :

Warehouse 200, Sheikh Saeed Bin Mohd Bin Hasher Warehouse Jebel Ali Industrial Areea Jebel Ali - Dubai, UAE

Group Companies – Business Activities

SALES

Marketing
Enquiry Generating
Understanding and Evaluating Client's Requirements
Techno-Commercial Negotiation
Proposal Submission
Pre-sales Follow-ups
Product Selection

Order Processing & Documentation
Order Follow-ups
On time projects completion
Invoice Submission
Post-sales follow-ups
Shipping / Delivery

SERVICES

Finding a solution
Solution Proposal
Off-shore & On-shore service
24 x 7 customer support
Quality in service
On time service completion
Commissioning / Installation Support
Spares Support
AMC (Anual Maintenence Contract)

Our Global
Partners

RAP ENGINEERS ASIA PACIFIC PTE. LTD.

Airlock India

P&A Conveyors

BFM Fittings

Solimar

Eclipse Magnetics

Morris

Sterivalves

RAP ENGINEERS & CONSULTANTS PTE. LTD.

Airlock India

P&A Conveyors

Keofitt

Ingersoll Rand

VALVECO PTE. LTD.

Airlock India

P&A Conveyors

Jacob

PT. AIRLOCK INDONESIA JAYA RAYA

Airlock India

P&A Conveyors

BFM Fittings

Solimar

Eclipse Magnetics

Keofitt

Jacob

AIRLOCK INDIA PVT. LTD.

P&A Conveyors

BFM Fittings

Solimar

Eclipse Magnetics

Jacob

Sterivalves

AIRLOCK INDUSTRIAL PLANT EQUIPMENT
& SPARE PARTS TRADING L.L.C

Airlock India

P&A Conveyors

BFM Fittings

Solimar

Eclipse Magnetics

Keofitt

Jacob

Piab

AIRLOCK INC.

Airlock India

P&A Conveyors

BFM Fittings

Solimar

Jacob

P&A CONVEYORS SDN. BHD.

Airlock India

P&A Conveyors

BFM Fittings

Solimar

Eclipse Magnetics

AIR-LOCK CORPORATION LTD.

Airlock India

P&A Conveyors

BFM Fittings

Solimar

Eclipse Magnetics

Jacob

NTR ENGINEERS PTY. LTD.

Airlock India

P&A Conveyors

Jacob

Introduction
To
Pneumatic conveying

About Pneumatic Conveying

Pneumatic conveying is a modern method of transporting / conveying bulk materials (powders, granules, or small solids) through a pipeline using air as the conveying medium. It is widely used in industries like food processing, pharmaceuticals, cement, and chemicals for efficient and dust-free material handling.

The advantages of Pneumatic Conveying are,

Dust-free and hygienic material handling.
Flexible layout - can transport materials over long distances.
Less maintenance compared to mechanical conveyors.

Types of Pneumatic Conveying

Lean Phase Conveying (also known as Dilute Phase Conveying)

Lean Phase Conveying works with low-pressure system of less than 1 bar. It is further subdivided into 2 types.

Pressure (Positive) Conveying
Vacuum (Negative) Conveying

Suitable for light to moderately dense materials such as flour, sugar, plastic pellets, and fine chemicals.
The material remains fully suspended in the airstream, preventing settling in the pipeline.

Dense Phase Conveying

Dense Phase Conveying works with high-pressure system of more than 1 bar.

It transports bulk materials at low velocities and high pressures, minimizing material
degradation and pipeline wear.
It is ideal for handling fragile, abrasive or heavy materials over long distances.

Dense phase moves the material in slugs or a continuous layer.

Key Differences between Dilute Phase Conveying and Dense Phase Conveying

S.No	Aspect	Dilute Phase Conveying	Dense Phase Conveying
1	Principle	High-velocity, low-pressure air stream	Low-velocity, high-pressure air stream
2	Material-to-Air Ratio	Low (more air, less material)	High (less air, more material)
3	Air Velocity	Typically, 15-30 m/s (50-100 ft/s)	Typically, 1-10 m/s (3-33 ft/s)
4	Pressure Range	0.1 to 1 bar (1.5 to 15 psi)	1 to 6 bar (15 to 90 psi)
5	System Design	Simpler design, more straight forward to install	More complex design, requires precise control systems
6	Material Types	Suitable for non-abrasive, light materials (e.g., flour, grain, plastic pellets)	Suitable for abrasive, fragile, heavy, and cohesive materials (e.g., sand, cement, sugar)

S.No	Aspect	Dilute Phase Conveying	Dense Phase Conveying
7	Conveying Distance	Short to medium distances (up to 300 metres or 1000 feet)	Long distances (up to 1000 metres or 3280 feet)
8	System Maintenence	Higher wear and tear on pipes and components	Lower wear and tear due to reduced Velocity
9	Material Degradation	Higher risk of material degradation due to high Velocity	Minimal material degradation due to gentle handling
10	System control	Simpler control system	Requires sophisticated control system for pressure and flow management
11	Initial cost	Generally lower due to simpler components	Generally higher due to complex components and controls
12	Typical Application	Food processing, pharmaceuticals, plastics	Cement, mining, chemical, food ingredients

S.No	Aspect	Dilute Phase Conveying	Dense Phase Conveying
13	Flexibility	More flexible for changes in conveyance baths and material types	Less flexible for specific application
14	Material Conveying Method	Suspension in air	Plug flow or slug flow
15	Example of Feed Devices	Rotary valves, blow-through valves	Screw pumps, pressure vessels
16	Dust Control	Require more robust dust collection systems due to high air volumes	Easier to manage dust due to lower air volumes
17	System Integration	Easier to integrate into existing system	Requires careful integration due to pressure and flow requirements
18	Safety Consideration	Dust explosion risk due to higher velocity and dust concentration	Lower Dust explosion risk, but high-pressure safety measures needed

Note : Pause the animation when hovered, and play it when the hover is released.

Pressure Conveying

In Pressure Conveying, the compressed air pushes the bulk materials through a pipeline from a feeding point to a receiving point. It is used for transporting powders, granules, and other dry bulk materials efficiently over short to long distances.

Vacuum Conveying

In Vacuum conveying, the bulk materials (powders, granules, or small particles) are pulled through a pipeline using negative pressure (vacuum).
This system is commonly used for clean, controlled material handling in industries like food, pharmaceuticals, chemicals, and plastics.

Optimized solutions for seamless

solids handling operations.

We deliver high-quality pneumatic conveying solutions, optimizing solids handling for industries across the global region.

Introduction
To
Rotary Valve

Rotary Valve

About :

Rotary valve is a compact mechanical device for continuously discharging & regulating the flow of bulk solids in the form of powders, granules or solids into the pneumatic conveying lines. It is used widely in lean phase conveying systems.
It is a simple machine consisting of a single moving part, the rotor, which rotates in close contact with the housing. The housing has an inlet at the top and an outlet at the bottom.

Functions :

Control Product Flow Rate to the Required Rate (Fixed or Variable)
Maintain a Gas Pressure Differential between the Inlet & Outlet (Airlock)

Other Names :

Airlock Valve
Rotary Feeder
Rotary Discharger
Star Valve

Applications :

Pneumatic Conveying (Pressure / Vacuum)
Dosing / Metering
Feeding (No pressure/Pressure/Negative)

Main Parts of Rotary Valve

Rotary Valve Models

Drop Through Rotary Valves

Drop thru DCSR (VER 2.0)

DCSR VER 2.0 is specifically designed for dairy and pharmaceutical applications, adhering to USDA and EHEDG specifications
DCSR VER 2.0 is designed with tapered housing and tapered rotor concept, ensuring that no matter how many times the rotary valve is opened or closed, the rotor will never come into contact with the housing
DCSR VER 2.0 comes with Easy Detachable Rotor and End Cover to perform Quick and Easy Cleaning
The Highlight of VER 2.0 is Rotor can be Rotated for Easy Cleaning in Pulled Out Condition
All product contact parts are polished to 0.8 microns, and the rotor is designed with U-shaped pockets to ensure smooth product flow and compliance with hygienic standards

Available Sizes and Rotor Capacities are,

Sizes (mm)	Rotor Capacities (m³)
150	0.003
175	0.006
200	0.011
250	0.019
300	0.034
350	0.058

Drop Through Rotary Valves

Drop thru (DT)

The DT model is commonly utilized in feeding and metering applications
In combination with a drop-out box, it is also used in pneumatic conveying systems
Different rotor configurations and sealing arrangements are available

Available Sizes and Rotor Capacities are,

Sizes (mm)	Rotor Capacities (m³)
100	0.001
150	0.003
175	0.06
200	0.011
250	0.019
300	0.034
350	0.058
400	0.091
450	0.134
500	0.230

Drop Through Rotary Valves

Drop thru Enlarged Round Inlet & Outlet (DVT)

DVT model is used in similar applications as the DT model
DVT comes with Enlarged Inlet and Outlet Openings offering better filling rate
Rotor Capacities of the DVT are one size smaller than those of the DT model. For example, the DVT 250 has 250 mm openings but a rotor capacity of 0.011 m³, which is equivalent to the rotor capacity of the DT 200.

Available Sizes and Rotor Capacities are,

Sizes (mm)	Rotor Capacities (m³)
200	0.006
250	0.011
300	0.019
350	0.034

Drop Through Rotary Valves

Drop Thru Round Inlet / Square Outlet or Vice Versa (DST)

DST model is used in similar applications as the DT model
DST model comes with a square inlet and round outlet by default, but it can also be configured with a round inlet and square outlet, depending on application requirements
Rotor Capacities of the DST are one size smaller than those of the DT model. For example, the DST 250 has 250 mm openings but a rotor capacity of 0.011 m³, which is equivalent to the rotor capacity of the DT 200.

Available Sizes and Rotor Capacities are,

Sizes (mm)	Rotor Capacities (m³)
200	0.006
250	0.011
300	0.019
350	0.034

Drop Through Rotary Valves

Drop Thru Simply Demountable (SD)

Extremely compact, easy and foolproof in operation and maintenance
Non-drive end cover and rotor can be easily removed without removing the drive
Fixed axial clearances that remain set, ensuring that the axial setting of the rotor is maintained time after time after being disassembled and reassembled
Available only in direct drive configuration

Available Sizes and Rotor Capacities are,

Sizes (mm)	Rotor Capacities (m³)
150	0.003
175	0.006
200	0.011
250	0.019
300	0.034
350	0.058

Drop Through Rotary Valves

Drop Thru Simply Demountable with Cross Supporting Rails (SD / CSR)

The SD/CSR model is equipped with supporting rails that allow easy opening and closing of the rotary valve along with the rotor, facilitating cleaning and maintenance. These rails are highly recommended for larger valve sizes

Available Sizes and Rotor Capacities are,

Sizes (mm)	Rotor Capacities (m³)
150	0.003
175	0.006
200	0.011
250	0.019
300	0.034
350	0.058

Drop Through Rotary Valves

Drop Thru Light Version (DTL)

DTL features a thin body and thin end covers, making it ideal for light-duty applications
DTL is also available in a demountable version

Available Sizes and Rotor Capacities are,

Sizes (mm)	Rotor Capacities (m³)
375	0.005
500	0.012
750	0.023
1250	0.035

Drop Through Rotary Valves

NDT

NDT models are direct replacements for NUCON DT models
NDT is available with both round and rectangular openings

Available Sizes and Rotor Capacities are,

Sizes (mm)	Rotor Capacities (m³)
375	0.006
500	0.013
750	0.022
1250	0.034
2000	0.017

NDT RND

NDT REC

Note : Pause the animation when hovered, and play it when the hover is released.

Rotary Valve Models

Blow Through Rotary Valves

Blow thru DCSR (VER 2.0)

Shares identical specifications with the Drop-Thru DCSR VER 2.0 model
Designed for Pneumatic Conveying applications (Pressure & Vacuum)
Different rotor configurations and

Available Sizes and Rotor Capacities are,

Sizes (mm)	Rotor Capacities (m³)
150	0.003
175	0.006
200	0.011
250	0.019
300	0.034
350	0.058

Blow Through Rotary Valves

Blow thru (BT)

Designed for Pneumatic Conveying applications (Pressure & Vacuum)
Different rotor configurations and sealing arrangements are available

Available Sizes and Rotor Capacities are,

Sizes (mm)	Rotor Capacities (m³)
150	0.003
175	0.006
200	0.011
250	0.019
300	0.034
350	0.058

Blow Through Rotary Valves

Blow thru Enlarged Round Inlet (BVT)

BVT model is used in similar applications as the BT model
BVT comes with Enlarged Inlet offering better filling rate
Rotor Capacities of the BVT are one size smaller than those of the BT model. For example, the BVT 250 has 250 mm openings but a rotor capacity of 0.011 m³, which is equivalent to the rotor capacity of the BT 200.

Available Sizes and Rotor Capacities are,

Sizes (mm)	Rotor Capacities (m³)
200	0.006
250	0.011
300	0.019
350	0.034

Blow Through Rotary Valves

NBT

NBT models are direct replacements for NUCON CV models
NBT is available with both round and rectangular openings

Available Sizes and Rotor Capacities are,

Sizes (mm)	Rotor Capacities (m³)
375	0.006
500	0.013
750	0.022
1250	0.034
2000	0.047

NBT RND

NBT REC

Note : Pause the animation when hovered, and play it when the hover is released.

Basic Construction

Main Components

Body x 1
End Covers x 2
Rotor x 1

Key features

Maximum Filling Efficiency
Minimum Air Leakage
Chain & Direct Drives
Easy to Maintain
Outboard Bearings, Lubricated & Sealed for Life

Options

Chrome Coating
Tungsten Carbide Coating
Nickel Coating
Ni-Hard Body
Air Purge Glands
Cross Slide Rails
Drop-out Box
Inlet Restrictor
Zero Speed Sensor
1Rotor Interference Sensor (RIS)

Options

High Temperature Modifications
Pressure Regulator
Flow Meter
ATEX / IECEx Rated Electrical Components
Ertalon Rotor
Reduced Capacity Rotor
Scalloped Rotor
Scrapper Blade
Knive Blade
Safety Switch

General Illustrations

Application Illustrations

Feeding Application

Pneumatic Conveying [ Drop Thru ]

Pneumatic Conveying [ Blow Thru ]

Rotary Valve leakage

Rotary Valve - Venting

Why ??

It is found that solid product getting into the RV will equally displaces the air inside the valve, so it is necessary to vent out the air present inside the rotary valve. If this air is not vented out, it restricts the product flow thereby affecting the product filling efficiency. On the whole the flowrate will be affected.

Uses :

Control product flow rate to the required rate (fixed or variable)
Maintain a air pressure differential between the inlet & outlet (airlock)

Types :

Vent holes drilled including plugs or ferrules or complete tri-clamp connections
Vent adaptor

Different Arrangements of Venting

Note : Pause the animation when hovered, and play it when the hover is released.

Rotary Valve Execution

Execution	Material of Construction			Blade Options	Vent	Seal Arrangement
Execution	Housing & Cover	Rotor	Blades	Blade Options	Vent	Seal Arrangement
CAST IRON EXECUTIONS
CI	Cast Iron	Mild Steel	Mild Steel	Fixed/Adjustable 8/9 Blades	Included	Gland Packing
HC	Cast Iron Body & End covers, Housing Bore & End cover Internally Chrome Plated	Mild Steel with Chromium Plated Shafts	Hardox	Fixed & Chamfered 8/9 Blades	Included	Air Purge Gland Packing
TC	Cast Iron Body & End covers, Housing Bore & End cover Internally Tungsten Carbide Plated	Mild Steel with Tungsten Carbide Plated Shafts	Hardox	Fixed & Chamfered 8/9 Blades	Included	Air Purge Gland Packing
TCS	Cast Iron Body & End covers, Housing Bore & End cover Internally Tungsten Carbide Plated	Mild Steel with Semi-end disc and Tungsten Carbide Plated Shafts	Hardox	Fixed & Chamfered 8/9 Blades	Included	Air Purge Gland Packing
NIH	Ni-Hard Body & Cast Iron End covers	Mild Steel with full end-disk	Hardened Steel with Stellite Tips	Fixed/Adjustable 8/9 Blades	Included	Gland Packing
CI-SD	Cast Iron	Mild Steel	Mild Steel	Fixed/Adjustable 9 Blades	Included	Gland Packing
HC-SD	Cast Iron Body & End covers, Housing Bore & End cover Internally Chrome Plated	Mild Steel with Chromium Plated Shafts	Hardox	Fixed & Chamfered 8/9 Blades	Included	Food Grade Seal
TC-SD	Cast Iron Body & End covers, Housing Bore & End cover Internally Tungsten Carbide Plated	Mild Steel with Tungsten Carbide Plated Shafts	Hardox	Fixed & Chamfered 8/9 Blades	Included	Food Grade Seal
TCS-SD	Cast Iron Body & End covers, Housing Bore & End cover Internally Tungsten Carbide Plated	Mild Steel with Semi-end disc and Tungsten Carbide Plated Shafts	Hardox	Fixed & Chamfered 8/9 Blades	Included	Food Grade Seal
STAINLESS STEEL EXECUTIONS
ST	Stainless Steel 316	Stainless Steel 316 L	Stainless Steel 316 L	Fixed/Adjustable 9 Blades	Optional	Gland Packing / Dairy Sanitary Seals (DSS)
SAN	Stainless Steel 316 (Polished to 0.8 microns)	Stainless Steel 316 L (U-shaped Pockets & Product Contact Parts Polished to 0.8 microns)	Stainless Steel 316 L	Fixed & Chamfered 8/9 Blades	Optional	Dairy Sanitary Seals (DSS)
DCSR / DCSR VER 2.0	Stainless Steel 316 (Polished to 0.8 microns)	Stainless Steel 316 L (U-shaped Pockets & Product Contact Parts Polished to 0.8 microns)	Stainless Steel 316 L	Fixed & Chamfered 8/9 Blades	Optional	Dairy Sanitary Seals (DSS)
ST-SD	Stainless Steel 316	Stainless Steel 316 L	Stainless Steel 316 L	Fixed/Adjustable 9 Blades	Optional	Gland Packing / Dairy Sanitary Seals (DSS)
SAN-SD	Stainless Steel 316 (Polished to 0.8 microns)	Stainless Steel 316 L (U-shaped Pockets & Product Contact Parts Polished to 0.8 microns)	Stainless Steel 316 L	Fixed & Chamfered 8/9 Blades	Optional	Dairy Sanitary Seals (DSS)
DCSR-SD	Stainless Steel 316 (Polished to 0.8 microns)	Stainless Steel 316 L (U-shaped Pockets & Product Contact Parts Polished to 0.8 microns)	Stainless Steel 316 L	Fixed & Chamfered 8/9 Blades	Optional	Dairy Sanitary Seals (DSS)

Choosing the Right Valve for Right Application

Selecting the appropriate rotary valve depends on the type of application and the characteristics of the product being handled. Several key factors must be considered to ensure optimal performance and reliability.

Application Considerations

Operating duty (continuous, intermittent, etc.)
Application (feeding, metering & pneumatic conveying)
Operating temperature
Installation environment (indoor or outdoor)
Area classification (e.g., hazardous zones)

Product Characteristics

Bulk density
Abrasiveness
Hygroscopic nature
Flowability (stickiness & angle of repose)
Corrosiveness
Explosiveness

Example : Handling Calcium Carbonate

Feeding application (no pressure differential): A standard cast iron valve with gland packing is sufficient. Hardened blades may be considered as an option.
Pneumatic conveying up to 0.7 bar(g): A hard-chromed valve with air purge is recommended.

Specification Selection

Determine materials of construction.
Determine rotor type.
Should the blades be chamfered, hardened, flexible, scrapers, etc.?
What type of drive? (chain, direct, right-angled drive, etc.)
Does the valve need to be explosion-proof or USDA approved?
Any specific requirements? (vent adaptor, zero speed sensor, safety switch, air injection, CSR, etc.)

Tips

For handling abrasive products, Drop Thru types are recommended.
Limitations : For pneumatic conveying applications , the DT model must be used in combination with a drop-out box. This setup requires additional vertical space for installation due to its increased overall height.
For handling sticky products in pneumatic conveying, Blow Thru types are recommended.
For handling low bulk density products, DVT, DST, and BVT models are recommended for better filling rate.
Depending on the abrasiveness the following executions are recommended:
1. Mild to Moderate abrasiveness – HC execution
2. High abrasiveness – TC & TCS execution
3. Very High abrasiveness – NIH execution

Advantages and Disadvantages of Drive Configurations

Drive Configuration	Pros	Cons
Direct Drive	Lesser Moving Parts and Easy to Maintain	Requires more space Required VFD to increase or reduce the RPM
Chain Drive	Less space required Rotor RPM can be altered to some extent by changing the sprockets	More moving parts Difficult to maintain and need external lubrication for the chain

Configuring the Rotary Valve

✔ Determine materials of construction.
✔ Determine rotor type.
✔ Should the blades be chamfered, hardened, flexible, scrapers, etc.?
✔ What type of drive, chain, direct, Eex d, etc.?
✔ Does the valve have to be explosion-proof or USDA approved?
✔ Are there any other specific requirements? (vent adaptor, Zero speed, safety switch, pulsating air injection, CSR option, etc.)

Rotor RPM & Valve Sizing Calculation

To determine filling efficiencies the following should be taken into account

Is there a pressure differential?, how much and where?
Will the valve be fed ?
The product characteristics from previous page
Will the product be aerated?

The calculation for determining the valve speed is as follows

Capacity in t/hr

-------------------------------- X 1000

Bulk density in t/m3

----------------------------------------------

60 x 0.7 x lit/rev

As a general rule of thumb, for pneumatic applications a filling efficiency of 70% can be assumed between 10 and 20 r.p.m. Same for feeding application we can go up to 25 rpm depending on the product characteristics. Of course lower speeds will give higher filling efficiencies and higher speeds lower filling efficiencies and the bulk density, flowability and pressure differential can also have considerable effect on filling efficiency. The maximum tip speed for a rotor should not exceed 0.66 m/sec, 0.5 m/sec being the norm

Rotor RPM & Valve Sizing Calculation

For Example

Flowrate = 10,000 kg/hr

Bulk density = 500 kg/m3

Application = Feeding

10 t/hr

-------------------------------- X 1000

0.50 t/m3

Rotor Rpm = -------------------------------------------

60 x 0.7 x 34 lit/rev

Rotor Rpm = 14 Selected valve size is 300mm

Rotor Configurations

Dairy Rotor

Full End Disc Rotor

Plastic Rotor

Reduced Capacity Rotor

Rotor with Adjustable Blades

Rotor with Fixed & Chamfered Blades

Scalloped Rotor

Semi End Disc Rotor

Note : Pause the animation when hovered, and play it when the hover is released.

Rotary valve Sealing

Why ??

Sealing are used in Rotary valve to avoid to product leakage & product contacting the bearing thereby increasing the life of bearings.

Thumb Rule - For air purge gland, it is necessary to maintain 0.5 bar pressure more than the convey line pressure for the effectiveness of air purge.

For Example - if the convey line pressure is 0.5 bar then the set pressure in air purge should be 1 bar

Types

Gland packing
Air Purge gland
Air Purge lip seal
FGS ( Food Grade Seal )
DSS ( Dairy Sanitory Seal )

Sealing Arrangements

Gland Packing

Air Purge Gland

Dairy Lip seal

Air Purge Dairy

Dairy Sanitary Seal (DSS) seal – Sanitary Air Purge

Note : Pause the animation when hovered, and play it when the hover is released.

Extra Options

Drop-out Box

It is used with DT type RV. It’s a transition piece connecting the RV outlet to the conveying line. It has a flange connection (available in DIN / ANSI / JIS) on the top and pipe connection (available in different sizes) on the bottom. Available in mild steel & stainless steel construction.

CSR (Cross Slide Rails)

CSR options enable safe and quick cleaning and maintenance operations with less effort,

These options are available for both Standard (ST) and Dairy versions.

Safety Switch

The safety switch in a rotary valve serves an important role in ensuring operator safety and equipment protection, especially during cleaning or maintenance.
The safety switch acts as an interlock ensures the rotary valve cannot operate (i.e., the motor cannot run) while the valve is opened or disassembled.
The safety switch acts as an interlock ensures the rotary valve cannot operate (i.e., the motor cannot run) while the valve is opened or disassembled.
Mounting options available on drive & non-drive side

Pulsating Air Holes

This option is applicable for handling sticky products. This option has small size air holes on bottom of the end covers. The holes are drilled at a desired angle so that the air getting in to these holes are directed onto the rotor pockets to ensure gradual flowing of the product.

RIS

The Rotor Interference Sensor (RIS) system has been designed to monitor rotor to housing contact, especially useful for process systems with a high hygienic requirement. The RIS can be installed to minimize damage to the rotary valve and warn of possible contamination of the conveyed product in the unlikely instance of the rotor fouling the valve body or end covers.

Features:

Metal to Metal alarm
Contamination alarm
CIP process alarm

Note : Pause the animation when hovered, and play it when the hover is released.

RIS & CONTROLLER SPECIFICATION

ROTOR INTERFERENCE SENSOR (RIS)

The Rotor Interference Sensor (RIS) is designed to detect any contact between rotor and housing or end covers. Also, it helps to detect any foreign matter caught between the body / End cover and rotor.

The RIS controller will give an output signal when rotor touches the body or end covers. The relay output can be used to stop the valve before serious damage can occur to the valve. Alarm set-points are configurable to allow product variations.

The rotor is electrically isolated by using hybrid ceramic bearings.

The resistance can be monitored through the RIS controller and alarm can be generated for M2M (Metal 2 metal), product contamination, circuit fault depending upon the change in resistance.

CONTROLLER SPECIFICATION

OPERATING VOLTAGE

24V DC

INPUTS

Rotor interference measurement range 0-100K Ohms
Product Temperature measurement range 0-100 Degrees (Optional)
Dual Mode select inputs (Normal/CIP) voltage range 15V-24V DC

OUTPUTS (5-LED outputs)

M2M
Contamination
Circuit fault
Temperature / Rotor status (Option)
SD Card error

RELAY OUTPUTS

Relay 1 – Resistance Threshold Breach Alarm
Relay 2 – Product Temperature Breach Alarm

DATA LOGGING:

Every second (Data, Time, Resistance, Mode, Alarm, Temperature, Rotor Status)
Support up to 8GB Micro SD Card (CSV/TXT) file format

SENSORS USED:

Temperature – Using RTD Sensor (Optional)
Rotor running status update (Using Inductive Sensors - Optional)

CONFIGURATION SOFTWARE:

PC interface software to set the configuration (M2M, CIP, Contamination, Temperature)

ALARM RESET:

User Reset Input

Note : Pause the animation when hovered, and play it when the hover is released.

No Speed Sensor (Zero Speed)

The sensor acts as a monitoring device; it will identify and signals whether the rotor is rotating or not
ATEX version is available on request
Mounting options available on drive & non-drive side

Pressure Regulator

Pressure Regulator is set to the air pressure in the air purge glands. Make – FESTO.

Solenoid Valve

Solenoid Valve is to allow / restrict the air flow into the air purge gland. Make – FESTO. Control voltage – 24 VDC or 230 VAC (on request).ATEX version available on request.

Air flow meters

Air flow meters is just an indication for the air flowing into the air purge glands

Note : Pause the animation when hovered, and play it when the hover is released.

Selling Points of Rotary Valve

✔ Economical compare to any other global brands RV with certification
✔ Quality on Par with any branded RV .
✔ Delivery is very quicker
✔ Spare parts readily available
✔ First manufacturer in Asia got USDA and EHEDG approval
✔ ATEX rated
✔ 10 bar Explosion certified by TUV
✔ Flame proof certified valves

✔ Foot prints same as DMN and Nucon Valves ..
✔ We can extend 18 months warranty ( if needed to win the order) Others are offering only 12 months
✔ If any problem at site, our service engineer will visit with in couple of days
✔ All our Stainless steel valves are completely SS 316
✔ 9 bladed rotor
✔ ISO certified
✔ SS castings are made in investment castings
✔ Spare parts are available across the globe

Frequently Asked Questions

1. When to choose Blow through rotary valve?

If there is height limitation for installation of rotary valve and also if the product is too light like thermo-cole granules, blow through valve is the right choice. Important note: for very abrasive products, blower through valve is not recommended.

2. What should be the air purge pressure for the shaft seal?

It should be 0.5barg more than the pressure inside the rotary valve.

3. How to decide the direction of rotation of rotor in an assembled rotary valve?

When one stands in front of drive shaft end of rotary valve, the rotor should turn clockwise to his view.

4. What is the use of inlet restrictor?

It is recommended for granular products. When it is the requirement to keep the product degradation (product breakage) to minimum, inlet restrictor must be used. Inlet restrictor also helps in preventing the hard granular products from getting caught between the rotor tip and housing radially. Granular valve (GL) has built-in inlet restrictor.

5. How and where to use the inlet restrictor ?

The feeding edge of inlet restrictor should be positioned in such a way that it is parallel to the radial tip of rotor as shown in the picture below.

6. In adjustable blades rotor, which side of the vane the adjustable blades are to be fitted?

When the rotor turns clockwise viewed from shaft end, the blades are to be on the leading face of the vanes.

7. In Blow through rotary valve, which side of blow line to be considered to connecting the air line to pick up the product?

It does not matter to which side of the blow line air pipe is attached. It can be from left to right or right to left.

8. Can Nilos rings be used for rotary valves supplied with RID?

No, the outer edge of Nilos rings will be in contact with the end covers. So electrically it will not isolate the rotor.

9. When to use scrapper blades?

Products which tend to bind on to the bore and inside surface of end cover would offer high resistance to rotor movement causing seizing of rotor. To prevent this from happening, two scrapper blades are used diametrically opposite to each other to scrape the product stuck to the bore and end covers.

10. What is the pressure shock resistance of standard rotary valve?

10 barg

11. Is standard rotary valve suitable for high pressure application?

No, all standard rotary valves with minimum clearances will work effectively with minimum air leakage only up to 600 - 700mbarg. Any thing above this pressure, the leakage will be more.

12. Do clearances in a rotary valve have any relation to product temperature?

Yes, very much. Clearances (radial and axial) are set based on product temperature.

13. When to use enlarged inlet rotary valve?

When product flowability is an issue, enlarged inlet rotary valve will help reduce this problem.

14. How to ensure air- purging on shaft seals is working?

By using a flow meter. If the float in the flowmeter is at the bottom most point, then air purge line is clogged.

15. When to use DTL rotary valve?

DTL Rotary valve is strongly recommended, when the application is feeding or vacuum conveying. The price is economical compared to the other model because of its construction. But DTL model are not 10 bar pressure resistant certified

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Group Companies – Business Activities

RAP ENGINEERS ASIA PACIFIC PTE. LTD.

RAP ENGINEERS & CONSULTANTS PTE. LTD.

VALVECO PTE. LTD.

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AIRLOCK INDIA PVT. LTD.

AIRLOCK INDUSTRIAL PLANT EQUIPMENT & SPARE PARTS TRADING L.L.C

AIRLOCK INC.

P&A CONVEYORS SDN. BHD.

AIR-LOCK CORPORATION LTD.

NTR ENGINEERS PTY. LTD.

About Pneumatic Conveying

The advantages of Pneumatic Conveying are,

Types of Pneumatic Conveying

Lean Phase Conveying (also known as Dilute Phase Conveying)

Dense Phase Conveying

Key Differences between Dilute Phase Conveying and Dense Phase Conveying

Pressure Conveying

Vacuum Conveying

Optimized solutions for seamless

solids handling operations.

Rotary Valve

About :

Functions :

Other Names :

Applications :

Main Parts of Rotary Valve

Rotary Valve Models

Drop Through Rotary Valves

Drop thru DCSR (VER 2.0)

Drop Through Rotary Valves

Drop thru (DT)

Drop Through Rotary Valves

Drop thru Enlarged Round Inlet & Outlet (DVT)

Drop Through Rotary Valves

Drop Thru Round Inlet / Square Outlet or Vice Versa (DST)

Drop Through Rotary Valves

Drop Thru Simply Demountable (SD)

Drop Through Rotary Valves

Drop Thru Simply Demountable with Cross Supporting Rails (SD / CSR)

Drop Through Rotary Valves

Drop Thru Light Version (DTL)

Drop Through Rotary Valves

NDT

Rotary Valve Models

Blow Through Rotary Valves

Blow thru DCSR (VER 2.0)

Blow Through Rotary Valves

Blow thru (BT)

Blow Through Rotary Valves

AIRLOCK INDUSTRIAL PLANT EQUIPMENT
& SPARE PARTS TRADING L.L.C

Sealing Arrangements