Customized Pressure Regulator Solutions for Clients

What does a Pressure Regulator do

A pressure regulator is a pneumatic component used to control air or hydraulic pressure and is widely used in pneumatic and hydraulic systems in modern industries. In fact, pressure regulators can be found in systems we frequently encounter in daily life, such as water supply systems, air conditioners, water heaters, and automotive engines.

It typically senses and adjusts pressure using a combination of a screw, spring, and diaphragm. Additionally, it serves a protective function by preventing damage to equipment caused by excessive or insufficient pressure.

Initial Customization Plan for the Pressure Regulating Valve

A customer contact us, saying that their company was upgrading its automated production line. The existing pressure regulators could not meet the requirements for starting the system, so they needed a customized pressure regulating valve solution.

The customer’s pneumatic system operates at a relatively low working pressure but has strict requirements on the upper pressure limit, so precise control was necessary. The production line environment is complex, with significant temperature fluctuations, dust, and chemical corrosion factors. Therefore, the stability and durability of the pressure regulating valve were crucial.

After thorough communication with the customer, we confirmed the technical requirements for the customized pressure reg ulating valve.

◆ Inlet and outlet with 1/4" NPT threads

◆ Two pressure gauge mounting holes with 1/8" NPT threads

◆ Regulator working pressure range: 0~30 psi

◆ Adjustable range with a minimum pressure not lower than 30 psi (0.207 MPa) and a maximum pressure not exceeding 36 psi (0.248 MPa)

◆ Product does not include pressure gauge or mounting bracket

◆ Each product must undergo air-tightness and maximum pressure testing

Soon, we produced the first batch of samples, and each sample underwent two maximum pressure tests, air-tightness tests, and thread gauge checks to ensure they fully met the customer's requirements. These were then air-shipped across mountains, rivers, and seas to the customer.

Upon receiving the samples, the customer conducted their own inspection, confirmed the samples performed well, and inquired about the latest pricing. They were calculating the order quantity while testing the samples in actual work to ensure everything was in order.

Identify the Issue, Resolve the Issue

About two days later, the customer reported an issue. Our pressure regulator performed well on the test bench, but in actual operation, the inlet pressure frequently fluctuated due to changing working conditions. The existing pressure regulator could not effectively handle this fluctuation.

Additionally, the maximum pressure needed to be adjusted to 34 psi to allow for a safety margin and avoid damaging other components in the pneumatic system.

Achieving a pressure fluctuation range of just 4 psi (about 0.027 MPa) was very difficult due to the precision of the components. Moreover, ensuring that the regulator would operate correctly under high-frequency pressure vibrations presented a new challenge.

However, providing customer service is our job, and solving technical problems is our responsibility. After discussing the issue, we decided to focus on improving the key component of the regulator—the screw.

Currently, the screw used in the samples is made from our standard screw, processed through cutting. This type of screw does not require new molds, has a short production cycle, and is cost-effective, making it suitable for regular industrial environments. It has not posed any problems in the past.

However, it does have some drawbacks. For example, pressure accuracy can be affected by the cutting process, making it difficult to control the pressure range precisely.

Additionally, the cutting process inevitably leaves an incomplete thread at the end of the screw, which can cause the actual pressure range to be higher or lower than the allowed range when pressure fluctuates frequently, resulting in unstable pressure control and a reduced lifespan of the regulator.

Once we identified the cause of the problem, the next step was to find a solution. 

Our technical team has decided to change the original standard screw to a custom fine-thread screw and apply electroplating treatment to enhance its lifespan. The pitch of a fine-threaded screw is smaller than that of a standard coarse-threaded screw, offering higher precision in pressure regulation. This means that the pressure adjustment range is less affected by machining accuracy.

Additionally, fine-threaded screws do not leave incomplete threads like cut threads do, which makes pressure regulation more stable and eliminates the previous issue of pressure fluctuation.

The only downside is that fine-threaded screws require custom molds, which increases the cost.

Win-win Cooperation

I must reiterate that Fescolo (Fokca) is fundamentally committed to high-quality products and always believes that honest, friendly, and efficient communication and customer satisfaction are the cornerstones of our development. Therefore, we explained the situation to the customer in detail and voluntarily took on the additional cost. Everything we did was to ensure that the customer received a satisfactory product, and we look forward to further cooperation with the customer.

We then produced a small batch of samples using the new fine-threaded screws, conducted tests and measurements, and sent the samples to the customer. At the same time, as requested by the customer, we equipped each regulator with two 1/8" NPT plugs.

After the customer’s inspection, the new pressure regulating valve performed excellently. The customer was very satisfied with both the product and our attitude and happily signed off on the subsequent order. The new cooperation project is progressing smoothly...

About Fokca (Fescolo)

With years of experience in the pneumatic field, Fokca (Fescolo) specializes in customizing pneumatic components for customers. Our technical team, through a deep understanding of customer requirements and extensive expertise in the pneumatic industry, provides creative solutions and is dedicated to offering tailored products and solutions.

You can explore more of our customer cases. If you need further assistance, please feel free to contact us.