During a trade fair in Germany, we met a manufacturer of sealing machines for the food processing industry, who ran into a problem with operating a heavy valve. Opening and closing this 50kg valve, supported by gas springs, turned out to be not only heavy, but also dangerous. Brimotech was brought in to develop a safe, efficient and user-friendly solution. Through our expertise in gas spring calculations and customised gas springs, we managed to turn the challenge into a success story.

Customer problem statement

The challenge was clear: the valve had to be easily and safely operated by anyone, without risk of injury. The existing gas springs provided insufficient support when opening and only struck after a large opening angle (vertical 95 degrees), leading to a risky closure. After we analysed the situation in detail, the customer decided to send the machine’s valves to us for a direct test solution. This caused a large truck to drive in front that contained the complete machine.

Approach from Brimotech

Our first step was to replace the existing gas springs (2x1000N) with four gas springs of 500N each, which provided more control over speed and damping. We also designed a special bracket that optimised the angular rotation of the valve over the full opening angle of 95 degrees. This measure provided better balance during opening and was in line with our accurate gas spring calculations.

Results

Although this improved the operating force, the end damping was still not perfect due to the horizontal position of the gas springs. By adding dynamic damping in the stainless steel 316 gas springs, we managed to tackle this problem as well. In the end, we were able to present a solution that allowed the valve to be opened and closed effortlessly and safely.

Conclusion

Thanks to our thorough approach and customisation of the gas springs, fitted with dynamic damping and stainless steel 316, the customer now has a fully optimised system. The opening and closing of the heavy valve is done with minimal effort and maximum safety. This solution has led to a long-term cooperation in which Brimotech supplies the complete assembly with gas springs and components. The system, which meets the strict requirements of the food processing industry, is now used as standard in all of this customer’s sealing machines.