Ensuring reliable fluid control in industrial processes not only increases production efficiency; it also preserves system integrity, prevents energy losses, and minimizes safety risks. Therefore, the selection of flow control elements such as valves is considered one of the most critical decisions in process engineering. Especially in systems working with chemical substances, abrasive fluids, or under high temperature and pressure conditions, the resistance level of the equipment used directly affects the system's performance and operational life.
In such challenging conditions, it is not enough for the valves used to merely change the direction of the fluid or stop the flow. These valves must also be completely resistant to the chemical structure of the fluid they carry, not deform over time, and maintain their sealing properties for a long time. Otherwise, serious problems such as chemical leaks, equipment failures, or production stoppages may occur in the system. In such cases, thermoplastic valves stand out as a safer and more sustainable solution, surpassing traditional metal valves with their superior chemical resistance, high mechanical stability, and long service life.
Thanks to their material properties, thermoplastic valves are highly resistant to both corrosive chemicals and environmental effects. In this regard, issues such as rust, corrosion, cracking, or gasket deformation that may occur over time in metal valves are observed at much lower rates in thermoplastic valves. Additionally, these valves provide advantages not only in terms of durability but also in parameters such as energy efficiency, ease of installation, and operating cost. Due to their low specific weight, they are easy to transport, practical to install, and their smooth internal surfaces minimize resistance to flow. This means lower pump load and less energy consumption throughout the system.
Today, thermoplastic valves, preferred in many different fields from the chemical industry to food production, shipbuilding to the energy sector, have become an important component of modern production understanding and sustainable engineering solutions. With increasing environmental sensitivity and the need for long-lasting and maintenance-free equipment, the areas of use and preference rates of these valves are increasing every year. The performance they provide in applications where metal is limited positions thermoplastic valves not just as an alternative but as a primary choice.
What are Thermoplastic Valves?
Thermoplastic valves are special types of valves used in industrial fluid control, made from engineering plastics with high durability. These valves are preferred especially in systems that require resistance to chemical, thermal, and mechanical effects. Commonly used materials in their production include advanced thermoplastics such as PVC-U (unplasticized polyvinyl chloride), PVC-C (chlorinated PVC), PP-H (homopolymer polypropylene), and PVDF (polyvinylidene fluoride). These materials, thanks to their special molecular structure, show stability over a wide range of temperatures and pressures and maintain their durability against many corrosive chemical substances for a long time.
Thermoplastic valves can operate smoothly in systems containing acids, bases, alkaline solutions, salts, chlorinated compounds, oxidizing agents, and various solvents. When metal valves come into contact with such substances, they may experience rust, surface degradation, gasket deformation, or leakage over time. However, since thermoplastic materials can remain inert to chemical interactions, they can serve for many years without structural degradation. With these features, they are used safely, especially in chemical process lines or environments with a high risk of corrosion.
Another important advantage offered by these valves is their high sealing performance. Equipped with advanced gasket systems, thermoplastic valves prevent fluid from leaking into the external environment, thereby preserving system efficiency and minimizing environmental risks. This is critically important for human health and environmental safety, especially in systems transporting hazardous or toxic chemicals.
Thermoplastic valves are also mechanically very stable structures. They can resist vibrations, impacts, or pressure fluctuations with their flexible structures. This durability offers a wide range of applications in both fixed installations and mobile systems. Depending on the type of valve (such as ball valve, butterfly valve, check valve, diaphragm valve), solutions can be produced for different operational needs. This diversity creates a flexible product range that can respond to the specific requirements of different sectors and process types.
Additionally, thermoplastic valves, due to their lightweight structure, greatly facilitate transportation, storage, and installation processes. Having a much lower weight compared to metal valves provides significant labor and time savings, especially in large-diameter pipelines. Thanks to their compact designs, they can be easily integrated into limited spaces, and maintenance operations can generally be carried out in a shorter time and at a lower cost.
In conclusion, thermoplastic valves have the capacity to meet the challenging demands of today's industry with features such as chemical resistance, long life, high sealing, lightness, easy installation, and wide application flexibility. Positioned not just as an alternative solution in modern process designs but as the first choice in most cases, these valves play a critical role in system safety and operational efficiency.
Why Choose Thermoplastic Valves?
Thermoplastic valves stand out not only with their chemical resistance in industrial fluid control systems but also with the versatile advantages they offer. The reasons for choosing these valves consist of numerous factors that increase system efficiency, reduce operating costs, and support long-term safety.
First and foremost, the extremely smooth internal surfaces of thermoplastic valves minimize the friction encountered by the fluid inside the valve. This low surface roughness reduces potential pressure losses throughout the system. As a result, pump systems operate more efficiently with less energy, optimizing energy consumption across the operation. Especially in large-capacity, continuously operating systems, this advantage creates significant savings both environmentally and economically.
Moreover, thermoplastic materials are significantly lighter compared to metal components. This lightness not only reduces labor costs during valve installation but also provides great convenience in transportation and storage processes. While heavy metal valves often require cranes or special transportation systems, thermoplastic valves can usually be carried by hand. Especially in cases requiring maintenance and renewal, valve replacement can be carried out in a much shorter time. This situation reduces potential downtime in the system and supports production continuity.
Compact design is another prominent feature of thermoplastic valves. Designed to be integrated into small spaces, these valves offer an ideal solution, especially in process lines with space constraints. Being easily mountable in narrow areas provides flexibility in engineering design. This creates a significant advantage in both new facility installations and the modernization of existing systems.
Ease of use is also a determining factor in the preference for thermoplastic valves. Thanks to ergonomic handles and user-friendly mechanisms, opening and closing operations can be performed quickly, safely, and effortlessly. This situation reduces the workload of operators, especially in systems requiring frequent intervention, minimizes errors, and increases operational safety. Some models of thermoplastic valves are designed to be integrated with pneumatic or electric actuators in addition to manual use. Thus, they can be easily adapted to automation systems.
Additionally, the resistance of thermoplastic valves to external environmental conditions makes them usable in a wide range of applications. They can be used in open areas thanks to UV-protected versions, while they can perform without losing their performance in humid, salty, or chemically contaminated environments. This environmental resistance contributes to the system remaining long-lasting and requiring low maintenance.
On the other hand, the high machinability of the materials used in the production of thermoplastic valves allows manufacturers to develop models suitable for special size and connection needs. This flexibility enables solutions tailored to the unique technical needs of each sector and line. These valves, which can be customized with wide diameter, connection type, gasket material, or actuator options, can work efficiently even in non-standard systems.
In conclusion, thermoplastic valves are indispensable elements of modern process lines with their flow performance, energy efficiency, lightness, ease of installation, space-saving, and practical use beyond their chemical resistance. Thanks to their versatile structures, they are not only capable of meeting today's needs but also the demands of future technological systems. Their advantage in terms of both initial investment cost and total cost of ownership makes them an ideal choice for industrial enterprises seeking sustainable and economical system solutions.
Material Selection: Which Plastic is Used Where?
The performance of thermoplastic valves within the system largely depends on the type of plastic used in their production. Each thermoplastic material has specific physical, chemical, and thermal properties, and these properties directly determine under what conditions, with what types of fluids, and in which industrial applications the valve can be used. Therefore, when selecting a thermoplastic valve, not only the type of valve but also the type of material should be
carefully evaluated. Incorrect material selection can lead to leakage, deformation, or system failures over time.
The most common materials in thermoplastic valves are PVC-U, PVC-C, PP-H, and PVDF. Each of these materials offers different advantages and is preferred for specific application scenarios.
PVC-U (Unplasticized Polyvinyl Chloride) is the most commonly used and economical among thermoplastic valves. It has a wide range of chemical resistance and is suitable for working with acidic or slightly basic solutions. It can be used in a wide range of applications from drinking water systems to swimming pools, light chemical processes to agricultural irrigation systems. The maximum operating temperature is generally around 60°C, so it is not recommended for processes involving high temperatures. However, due to its low cost and high sealing performance, it is quite advantageous in terms of cost/performance ratio.
PVC-C (Chlorinated Polyvinyl Chloride), although structurally similar to PVC-U, stands out with its ability to operate at higher temperatures. PVC-C valves, whose thermal resistance is increased through chlorination, can be safely used in systems up to approximately 90°C. Thanks to this feature, they are frequently preferred in areas with temperature sensitivity such as hot water distribution systems, central heating lines, chemical processes, and industrial cleaning systems. Additionally, since they show high resistance to many chemicals, they offer a safe solution in both residential and industrial installations.
PP-H (Polypropylene Homopolymer) is known for its high resistance to aggressive chemical substances. As the homopolymer version of polypropylene, PP-H behaves inertly against both acids and bases and is therefore widely used in the chemical industry, pharmaceutical production, laboratory systems, and wastewater treatment plants. It can also be preferred in applications requiring high purity because the material content does not release ions into the external environment. The operating temperature can generally reach up to 90°C. With these features, it is both a durable and environmentally compatible option.
PVDF (Polyvinylidene Fluoride) has the highest chemical and thermal resistance among thermoplastic materials. PVDF is the ideal solution in extremely corrosive environments, high-temperature operating lines, and processes requiring high purity. The maximum operating temperature can reach up to 140°C and it is compatible with almost all acids, bases, solvents, and oxidizing agents. Therefore, it is frequently preferred in nuclear power plants, semiconductor production lines, pharmaceutical production environments, and ultra-pure water systems. PVDF is also resistant to fire and does not experience performance loss in outdoor applications thanks to its excellent UV resistance. It is more costly compared to other thermoplastics, but its superior performance makes it indispensable, especially in critical applications.
The correct selection of thermoplastic material is vital for the integrity and safety of the system. In the selection process, not only the chemical structure of the fluid but also parameters such as temperature, pressure, UV exposure, mechanical load, installation conditions, and contact duration with the valve should be considered. For example, while PVC-U is sufficient in a system working with short-term contact, PVDF should be preferred in a line carrying hot solvents continuously. Additionally, the gasket and connection elements used with the valve must also be chemically compatible with the material.
In this context, material selection is not only a technical decision but also related to the economic and environmental sustainability of the system. The right material reduces maintenance needs, extends system life, and minimizes risks such as leakage. This directly affects both user safety and the long-term operating costs of the facility.
Usage Areas and Industrial Applications
Thermoplastic valves are used safely in many industrial applications thanks to their features such as chemical resistance, mechanical durability, and long life. In systems where these valves are preferred, aggressive, corrosive, or temperature-challenging fluids are usually involved. Therefore, their areas of use are not only broad but also encompass applications of vital importance. Thanks to the material variety and valve types that can respond to different needs in each sector, thermoplastic valves offer versatile and flexible solutions.
The Chemical Industry is one of the main areas where thermoplastic valves are most intensively used. In this sector, various acids, bases, solvents, salt solutions, and gases are worked with, which are highly reactive and abrasive fluids. Thermoplastic valves used in reactor inlets and outlets, chemical mixers, dosing systems, and intermediate tank connections play a critical role in ensuring the safety of the system. Especially materials like PVC-C, PP-H, and PVDF maintain their structural integrity even in long-term contact with aggressive chemicals, providing high sealing and process continuity. This reduces production downtimes and minimizes maintenance costs for businesses.
In sectors like the Food and Beverage Industry, where hygiene is prioritized, thermoplastic valves are used in cleaning and disinfection systems. Their compatibility with chemical cleaners circulating in CIP (Cleaning in Place) systems helps meet hygiene standards. At the same time, due to their inert structures, they do not impart taste, odor, or color to the fluid. This provides high food safety, especially in bottling lines, additive dosing units, and liquid transfer systems. With special production materials compatible with FDA and European Union regulations, they provide both hygienic and economic solutions.
In the Energy and Natural Gas Sectors, thermoplastic valves provide advantages against corrosive external factors, especially in lines where LPG, LNG, and other flammable gases are transferred. Problems such as oxidation or internal corrosion that metal valves may experience over time are not an issue with thermoplastic materials. Additionally, these valves are resistant to harsh conditions encountered in salty marine environments. With these features, they can be safely preferred in open field pipelines, refineries, or offshore platforms.
Shipbuilding and Maritime Applications are another area where the durability of thermoplastic valves against external environmental conditions is important. In maritime systems dominated by harsh environmental factors such as saltwater, high humidity, UV rays, and vibrations, stainless steel components may deform over time, while thermoplastics like PVC-U or PVDF show much longer-lasting performance. These valves are used in shipboard cooling systems, bilge water lines, desalination systems, and wastewater management.
The Paper and Pulp Industry is also one of the sectors with a high need for thermoplastic valves due to the intense use of aggressive chemicals in its processes. Especially in stages involving bleaching, dyeing, and lime removal, the material resistance of the valves is of critical importance. PVC-C and PP-H materials ensure the system operates safely thanks to their resistance to such chemicals. Additionally, their low maintenance requirements make it easier to keep up with the high production pace in these sectors.
Heating and Cooling Systems are another important area where thermoplastic valves are used in different ways in both industrial and commercial areas. Especially PVC-C valves are preferred in hot water lines, central heating systems, and steam-operated secondary processes due to their resistance to carrying high-temperature fluids. Similarly, in cooling towers or industrial chiller systems, valves made from materials compatible with chemical additives used to maintain the chemical condition of the water support system stability.
Wastewater and Treatment Plants are also among the areas where thermoplastic valves are most intensively used. Especially in these facilities, where acidic or basic pH levels are worked with, all components of the system must have high chemical resistance. Thermoplastic valves are used at many different points, from dosing treatment chemicals to sludge transfer and filtration lines. Their corrosion resistance extends the life of the system and significantly reduces maintenance costs.
Pool and Spa Systems are areas where the use of thermoplastic valves is lighter but widespread. PVC-U valves offer ideal solutions in pool circulation systems, dosing pumps, and automatic control lines due to their high resistance to chlorinated and salty water.
As can be understood from all these examples, thermoplastic valves are components that can adapt to sector-specific needs, can be customized with a wide range of material options, and offer superior performance against environmental challenges. They not only ensure the operation of the system but also make a difference in many areas such as operational safety, ease of maintenance, and total cost optimization.
Advantages Compared to Metal Valves
Metal valves have been among the fundamental flow control elements of industrial systems for many years. Known for their ability to withstand high temperatures and pressures, these valves have provided reliable solutions in the control of water, steam, gas, and various liquids. However, with the advancement of technology and diversification of processes, some disadvantages of traditional metal valves have become more visible. Especially in systems exposed to chemicals, saltwater, abrasive vapors, or solvents, metal valves experience performance loss over time; issues such as rust, internal decay, and gasket deformations arise. Such deteriorations threaten system safety and jeopardize production continuity.
Thermoplastic valves, on the other hand, offer a much more resistant solution to such adversities. While stainless steel or cast valves can oxidize over time, thermoplastic materials are inherently immune to oxidation. Their surfaces are closed to chemical interactions and do not react with moisture and air. Therefore, even when used outdoors, they can maintain their performance for many years. Additionally, since they do not contain heavy metals or toxic components, they provide a safer use for both the environment and user health. This feature is a significant advantage, especially in sectors where hygiene is critical, such as food, pharmaceuticals, and drinking water.
Corrosion, another weak point of metal valves, not only causes material loss but also leads to roughness on the internal surface, increasing flow resistance. This situation reduces the overall energy efficiency of the system. The internal surfaces of thermoplastic valves, however, are smooth and non-stick. As a result, the fluid passes through the valve with minimal friction. Thus, pressure loss is low, pump load decreases, and energy savings are achieved. This creates a significant operational advantage, especially in long lines or high-flow systems.
In terms of mechanical durability, thermoplastic valves are competitive with metal valves within certain limits. Although metal materials are still preferred in very high temperature and pressure processes, thermoplastic solutions have become much more economical and sustainable in systems requiring medium-level temperature and chemical resistance. Failures such as gasket hardening, flange deformation, or cracks at weld points seen in metal valves occur much less frequently in thermoplastic valves. This is because these valves are made from engineering plastics designed with controlled flexibility and high impact resistance.
In terms of maintenance processes, thermoplastic valves are user-friendly. The worn parts of metal valves are often difficult and costly to replace. Thermoplastic valves, on the other hand, can be easily disassembled, cleaned, or renewed in parts thanks to their modular structures. This feature shortens maintenance times within the operation, reduces downtime, and keeps production loss to a minimum. Additionally, since thermoplastic material is easier to process, customization options are wide; this provides manufacturers with the flexibility to develop solutions suitable for specific needs.
In addition to all these technical advantages, thermoplastic valves offer significant gains in terms of cost. Both initial investment costs are generally lower than their metal counterparts, and long-term maintenance and replacement costs are less. Additionally, being lighter provides logistical advantages during transportation and installation stages. For example, while the installation of a large-diameter metal valve requires a crane or special equipment, a thermoplastic valve can usually be carried and installed manually.
In conclusion, thermoplastic valves stand out not only with their durability compared to metal valves but also with their ease of maintenance, energy efficiency, environmentally friendly structures, and economic advantages. Considering the modern industrial demands that push the limits of traditional systems, thermoplastic valves have become a more rational, sustainable, and safe alternative for most applications.
What to Consider When Choosing a Thermoplastic Valve?
The correct selection of thermoplastic valves is critically important for the performance, safety, and long-term sustainability of an industrial system. Although thermoplastic materials offer advantages such as high chemical resistance, lightness, and low maintenance needs, an incorrect selection can make the system inefficient, increase the risk of failures, and raise costs. Therefore, a detailed engineering evaluation is necessary before purchasing a thermoplastic valve.
The first and most fundamental step in valve selection is to thoroughly analyze the chemical composition of the fluid to be transported in the system. Fluids such as acids, bases, solvents, saltwater, gases, organic solvents, or aggressive chemicals are not compatible with every material. A common material like PVC-U is suitable for light chemicals, while advanced materials like PVDF can be used in extremely corrosive
environments. However, if this difference is not correctly evaluated, the body or sealing elements of the valve may be damaged in a short time. This situation can lead not only to valve failure but also to the entire line being out of service. Therefore, manufacturer technical documentation should be reviewed, and material-fluid compatibility tables should be used as a basis.
In addition to the chemical structure of the fluid, the operating temperature and pressure level in the system should also be carefully evaluated. Each thermoplastic material shows stable performance within a certain temperature and pressure range. For example, while PVC-U is generally suitable up to 60°C, PVC-C can withstand up to 90°C. Materials like PP-H and PVDF have higher temperature tolerance. However, as the temperature increases, the strength of the material may decrease; this can lead to valve deformation, sealing elements failing to perform their function, or body cracks. Similarly, in high-pressure lines, not only the body but also the connection points, gaskets, and handle mechanisms of the valves should be evaluated.
Another important criterion is the valve connection type and installation method. The valve can be flanged, threaded, socket welded, or quick connection (union) type. This selection depends on factors such as the design of the pipeline, the installation area, and service convenience. Additionally, how the valve will be positioned is also important. Whether it will be mounted horizontally or vertically, the level of exposure to environmental factors (such as sunlight, dust, humidity, vibration) can affect material selection. If a material unprotected against UV rays is used outdoors, deterioration such as color change, cracking, or breaking may occur over time. For such situations, UV-stabilized versions or protective coatings should be preferred.
The environmental conditions where the valve will be used should also not be overlooked in the decision-making process. A valve to be used in underground installations is expected to be resistant to challenges such as underground moisture, soil pressure, chemical leaks, and limited access. In lines close to a pump where vibration is intense or in moving systems, the valve should have the flexibility to maintain body integrity and gasket systems that can absorb vibration.
Additionally, the operating scenario of the system should be taken into account. In applications where the valve is frequently opened and closed (such as dosing systems), it is important for the handle mechanism to be ergonomic and durable. If it will work integrated with automation systems, a design compatible with electric or pneumatic actuators should be preferred. At this point, technical details such as the valve's torque value, compatibility with the actuator, and mounting adapters should be carefully examined.
In addition to these, operational conveniences such as maintenance access, replaceable part structure, ease of cleaning, and service support should also be part of the selection process. Especially for large-scale systems or businesses working in critical processes, products that shorten maintenance times and spare parts supply times should be preferred. Some manufacturers offer modular designs that allow only the replacement of faulty parts; this provides significant cost advantages in the long run.
Finally, the certifications and compliance with standards of the selected product should be checked. Certifications such as NSF for drinking water applications, FDA for systems in contact with food, and ISO, DIN, or EN standards for industrial installations are indicators that verify the safety and quality of the product.
In light of all these criteria, selecting a thermoplastic valve requires technical expertise. Random or solely price-focused choices may seem like a gain in the short term but can pose serious operational risks in the long term. Therefore, valve selection should be made together with process engineers, system designers, and manufacturer technical teams; needs should be thoroughly analyzed, and the most suitable material and structure should be chosen in harmony with long-term goals.
Conclusion: Indispensable for Modern Industrial Systems
Thermoplastic valves, with their technical superiority and versatile usage features, have become not just an alternative option but a primary choice for many applications in today's modern industrial systems. Their high resistance to chemicals, natural resistance to corrosion, ease of installation provided by their low specific weight, and contribution to system efficiency with low friction on their internal surfaces clearly demonstrate why these valves have become so widespread.
Minimizing energy consumption, maximizing system safety, and reducing maintenance requirements are critical success factors in the increasingly competitive industrial world. Thermoplastic valves, with their low operating cost, long service life, and modular structures, meet the expectations of both system engineers and operation managers at this point. Especially in chemical process lines, water treatment plants, food and pharmaceutical production lines, or applications requiring high purity, thermoplastic solutions stand out with their high performance in many areas where metal valves fall short.
In new facility installations, engineering teams are acting more consciously than ever in material selection to increase system efficiency and ensure long-term sustainability; this causes thermoplastic valves to stand out even at the project planning stage. Similarly, in the revision or modernization processes of existing systems, the preference for longer-lasting, more economical, and environmentally friendly thermoplastic valves instead of aging metal valves significantly reduces the total cost of ownership of systems.
Moreover, the environmental impacts of the materials used in the production of these valves are lower compared to metal products. Environmental benefits such as recyclability, not containing heavy metals, and consuming less energy during production also provide an important advantage for companies adopting a sustainable production approach. In this regard, thermoplastic valves offer a solution suitable for the requirements of the age not only in technical but also in environmental and economic criteria.
As Ekin Industrial, with our years of sector experience and engineering infrastructure, we offer high-quality thermoplastic valve solutions suitable for the needs of different sectors. With different material options such as PVC-U, PVC-C, PP-H, and PVDF, we develop solutions specific to all kinds of process conditions and stand by our customers in both project planning and after-sales technical support processes. With our product variety and engineering consultancy services, we aim to ensure safe, efficient, and sustainable flow control in your facilities.
It should be remembered that the correct valve selection is not just an equipment choice but a strategic decision that directly affects the overall health of the system, employee safety, and operating cost. Therefore, the selection of thermoplastic valves should be carried out based on technical knowledge, considering process details, and in harmony with long-term goals. For thermoplastic valves, which will be an indispensable part of more environmentally friendly, more economical, and smarter solutions in future industrial systems, you can also benefit from Ekin Industrial's expertise and contact us for special solution suggestions for your business.