�ǳ�web Knowledgebase - DR-2

Precision Control Solutions for Commercial Inkjet Printing

Rachel Desenberg — Tue, 30 Jul 2024 19:51:21 +0000

Category:

�ǳ�web offers a variety of precision control solutions that resolve critical issues for commercial inkjet printing OEMs such as inconsistent ink flow, inefficient cleaning, uneven coating applications, and component durability.

Problem:

Inconsistent ink flow, inefficient cleaning, uneven coating applications, and inadequate component durability contribute to poor print quality and costly downtime.

Commercial inkjet printing OEMs face a variety of critical issues that significantly affect the quality and efficiency of their printing operations. The primary problem is often inconsistent ink flow, caused by air bubbles and blockages in the ink delivery systems. This inconsistency leads to frequent print quality defects and increased downtime for maintenance. Additionally, the cleaning system for the print heads and other components often does not effectively remove ink residues, causing frequent clogging. This reduces the lifespan of the print heads and necessitates more frequent replacements.

OEMs also often experience issues with the coating process for varnishing and laminating, which results in uneven application, product waste, and inconsistent finishes. In addition, the durability of the valves is often inadequate, leading to frequent replacements and increased operational costs.

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Solution:

�ǳ�web's precision control components enhance print quality and operational efficiency for commercial inkjet printing OEMs

To address these challenges, �ǳ�web precision control components are integrated directly into the OEM printing systems. For the ink delivery system, �ǳ�web’s PIV series valves, with their PTFE and PEEK bodies and absence of elastomers, are ideal for preventing the clogging issues that often result from ink drying on the valve poppet or orifice. This significantly reduces the risk of the valves leaking or sticking over time, ensuring reliable long-term performance. These valves are also ideal for use in the cleaning systems to control the flow of cleaning solvents to the print heads and other components. �ǳ�web media isolation valves efficiently handle various cleaning agents, ensuring thorough and effective cleaning processes that minimize clogging and extend the lifespan of the print heads.

�ǳ�web’s E2S series compact 10 mm media isolation valves can also be installed to regulate the ink flow from the storage tanks to the printing presses. These valves provide precise control and prevent air bubbles and blockages, ensuring a consistent and reliable ink supply. Additionally, the Cordis CPC series microcontroller can be integrated for ultra-high resolution and repeatable digital pressure control. This closed-loop system will maintain consistent pressure, further enhancing the ink delivery process and reducing defects.

For coating applications, �ǳ�web’s DR-2 series precision regulators provide fine control over the flow rates of coating materials, ensuring even application of varnishes and laminates. This reduces material wastage and achieves a uniform finish on the printed materials. �ǳ�web’s stainless steel push-quick fittings can also be installed to further enhance component durability and simplify maintenance. Constructed from high-grade 316 stainless steel, these fittings provide robust connections and allow full flow through the hose or tubing I.D., eliminating the smaller orifice often required in barb fittings.

By integrating high quality precision control components from �ǳ�web, commercial inkjet printing OEMs are able to realize significant improvements in their printing operations. The solutions �ǳ�web provides not only resolve existing problems, but also enhance overall efficiency, reliability, and quality of the printing processes.

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Related Products
E2S Series Compact 10 mm Isolation Valve	Cordis CPC Series Electronic Pressure Controller	Stainless Steel Push-Quick Fittings	DR-2 Series Precision Regulator

PIV Series PEEK Media Isolation Valve

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CPC

E2S10

DR-2

PIV

NIV

NPV

Custom Refrigerant Valve for Monopolar RF Equipment

Rachel Desenberg — Tue, 25 Jun 2024 13:43:50 +0000

Category:

Applications

A cosmetic surgery OEM was experiencing challenges with the valves in their monopolar RF equipment. To address the issue, �ǳ�web developed a custom electronic valve with high-performance seals to meet the specific needs of the OEM's unique application.

Problem:

Valve leak issues undermine performance in OEM's monopolar RF equipment

An OEM of monopolar RF equipment for collagen regeneration required a specialized valve capable of withstanding high pressures and preventing refrigerant leakage. The existing valves were unable to maintain a low leak seal under the elevated pressures necessary for the application, and standard valves were not compatible with the R-134 refrigerant media.

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Solution:

�ǳ�web develops custom valve to meet OEM's specific application needs

�ǳ�web developed a custom electronic valve that incorporated high-performance seals suitable for the media and was specially engineered to meet the performance requirements of the application's high-pressure conditions. In this application, RF energy is transmitted to penetrate the skin, heating cells to promote new growth and improve elasticity, thereby restoring skin vitality. The valve precisely controls the flow of refrigerant media to cool the skin during this process, preventing surface burns. By collaborating closely with the OEM, �ǳ�web ensured that the valve achieved ultra-low leak rates and compatibility with noise and power requirements, providing a reliable solution that enhanced the equipment's performance.

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Custom Solutions	DR-2 Series Precision Regulator	ES Series Electronic Valve

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DR-2

Custom Solutions

custom

Residual Gas Analyzer for Semiconductor Manufacturing

Rachel Desenberg — Fri, 02 Jun 2023 16:02:33 +0000

Category:

Videos

Semiconductor manufacturing is a complex and specialized process with numerous applications for precision gas and pressure control. Learn more about how �ǳ�web's engineering team combined our DR-2 regulator and analytical valve with a special manifold to create a precision flow controller that solved a unique challenge.

Video filmed at �ǳ�web in Cincinnati, Ohio

VIDEO TRANSCRIPT:

The manufacturing of semiconductors is a complex and specialized process with numerous applications for precision pressure and flow control. One specific device used in semiconductor manufacturing is a residual gas analyzer. In this application, harsh chemicals are pumped into the device, with numerous sensors used to monitor the process.

A semiconductor manufacturer was facing a big challenge with premature pump failure. The harsh media was degrading the bearings inside the pumps. To address this issue, they devised a solution to install a device that would create a nitrogen blanket around the pump bearings—thus preventing the media from damaging the bearings. However, size, weight, and cost made implementing this solution challenging. That’s when they reached out to �ǳ�web for assistance.

We developed a solution that utilized a precision DR-2 mechanical regulator and an analytical valve with a specific orifice inside to create a precision flow controller. Both products were combined in a small manifold, and we calibrated them to ensure every assembly would maintain the nitrogen blanket and protect the pump bearings.

The accuracy of the DR-2 mechanical regulator allowed the customer to choose a smaller, more cost-effective option to control the pressure flowing through the fixed orifice. The result was a precision flow controller that could be controlled with a simple analog signal open and close the valve. �ǳ�web’s ability to precisely tune the controller to the customer’s exact flow requirements solved the problem and created a long-lasting, robust solution.

�ǳ�web has the expertise and value-added solutions to meet your application needs. If you need assistance with a challenging application, please give us a call.

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Analytical

DR-2

Pressure Driven Flow Control

Rachel Desenberg — Wed, 04 Aug 2021 18:46:35 +0000

Category:

Applications

�ǳ�web pressure and flow control components make for an ideal solution for precise control of critical gases in bioprocessing applications and are a smart alternative to syringe and peristaltic pumps. Smooth acceleration and stable, pulsation-free, bidirectional flow of liquids are achievable, minimizing the damaging effects of acceleration, pressure surges, shear, and impact forces on sensitive media.

A �ǳ�web Cordis Electronic Pressure Controller is precisely maintaining the headspace pressure of a reservoir. The very fine resolution capability of a second Cordis is actively controlling differential pressure to smoothly accelerate the flow of the liquid media to a stable, pulsation-free rate into and out of the reservoir. The piloted pinch valves allow use of the same pressure controllers to control multiple flow paths, in both directions and at differing flow rates.

Watch a video of a similar demo:

Related Products
15 mm Electronic Valves	DR-2 Precision Regulator	Electronic Pinch Valves	Pneumatic Pinch Valves

Cordis Electronic Pressure Controls	Cordis Electronic Flow Controls

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Mechanical vs. Electronic Pressure Regulators: A Detailed Comparison

Rachel Desenberg — Wed, 14 Jul 2021 20:32:37 +0000

Category:

Videos

Pressure regulators are essential components in many systems, tasked with maintaining consistent pressure despite fluctuations in input or downstream demand. The choice between mechanical and electronic pressure regulators can have a significant impact on performance, and understanding the strengths and weaknesses of each type is crucial for selecting the right one for a given application. The decision often boils down to controllability, accuracy, dynamic performance, and cost.

Mechanical Regulators

Mechanical regulators have been around for a long time and are widely used due to their simplicity and reliability. These devices rely on physical components like springs, diaphragms, and orifices to maintain a steady pressure. Once set, they are largely "set it and forget it" devices, ideal for stable systems with minimal fluctuations.

Electronic Pressure Regulators

Electronic regulators, on the other hand, use sensors, processors, and electronically controlled valves to regulate pressure more dynamically. They are more complex but offer superior precision and adaptability, making them ideal for applications that require real-time adjustments and integration with other systems. These devices rely on physical components like springs, diaphragms, and orifices to maintain a steady pressure. Once set, they are largely "set it and forget it" devices, ideal for stable systems with minimal fluctuations.

Video filmed at �ǳ�web in Cincinnati, Ohio

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Controllability: A Clear Advantage for Electronics

In terms of controllability, electronic regulators far outpace mechanical regulators. Electronic systems are designed to adjust pressure in real-time, based on feedback from integrated sensors. This feedback loop allows for constant monitoring and precise adjustments to the system’s pressure, even when conditions change.

Electronic Pressure Regulators	Mechanical Pressure Regulators
Their ability to interface with other systems and adjust on-the-fly makes them highly versatile. Systems can be automated, and pressure can be fine-tuned based on varying inputs or external factors.	A mechanical regulator, by contrast, is controlled by a fixed adjustment screw. Once set, it stays at that level until manually adjusted again. There is no real-time adaptability or integration with other systems, making it less suited for dynamic environments.

Accuracy: Fixed vs. Dynamic Precision

When it comes to accuracy, electronic regulators offer greater potential for precision.

Electronic Pressure Regulators	Mechanical Pressure Regulators
These systems take advantage of internal sensors and processors that monitor pressure continuously. This allows for dynamic adjustments to ensure pressure remains within the desired range, even in systems with fluctuating demands or inlet pressures. This real-time feedback enhances accuracy, particularly in systems that require precision under varying conditions.	The accuracy of a mechanical regulator is determined by its design—specifically, the diaphragm size, orifice size, and spring tension. While the performance is predictable and consistent, once set, there’s no way to adjust or compensate for fluctuations in real-time. Accuracy is generally fixed based on the model’s design.

Dynamic Performance: Flexibility for Changing Conditions

Dynamic performance refers to how well a regulator handles fluctuations in pressure. This is another clear advantage for the electronic regulators.

Electronic Pressure Regulators	Mechanical Pressure Regulators
Electronic pressure regulators can adjust quickly to changes in both inlet pressure and downstream demands. This is crucial for systems where conditions are constantly changing, such as in high-performance manufacturing or medical applications. Their ability to make quick adjustments ensures stable operation even in fluctuating environments.	In contrast, mechanical regulators are designed for more static environments. Once set, they are less adaptable to changes in system conditions. For stable, low-demand systems, mechanical regulators work well. However, if the pressure fluctuates or if dynamic changes are frequent, a mechanical regulator may struggle to keep up.

Cost: Weighing Performance Against Price

Cost is often a deciding factor when choosing between mechanical and electronic regulators. While electronic regulators offer enhanced performance and flexibility, they also come at a higher price.

Electronic Pressure Regulators	Mechanical Pressure Regulators
The additional complexity of sensors, processors, and feedback loops means that electronic regulators are generally more expensive. However, the added cost is often justified in high-demand applications where precision and adaptability are crucial. For example, industries such as aerospace or robotics benefit from the advanced capabilities that electronic regulators provide.	Mechanical regulators are simpler and therefore more affordable. They are ideal for applications that don’t require constant adjustments or advanced features. For systems that operate in stable conditions and have straightforward pressure control needs, a mechanical regulator offers a reliable, cost-effective solution.

Choosing the Right Regulator for Your Application

The choice between mechanical and electronic regulators depends largely on the specific needs of your system. Here's a quick breakdown to guide your decision:

Electronic Pressure Regulators	Mechanical Pressure Regulators
Choose an electronic regulator if... • You need real-time adjustments or dynamic control • Your system requires high accuracy and adaptability • Integration with other systems or automation is needed • The cost is justifiable due to the need for enhanced performance and flexibility	Choose a mechanical regulator if... • Your system operates in a stable, low-demand environment • You need a simple, reliable solution without the need for constant adjustments • The cost needs to be minimized while still maintaining good performance

Both mechanical and electronic regulators have their place in engineering applications, and the right choice depends on balancing factors like performance requirements, cost, and system demands. Ready to select a pressure regulator for your system? Contact us today for expert advice, or click here to locate your nearest �ǳ�web distributor.

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MAR-1 Series Regulator	DR-2 Series Precision Regulator	Cordis Series Electronic Pressure Regulator

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MAR-1

CPC

DR-2

Nitro Cold Brew Coffee

Rachel Desenberg — Wed, 23 Jun 2021 20:12:14 +0000

Category:

Applications

Did you know? �ǳ�web products are used in cold brew coffee applications to help deliver a consistent cold brew, glass after glass, by utilizing nitrogen infusion.

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DR-2 Series Precision Regulator

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DR-2

dispensing

Precise, Consistent Control Supports Cell Proliferation

Rachel Desenberg — Thu, 25 Mar 2021 18:47:36 +0000

Category:

Applications

Bioreactors are manufactured devices or systems that support biologically active environments. They are essentially vessels in which a chemical process is carried out involving organisms or biochemically active substances derived from organisms. Part of this process is sparging, which is the introduction of air, oxygen, carbon dioxide, and nitrogen to the cell culture media.

Problem:

Obtaining better control of the environment to better optimize cell proliferation

Optimal cell culture growth requires not only precise control, but also consistency. In this case, this bioreactor manufacturer was looking to enhance cell proliferation by improving both of these factors.

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Solution:

DV series valves provide exceptional precision and repeatability

�ǳ�web’s DV series valves were ideal for this application due to the exceptional level of precision, repeatability, and low leak performance they provide. Four DV series valves were selected to be used to control oxygen, air, carbon dioxide, and nitrogen being fed through the bioreactor’s sparger in order to control pH and dissolved oxygen (perfusion media) in the cell culture media during cell cultivation. �ǳ�web also configured a custom manifold to fit the application’s special mounting and porting requirements. The DV series valves enabled better, more precise, more consistent control over the critical parameters impacting cell growth proliferation within the bioreactor.

Pinch valves and proportional controls can also be used to automate the addition of perfusion media to cell culture media in order to optimize the proliferation environment. Additionally, precision proportional pressure controls are well-suited for maintaining the pressure and gas mixture in the headspace of bioreactors.

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DV Series Precision Electronic Valves	NIV Series Solenoid-Operated PTFE Media Isolation Valves	NPV Series Solenoid-Operated Miniature Pinch Valves	NPP Series Pneumatic Miniature Pinch Valves

Cordis Series Precision Electronic Controls	DR-2 Precision Regulator	EVP Series Proportional Valves	D VP Series Proportional Valves

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How does �ǳ�web's DR-2 precision regulator compare to the MAR series?

Rachel Desenberg — Fri, 13 Oct 2017 19:11:25 +0000

Category:

Videos

�ǳ�web's new DR-2 regulator provides the same robust durability as the original MAR regulator but with greater accuracy and repeatability. This video highlights some of the features and benefits of these regulators and explains the new application possibilities available with the DR-2 line.

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MAR Series Regulators	DR-2 Series Precision Regulators

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DR-2

MAR-1

How to Reduce Operating Costs by Adding Pressure Regulators

Rachel Desenberg — Mon, 24 Oct 2016 15:06:14 +0000

Category:

Videos

Steve Vance, Central District Manager for �ǳ�web distributor Gulf Controls of Tampa, Florida, demonstrates how adding pressure regulators to your system can reduce costs.

Related Products:
DR-2 Series Precision Regulators	MAR-1 Series Pressure Regulators

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Regulator

DR-2

MAR

Laboratory Automation for Pesticide Residue Analysis

Rachel Desenberg — Sun, 28 Feb 2016 15:00:06 +0000

Category:

Applications

To help keep consumers safe, laboratories test fruits, vegetables, and other foods for pesticide residues. Cutting edge laboratories are now able to test more of these samples than ever before—with improved precision and greater accuracy—through automation made possible with �ǳ�web miniature pneumatic valves.

An October 2014 report by the U.S. General Accountability Office (GAO) suggests the Federal Drug Administration (FDA) and the U.S. Department of Agriculture's (USDA) Pesticide Data Program "have room for improvement in the way they collect and share data on pesticide residues on fruits and vegetables and other food." The GAO claims that the FDA's "approach to monitoring for violations has limitations," pointing to the fact that while the FDA shows that "pesticide residue violation rates in 10 selected fruits and vegetables were low" from 2008 to 2012, "less than one-tenth of 1% of imported shipments in 2012" were tested for the pesticides. However, cutting edge laboratories now have the potential to test more samples thanks to an innovative new machine designed to increase efficiencies in the pesticide residue analysis process.

The most common method for examining pesticide residues in fruit, vegetables and other foods is known as the QuEChERS Method. QuEChERS (pronounced "catchers") stands for Quick, Easy, Cheap, Effective, Rugged and Safe. Originally published in 2003, this method has since been accepted around the world and is possibly the most used preparation method for multi-residue analysis today. Using the QuEChERS Method, the analyst homogenizes a sample (fruits, vegetables, etc.) in a blender and puts it in a centrifuge tube with a reagent, then agitates it for one minute. The reagents used depend on the type of sample to be analyzed. Following this, the sample is put through a cleanup column prior to analysis by gas-liquid chromatography.

The AutoMate-Q40, designed by Teledyne Tekmar, Mason, Ohio, is the first product specifically designed to optimize and automate the QuEChERS extraction process. It enables laboratories to achieve improved precision and accuracy for QuEChERS sample preparation while increasing sample capacity and improving workplace safety. Prepared sample trays are loaded into the machine and a method and/or schedule is selected through the TekTouch™ software control. The chemist can now step away and perform other tasks, such as important data analysis, while the AutoMate-Q40 methodically executes a litany of manual tasks to complete the sample extraction. It decaps the sample vial, adds solvent and standard, recaps and vortexes the sample, decaps and adds salt to the sample, recaps and shakes the sample, centrifuges the sample and validates the sample's extract volume. If clean-up is desired, the AutoMate-Q40 will then pipette the sample extract into dSPE clean-up, shake the clean-up vial, centrifuge the clean-up vial, validate the clean-up extract volume, and pipette the clean-up volume into a final extract volume. Finally, the extract vial is returned to the sample tray for analysis.

This automation is powered by pneumatics, a decision that was ultimately based on cost and ease of programming. For Michael Maroon, Mechanical Engineer at Teledyne Tekmar, the choice was clear. "The air valve actuates, then the cylinder moves. As opposed to using a motor to drive a lead screw or a pulley or a belt until it hits an end stop—all while utilizing encoder feedback to verify how many steps were required to make the motion. It was simpler," says Michael. "For example, on our capping wheel where we're capping different diameter vials, we just want to push the wheel over apply a force on the vial, then spin it to remove the vial cap. Electronically, that would difficult to implement because a feedback device would be needed to signal how much force the unit is applying against the vial. That would be very time-consuming and costly to implement." Additionally, according to Tom Hartlein, Tekmar's Product Line Manager, "We know historically from using pneumatic solutions for our other product lines for 30+ years, our warranty values are typically less than 1%. That translates into a high probability of success using pneumatics."

When the time came to specify components, Tekmar consulted with Isaacs Fluid Power who recommended �ǳ�web's line of 10 and 15 mm valves. Offered in both Normally-Open or Normally-Closed models, these valves are perfect for small areas where compact electronically-controlled pneumatics are needed. According to Michael Maroon, an added benefit was the flexibility of having the same valve throughout the machine, thereby simplifying the need for inventory. In addition to the pneumatic valves, other �ǳ�web products integral to the machine include fittings, pressure regulators, and tubing. Working in concert, Teledyne Tekmar, �ǳ�web Instrument Laboratory and Isaacs Fluid Power engineer, manufacture and build the components and subassemblies that make up the machine's pneumatic controls.

Teledyne Tekmar's AutoMate Q-40 is an impressive example of laboratory automation made possible with �ǳ�web pneumatics. In addition to pesticide multi-residue analysis, other possible applications include analysis of polycyclic aromatic hydrocarbons (PAH) in seafood, analysis of veterinary drug residues in livestock, analysis of nutraceuticals and dietary supplements and more. Hartlein says, "the possibilities are basically unlimited. Generally, anything that goes through an extraction that requires a solid, addition of a solvent, shaking, centrifuging and pipette vetting is a candidate for the AutoMate-Q40."

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10 mm Valves	15 mm Valves	Pressure Regulators	Hose & Tubing

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