31. März 2025

Pioneering breakthrough in high-pressure valve technology

Kategorie News

• Significant reduction in installation space and weight: ValvolutionX is 50 % smaller and 75 % lighter than conventional, compressed air-operated high-pressure needle valves.
• The valves in the ValvolutionX series have separate leakage connections for the controlled discharge of high-pressure leakage.
• Reduction of maintenance time by more than 60%: In-situ maintenance enables valve maintenance in the installed state and in just a few steps.

Increased efficiency, automation, compact design and higher performance - the demands on modern high-pressure valves are constantly increasing. The larger the nominal size and the higher the operating pressure, the more force and correspondingly larger air actuators are required to operate high-pressure needle valves. This increases the installation space considerably and poses a challenge for the realisation of compact system solutions. With ValvolutionX, Maximator GmbH is now presenting a pioneering solution that addresses precisely this point and revolutionises the high-pressure valve technology that has been around for 50 years: The new valves in the series are designed to be ultra-compact and developed for flow rates from 9/16″ to 1″ connections.

Thanks to a new operating principle, the air actuator can be reduced to a diameter of 3 inches. As a result, the size of the compressed air actuator for shutting off and relieving high-pressure applications with hydrogen and inert gases up to 1050 bar can be realised in an unprecedentedly compact size. ‘The functional principle of all high-pressure valves available on the market has hardly changed for around 50 years,’ explains Julian Krause, Product Manager at Maximator GmbH. ‘With ValvolutionX, we have succeeded in massively reducing the size - while maintaining the same performance and reliability. This is our response to our customers' long-standing need for a compact and powerful solution for demanding high-pressure applications.’

Significant reduction in installation space and weight for greater efficiency and flexibility

The installation space of the valves in the ValvolutionX series has been reduced by more than 50 per cent compared to the market standard of a 1’ needle valve with compressed air actuator. The compact design not only saves space in the overall system, but also makes it easier to implement the valve. Users can therefore save considerable costs. The use of cartridge technology developed by Maximator enables an ultra-compact valve design and reduces the number of valve components. This reduces the overall weight of the valve by up to 75%.

The high-pressure specialist has also made improvements to air consumption: ValvolutionX reduces the amount of compressed air required for valve actuation by up to 90 per cent, allowing the compressed air supply for the entire system to be reduced. This leads to significant cost and effort savings for users. The valves in the ValvolutionX series are designed for bidirectional use and are not restricted to one flow direction. This means that the valves can be pressurised on both sides and can therefore also be used for testing applications, for example.

Long service life and 60 per cent reduction in maintenance time

With ValvolutionX, users not only benefit from precise flow control, simplified installation processes and extended application options, but also receive a solution that can be seamlessly integrated into existing systems. ValvolutionX delivers a long service life even under extreme conditions. This results in less downtime and maintenance costs for users, greater efficiency and productivity thanks to longer uninterrupted use and lower operating costs thanks to the longer service life of the valve.

With its innovative design, ValvolutionX makes it possible for the first time to service the valve in its installed state, i.e. in-situ, with just a few simple steps and within a few minutes. This reduces maintenance time by more than 60% and considerably simplifies handling of the system. In addition, all valves in the ValvolutionX series can now be easily maintained with just two maintenance kits (Dynamic and Static Seal Kits), regardless of the connection size. The reduced complexity also increases the availability of the required maintenance kits.

Compact high-pressure solution for hydrogen applications

In the hydrogen economy in particular, high-pressure technology plays a central role in storage, compression and refuelling. Large nominal diameters are crucial for supplying hydrogen efficiently and quickly in large quantities - they enable a high volume flow at a low flow rate and minimise pressure losses. ‘The refuelling capacities are enormous, especially for large vehicles such as buses and trucks. Without innovative technologies, it is hardly possible to refuel the required quantities of hydrogen in a short time,’ explains Matthias Blome, Director Sales & Marketing at Maximator GmbH. ‘With ValvolutionX, we are able to constantly provide larger quantities of hydrogen in a shorter time, even with large nominal diameters, despite a smaller compressed air drive.’

The new valve series also brings decisive innovations in the areas of service and safety, paving the way for new industry standards. High system availability is crucial for H2 refuelling stations. The applicable standard stipulates that sealing elements of petrol station valves may only be replaced after 16,000 cycles. With ValvolutionX, Maximator is able to exceed this requirement and raise the limit to a minimum of 20,000 cycles before replacement is necessary. The new valves therefore contribute to higher system availability. In order to safely prevent the formation of safety-critical atmospheres in H2 applications, it is important to safely divert potential leaks from the system environment. The ValvolutionX series is also fully equipped for this with separate connections for leakage tubing. Additional leakage holes with corresponding threaded connections ensure the controlled discharge of potential high-pressure leaks. These are unique to H2 high-pressure valves, as Blome explains.

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