Projects Flagship Case Study

Turnkey High-Pressure
Valve Manufacturing Line

A fully integrated production, testing, and certification line engineered for safety-critical components and export compliance.

Scope: Full Turnkey Industry: Gas & Safety Result: Localized Production

The Challenge

The client aimed to establish a local manufacturing facility for high-pressure cylinder valves. This was not a simple machining project; it was the creation of a regulated manufacturing system requiring absolute precision and safety.

  • Extremely high safety and quality requirements (Pressure Equipment).
  • Mandatory full traceability and hydrostatic testing.
  • Compliance with international export standards.
  • Complex integration of machining, assembly, and testing.
"Any failure in a high-pressure gas valve has serious consequences. Quality cannot be inspected in; it must be manufactured in."

Project Objectives

To build a scalable, auditable, and repeatable production line that enables local manufacturing with export readiness.

Localization

Reduce import dependency by establishing local capability.

100% Compliance

Ensure pressure, leakage, and safety standards are met for every unit.

Integrated Testing

Embed testing and verification directly into the production flow.

Scalability

Design the line for future capacity growth and product variants.

Manufacturing Solution

Scope & Responsibility

Process Engineering

Valve design review and production routing.

  • Machining steps definition
  • Assembly sequence
  • Takt time calculation

Production Line

CNC machining and finishing stations.

  • Body & Stem machining
  • Precision threading
  • Surface preparation

Assembly Stations

Standardized workstations with control.

  • Torque-controlled tools
  • Clean assembly area
  • Jigs and fixtures

Testing Systems

Integrated verification equipment.

  • Hydrostatic pressure test
  • Leakage & sealing check
  • Dimensional gauging

Utilities & Infra

Supporting plant infrastructure.

  • Compressed air systems
  • Hydraulic power units
  • Power distribution

Validation

Ensuring production readiness.

  • Trial production runs
  • Test calibration
  • Operator training

Engineering Challenges Solved

Challenge 1

Safety-Critical Product

Any failure in a high-pressure gas valve has potentially fatal consequences. Quality assurance could not be left to a final random check.

Our Solution:

Testing was integrated directly into the production flow. Every single valve must pass a hydrostatic and leakage test station before it can proceed to packaging.

Challenge 2

Compliance & Traceability

Export markets require full auditability of materials and processes.

Our Solution:

A traceable production logic was embedded, linking machining batches, assembly dates, and test results to ensure full product history tracking.

Challenge 3

Production Consistency

Manual variations in torque or assembly can affect valve sealing and long-term reliability.

Our Solution:

We implemented controlled machining parameters and calibrated torque tools at standardized assembly stations to remove operator variability.

Production Line Architecture

1. Raw Material

Brass Forgings

2. CNC Machining

Body & Components

3. Precision Drilling

Threading & Finishing

4. Surface Prep

Cleaning & Washing

5. Assembly

Torque Controlled

6. Pressure Test

100% Verification

7. Final Inspection

Visual & Dimensional

8. Dispatch

Certified Product

Integrated end-to-end flow with embedded quality gates.

Project Outcomes

Manufacturing

  • Localized valve production
  • Consistent, repeatable quality
  • Full test integration

Commercial

  • Reduced import dependency
  • Competitive production cost
  • Export-ready capability

Strategic

  • High-value localization
  • Future product platform
  • OEM-level positioning

Line Gallery

CNC Machining

CNC Production

Assembly Station

Assembly & Testing

Finished Product

Finished Valves

Why This Is A Flagship Project

This project elevates us from an EPC contractor to a Technology Partner. It demonstrates our ability to deliver complete manufacturing plants for safety-critical, regulated products, integrating production with testing and certification to support national localization strategies.

Localize Your Manufacturing

Planning to manufacture safety-critical components or establish a regulated production line? We deliver fully compliant, production-ready solutions.

Discuss Manufacturing

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