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In , the agronomy department at Midwest pork producer Christensen Farms set a goal to visit every production facility farm to assess and reduce water waste, which consumes manure storage capacity.

As they studied the data they gathered, they noticed a trend: The volumes of both water and manure application were higher than forecast. They set out to find out why. As the agronomy team reviewed operations, it noticed a consistent failure of watering toggle valves in the farms.

While water was delivered to the pigs, flow was inconsistent. The inconsistency influenced water waste volume, with excess water flowing over water pans and running into manure pits. Equipped with this data, the department collaborated with The Specialty Mfg. Headquartered in Sleepy Eye, Minn. With nearly 1, employees and 1, contract partners, the company spans five Midwest states and includes more than farms.

Understandably, then, replacing the water valves throughout its production facilities was a large undertaking. To start, the agronomy team disassembled the current valve to identify key areas where its valves were failing.

The first piece the team needed to improve was the plastic nozzle that controls the flow of water from the system through the valve. The existing valve had inconsistent hole sizes for water to run through, which led to varied water flow. A new plastic nozzle was developed that could replace the faulty ones, but still fit as a component of the existing valve. After an initial yearlong success with the new nozzle, Christensen Farms wanted to improve the overall valve design.

While the nozzle worked well, the rest of the valve was failing because of wear and tear from the application and inconsistencies in manufacturing.

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