The first Kunkle valves used in our industry (to my knowledge) was 25 years ago...On Steamway's unit. You can still occasionally find these old workhorses. Currently Masterblend is using them on their hot little El Diablo unit.
The only problem we've ever encountered with these valves had to do with these two issues:
1. These valves (over 100 years old) were not designed for our industry. They were installed for dry material handling. Specifically loading and unloading grain and other dry products from trucks and trains. There is little need for extreme attention to lift tolerances with this application.
The Kunkle Company has an "acceptable tolerance" of plus or minus 4" of mercury. Totally unacceptable in our industry. We found that a new valve often had to be adjusted on the machine to the correct settings for open and closing. The adjustment is simple, but does require breaking the factory seal, and knowing what you are doing. A properly adjusted Kunkle will then perform flawlessly.
2. Because these valves were designed for dry environments, the moisture in our application can cause rust to build up on the cast iron parts, eventually causing the valve to stick. If you use a Kunkle it is important to lubricate it often to avoid this stickiness. Kunkle company recommends NOT lubing the valve, but again, they are basing this on a dry environment.
Frustrated by the wide tolerance in lift setting, we sought out alternative valves and found Bayco valves. They are an aluminum and Stainless version of the Kunkle (which is cast iron and brass), and are slightly less expensive than Kunkles, are set to tighter specifications from the factory and avoid the rust issues. They are also lighter. Unfortunately they do not come in the 2.5" size which is good for fast spinning 47's and 56's. They are only available in 2" and 3" sizes. Requiring many owners of these fast 47's and 56's to do some cutting and arranging to make the 3" installation work.
On our site, 2" Baycos's run $219, 2" Kunkles run $229, 2.5" Kunkles are $399 and 3" Baycos are $499. So the price goes up a lot as you go bigger. We have also found that they make the most difference on smaller machines and/or long hose runs.
We have searched all alternatives and have never found anything to rival a well adjusted Kunkle/Bayco for performance increase.
If someone would like to do a little testing at Mikefest, Summerfest or Connections...we can have someone bring in a properly operationg 33 or 36 blowered unit, with stock spring relief installed, then install alternately, free flow, Cobb, and Bayco valves on the units and test CFM and lift at 50', 100', 200' and 400' of hose out. Wand on and off the carpet. We just need a nearby willing subject truckmount and a high quality cfm gauge.
My guess is that even if we all assembled together and conducted the tests, later there would be accusations of rigging or falsifying results. Why? Because men are involved and something about having a penis makes it very difficult for any of them to admit they were wrong...men and their egos can be very fragile.
You all sound like a bunch of 13 year olds on the playground postulating and chest pounding about how your big brother will beat up the other guy's big brother.
Let's all get together and really learn something valuable, and based in fact, not theory or subjective testimonials.
Take care,
Lisa