Butterfly valves and ball valves are two of the most common quarter-turn valves used for fluid control across industries such as water treatment, HVAC, chemical processing, and oil and gas. Both types provide efficient flow regulation and quick shut-off, but they differ in design, performance, and ideal applications. In this guide, we’ll break down the key differences between butterfly valves and ball valves, outlining their advantages, disadvantages, and best-use scenarios to help you choose the right valve for your system — whether you’re aiming for cost-effective flow control or reliable, high-pressure performance.

Understanding the Basics: What is a Butterfly Valve

How Butterfly Valves Work

A butterfly valve features a circular disc mounted in the very centre of the valve body, attached to a stem that runs through it. When the stem is rotated, the disc turns by 90° (one quarter turn) — when the disc is aligned with the flow it allows the fluid to pass; when it is perpendicular, it blocks the flow.

Because the disc remains within the flow path even when fully open, some pressure drop is inevitable; but the quick-action quarter turn means it is efficient for open/close operations.

Operation is straightforward: turn the actuator or handle, the disc rotates on the stem, and the valve moves from fully closed to fully open (or vice-versa) with a simple motion.

In simpler terms: imagine a round flat “wing” (the disc) sitting across a pipe; rotate it 90° to either stop or allow flow.

 

Common Types of Butterfly Valves

Butterfly valves come in several design variants that optimise performance for different conditions:

• Concentric (or zero-offset): The stem axis is aligned with the centre of the disc and the pipe bore. It’s the simplest design.

• Double-offset (or double-eccentric): The stem axis is placed behind the disc and/or offset from the centre of the pipe bore, which reduces disc-seat contact and improves sealing and wear performance.

• Triple-offset: Adds a third offset (often in the geometry of the seat/disc contact) so the disc contacts the seat only at the final portion of the closing stroke, making tight metal-to-metal sealing possible in demanding applications.

These types reflect increasing levels of performance (and cost) and are selected depending on factors like pressure, temperature, media and required shut-off.

 

Typical Applications for Butterfly Valves

Butterfly valves are widely used across many industries, particularly where large volumes and moderate pressures are involved, because of their compact design and quick operation. Common application areas include:

• Water treatment, distribution and supply systems (large diameter pipelines, flow isolation)

• HVAC systems (air handling, chilled/hot water lines)

• Large-volume liquid flows (for example in chemical or process plants)

• Gas transfer and large-bore pipelines where rapid shut-off is beneficial

In general, systems where space is limited, weight matters and moderate sealing performance is acceptable.

Because some advanced types (double/triple offset) can handle higher pressures and more demanding conditions, you’ll find them in chemical processing, oil & gas and power plants too.

 

 

Understanding the Basics: What is a Ball Valve?

How Ball Valves Work

A ball valve uses a hollow, spherical element—known simply as the ball—that has a central bore (or port) drilled through it. In operation, when the bore in the ball is aligned with the flow path in the pipe, fluid or gas can flow through the valve unhindered. By turning the ball (typically via a handle, lever, or actuator) by 90° (one quarter turn), the bore is rotated out of alignment so that the solid side of the ball blocks the flow path, stopping the fluid. Because of this simple mechanism, ball valves provide very fast on/off action, reliable shut-off even after long idle periods, and a clear visual indication of whether the valve is open (handle aligned with flow) or closed (handle across flow).

 

Common Types of Ball Valves

Trunnion-mounted ball valve

There are several types of ball valve designs, tailored to specific operating conditions and performance requirements:

Floating ball valve: In this design, the ball is not anchored and “floats” slightly. Under pressure, the ball is forced against the downstream seat to form a seal.

Trunnion-mounted ball valve: Here the ball is supported by trunnion shafts or bearings, so it is held in place and doesn’t rely on upstream pressure to seal. This makes the design more suited for high-pressure or large-bore systems.

Port / bore types:

• Full-port (full-bore): The bore of the ball is equal to the pipeline’s bore, giving minimal flow restriction.

• Reduced-port (reduced-bore): The bore is smaller than the pipeline diameter, meaning some flow restriction occurs but cost and design size may be reduced.

• There are also multi-port designs and V-port or characterised ball designs for flow control, not just on/off service.

 

Typical Applications for Ball Valves

Ball valves are widely employed across industries where reliable shut-off, high performance, and minimal leakage are required. Some of the key use cases include:

• High-pressure systems: The trunnion-mounted style in particular is common in oil & gas pipelines, petrochemical plants, and power generation where pressures are large.

• Applications requiring tight shut-off: Ball valves are known for reliable on/off control even after long periods of inactivity.

• Chemical processing: Handling aggressive media and gases often requires robust sealing and corrosion-resistant materials, which many ball valves provide.

• Sanitary/clean-service environments: Used where leak-tightness and ease of cleaning are important, such as in food, beverage, and pharmaceutical lines.

• General industrial piping systems: Ideal where on/off control rather than fine flow modulation is needed.

 

 

Butterfly Valve vs. Ball Valve: A Head-to-Head Comparison

 

Deciding Factors: When to Choose a Butterfly Valve

For Large Pipe Diameters (Above DN150 / 6″)

When dealing with large-bore pipelines, the advantages of a Butterfly Valve really shine. Because the disc-and-stem design uses far less metal than a similar-sized Ball Valve, the valve is much lighter in weight — in large-diameter lines, a butterfly valve can weigh just one-third to one-fifth of a ball valve of the same size.

That reduced weight translates to easier handling, simpler support structures, and lower installation costs in large-scale applications like municipal water networks or district heating systems.

Moreover, for diameters above around DN300, the cost-per-unit for ball valves increases dramatically, making butterfly valves the more economical choice for the same bore size.

 

When Space is Limited

If you’re working in a confined plant layout or tight piping corridor, a butterfly valve offers a clear benefit. Its wafer or lug-style body fits neatly between flanges and requires less installation envelope than a comparably sized ball valve, which tends to be bulkier and heavier.

This compactness not only helps in new installations, but also in retrofit situations where space is at a premium.

 

For Cost-Sensitive Projects

For projects where budget matters, the butterfly valve is often the better option. Its simpler construction, fewer internal parts and reduced material usage all contribute to a lower purchase cost, especially in larger sizes. For large diameters, the valve cost advantage can be as much as 30–60% less compared to ball valves.

In addition, lighter weight means lower shipping and handling costs, and less requirement for heavy supports — all helping to keep the overall project cost down.

 

For Moderate Pressure and Throttling

Butterfly valves are particularly suited for applications where ultra-tight shut-off is not critical and pressures are moderate. Typical examples include HVAC systems, chilled/hot water distribution, and general fluid transfer in water-treatment plants. Because the disc remains in the flow path, some pressure drop is expected; however, for many process and utility duties, this is acceptable.

Their quicker actuation (quarter turn), simpler mechanism and ability to be partially open for throttling make them a good choice in those “medium duty” use cases rather than heavy high-pressure isolation where a ball valve would be preferable.

 

Deciding Factors: When to Choose a Ball Valve

For High-Pressure or High-Temperature Service

When your system operates under high pressure or elevated temperature, a ball valve is often the prudent choice. The robust construction of the spherical ball and seat design enables these valves to withstand extreme conditions with strong safety margins. High-pressure ball valves offer tight and reliable sealing performance and low fluid resistance even under intense load.

Because the ball provides a nearly unobstructed flow path when open, the valve handles high flow rates and demanding service without undue wear. The simplicity of the 90-degree rotation mechanism also supports safe operation in critical environments.

 

When Zero Leakage is Critical

In applications where leakage simply isn’t acceptable—think of hazardous chemicals, high-pressure gas, or critical process lines—a ball valve’s sealing capability makes it the go-to option. They consistently deliver bubble-tight shut-off, thanks to the spherical closure element that aligns precisely with its seat. Ball valves are known for excellent sealing performance, closing securely even after long periods of disuse.

This reliability in shut-off helps ensure system integrity, regulatory compliance, and operational safety.

 

For Applications Requiring Precise Flow Control

While many use ball valves simply for on/off control, specialised forms such as the V-port ball valve enable high-accuracy flow modulation. The V-shaped bore or seat allows a controlled, linear relationship between valve position and flow rate.

If your process involves variable flow rates, precise control of temperature or pressure, or you wish to integrate the valve into an automated control loop, then a V-port ball valve can be an excellent fit.

 

For Slurries or Media with Particulates

When the media in your system contains solids, slurries or fibrous particles, a full-port ball valve stands out for its clear, unobstructed flow path. The large bore matches the pipe diameter, so the ball valve permits passage of solids with minimal turbulence or risk of clogging.

This makes them an ideal choice for applications in wastewater treatment, pulp and paper, mining, or chemical processing where clean flow and minimal trapping of media are essential.

 

Conclusion

Choosing between a butterfly valve and a ball valve ultimately depends on your system’s specific requirements. Butterfly valves are ideal for large-diameter, low to medium-pressure, and cost-sensitive applications, offering a lightweight, compact, and budget-friendly solution for systems like water distribution and HVAC. In contrast, ball valves excel in high-pressure, high-temperature, and critical shut-off environments, providing bubble-tight sealing and precise flow control for demanding industries such as oil and gas, chemical processing, and power generation. The right choice ensures efficiency, reliability, and safety — and if you’re still unsure which valve best fits your project, contact our engineering team today for expert guidance tailored to your application.