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Sanitaryware systems


Thinking differently and valuing feedback


Dart Valley Systems has, since 1985, specialised in the design, manufacture, and supply of electronic water efficiency controls – including bath, tap, shower, WC, and urinal controls. Some 15 years ago it extended its range to offer ‘safe en-suite sanitaryware’, with a ‘lightweight, extremely strong’ range of en-suite units suitable for use in mental healthcare facilities, high security washrooms, and other ‘specialist applications’. Here the company’s Design manager, Craig Holmes, describes – from the early beginnings – the DVS approach to designing and manufacturing products for mental healthcare and other ‘secure’ applications.


Our sanitaryware products and systems are designed for the toughest environments, and are manufactured using the latest advanced technologies; we pride ourselves on innovative, quality products that are designed with the healthcare sector – including mental healthcare applications – in mind. As a company DVS is renowned for its Safe Ensuite Sanitaryware and accessories, and we have seen this range go from strength to strength, as an increasing number of private healthcare providers and NHS Trusts install and see the benefits of these products. From anti- shatter moulded resins to integrated ligature- resistant water-saving spouts, the reliability and durability of the range is, we believe, unrivalled. In addition to the resin sanitaryware products, the DVS High Security range covers various ligature-resistant solutions suitable for low to high secure facilities, including stainless steel shower towers, deck and wall-mounted taps, and bath filling spouts, as well as accessories and various water-saving programmable control options. Within the healthcare and mental health sectors we have successfully supplied a host of high profile projects for private healthcare providers and NHS Trusts across the UK, including West London Mental Health NHS Trust, Mersey Care NHS Trust, Cygnet Healthcare, The Huntercombe Group, and many more. DVS is a member of the Design In Mental Health Network, which allows us to exhibit at the annual DIMH exhibition and conference event, to showcase the latest and most popular products for this specific market.


HOW DID WE ENTER THE MENTAL HEALTH/SECURE MARKET? When DVS first entered this market, we started buying solid surface sanitaryware from different suppliers. This was an expensive exercise, and the


12 THE NETWORK JANUARY 2018


weight of the products caused many issues with logistics and installation. Other manufacturers were all producing solid surface products that are extremely heavy, and require two persons to lift and install. DVS, conversely, sought a strong but lightweight solution, so we decided to look into the possibility of composite construction. With the marine industry on our doorstep, we decided to contact Plymouth University, which put us in touch with two experts from the sector that could advise and help design and build our sanitaryware. They still both advise us and work with us today. The first product DVS launched was our wall- hung basin, quickly followed by the V1 WC pan, with both products manufactured using a foam core and a closed mould technique. These products proved to be very successful, but very expensive to produce, requiring many hours of manual labour to hand finish.


‘NEXT GENERATION’ SOLUTIONS Once we launched these products we were already working on the next generation, the V2 WC pan and basin. We were also keen to obtain WRAS approval, but to do this we had to make minor changes, both inside and out. Another issue was their high manufacturing costs, so again we looked at how we could reduce these. DVS has an in-house 3D design team with experience in the moulding industry, so we created 3D parts and were able to build and test a WC and basin before we made patterns and tools, using 3D computer-generated models. All patterns and tools today are 3D-generated, which gives us exceptional repeatability and quality products. The key requirements for V2 were that the new components be aesthetically superior to the V1, and able to achieve WRAS approval. Both goals were achieved. The V2 WC pan and


The DVS Handheld Programmer can be used by engineers to efficiently adjust settings to outlets without having to gain access through maintenance hatches and cupboards.


basin have proven to be a major success; both make economical use of water and are very strong, passing the very stringent BMA testing guidelines for safe en-suite sanitaryware. The V2 WC pan would not look out of place in any bathroom, making it ideal for mental healthcare applications. From the same internal design we developed the rest of the WC range – which now includes a wall-hung and a disabled variant – all using the same internals, giving a very efficient four-litre single flush. The WC pan has WRAS approval, and in 2015 was approved by Watermark for use in the Australian market. Another requirement for the system was that it be ligature-resistant. We sought feedback and advice from the Ministry of Justice and various mental healthcare establishments, and believe now that the DVS range of sanitaryware is fully compliant with all requirements for use in mental healthcare or MOJ environments.


BALANCING AESTHETICS AND LIGATURE RESISTANCE With differing requirements in terms of levels of security, coupled with the need for parts to ‘look more domestic’, it can at times be difficult to manufacture products which both look good, and are fit for purpose. Our main consideration is to ensure that products are fit for the application and market they are destined for. We have to produce a product which will suit all applications – from those requiring the lowest to the highest levels of security. Ligature resistance is something we strive greatly to design into our


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