Optimising In-House Metal Fabrication with On-Site Nitrogen Generation
The Challenge
A long-standing client of Maziak, based in Northampton and specializing in cooling systems for the power generation industry, decided to bring previously outsourced metal fabrication services in-house. This required the procurement of an Optiflex 4020 Fibre 111 8kW laser cutting machine.
Using nitrogen gas with a fibre laser accelerates the cutting process and produces a cleaner metal finish by reducing oxidation around the laser nozzle, thereby minimizing the need for secondary cleaning processes. The options for nitrogen gas supply included high-pressure gas cylinders, a bulk liquid tank, or on-site nitrogen gas generation. Each option was rigorously evaluated for its pros and cons to determine the best return on investment.
As their trusted partner, Maziak was consulted to support the decision-making process. Ultimately, the on-site nitrogen gas generation option was selected as it offered the best solution, providing controllable costs and a reliable gas supply.
The Solution
Atlas Copco machinery was chosen for its excellent reliability, backed by Maziak's long-term service and warranty package. Due to a shortage of plant-room space, Maziak provided a bespoke turn-key climate-controlled plant room, assembled off-site at Maziak's premises and delivered to the factory ready for plug-and-play operation.
The system uses a low-pressure standard air compressor with oil removal filtration to supply the Atlas Copco nitrogen generator. This generator removes oxygen from the air supply, leaving clean, dry nitrogen gas at the required purity and volume for the application. Calibrated instrumentation continuously validates the purity and volume to ensure they remain within the desired specifications. In the event of an issue, the nitrogen generator automatically initiates a cleaning cycle to prevent poor-quality gas from entering the system, resuming supply once purity is restored.
The nitrogen gas is then boosted to 300 bar pressure and stored in a bank of permanently sited cylinders, ready for use. This setup allows the site to benefit from off-peak energy prices by producing and storing gas overnight.
The Result
he implementation of this solution provided the client with reliable equipment and the most cost-effective method for supplying high-purity nitrogen gas for their fibre laser cutting equipment. This ensured a cleaner, more efficient cutting process and reduced operational costs.
