Transforming Nitrogen Supply for a Leading Rotomoulding Manufacturer

Established in 1984, our client is a renowned manufacturer of high-quality machinery and a specialist in Rotomoulding, operating from a steadily expanding facility in Cambridgeshire, England. Now spanning two sites, the business boasts comprehensive design and manufacturing capabilities, including a fabrication workshop and five Rotomoulding machines.

However, a significant operational challenge had emerged: the site was incurring unsustainable costs on nitrogen gas cylinder packs—essential for their laser cutting and profiling equipment. Beyond the financial burden, the logistics of ordering, receiving, and storing large volumes of cylinders introduced health and safety risks and operational inefficiencies.

Maziak, experts in nitrogen generation and compressed air systems, were brought in to identify a more efficient and cost-effective solution.

By analysing historical invoices and usage data, Maziak calculated that the client was spending approximately £280,000 per year on nitrogen gas cylinders. Additionally, around 5% of the gas was being returned unused each month due to pressure levels falling below the usable threshold—representing a direct loss.

Leveraging our technical expertise and deep understanding of the client’s processes, we proposed a tailored On-Site Nitrogen Generation System. This solution was designed not only to meet current demand but also to accommodate future growth and production peaks.

At the heart of the system is the Atlas Copco NGP+ Nitrogen Generator, engineered to deliver the precise gas purity, pressure, and flow required for laser cutting. Delivered as a factory-built, plug-and-play skid package, the system includes:

• A high-pressure gas booster
• Integrated storage cylinders
• Smart automation for off-peak electricity usage
• Minimal daily intervention from site staff

To further enhance reliability, the client also opted to replace two existing air compressors. All new equipment is covered by a 5-year no-quibble warranty, ensuring peace of mind and operational continuity.

Smart Monitoring & Control

All installed equipment is connected via Atlas Copco’s SmartLink—an integrated remote monitoring platform that allows users to manage and monitor system performance from a PDA or smart device, ensuring maximum uptime and efficiency.

• Immediate cost savings: Eliminated the need for costly nitrogen cylinder packs
• Rapid ROI: Achieved a full return on investment in just 6 months
• Operational efficiency: Reduced manual handling and improved safety
• Future-proofed: Scalable system ready for production increases
• Peace of mind: Backed by a comprehensive warranty and Maziak’s expert aftercare