Optimizing Gas Usage in Production: How nexAir Helps Reduce Waste and Improve Efficiency

Industrial gas often represents a significant but overlooked expense in production environments. Many operations accept gas consumption as a fixed cost, missing opportunities to reduce waste and improve efficiency. At nexAir, we help customers identify these opportunities through assessment, equipment optimization, and proper application techniques.

Uncovering Hidden Waste Through Process Assessment

Most production managers can identify their major gas consumers but may miss subtle sources of waste. Our technical team examines your entire process flow, measuring actual consumption against expected rates. This assessment often reveals common issues like leaking connections, improper equipment settings, or suboptimal application methods.

For welding operations, we analyze shielding gas delivery systems where minor adjustments to flow rates can yield substantial savings. In food packaging, we examine modified atmosphere systems to ensure optimal gas mixtures without excess consumption. These focused assessments provide concrete data that guides improvement efforts.

Equipment Solutions That Reduce Consumption

Outdated or poorly matched equipment frequently contributes to excessive gas use. Flow meters calibrated incorrectly can deliver more gas than necessary. Regulators that pulse or fluctuate waste gas without improving results. Our equipment specialists can identify these issues and recommend appropriate upgrades.

For oxy-fuel cutting operations, modern torch designs can reduce oxygen consumption by 15-25% while improving cut quality. In laboratories, properly sized purge systems prevent wasteful overpurging of analytical instruments. These targeted equipment improvements deliver ongoing savings by establishing proper consumption baselines.

Application Expertise That Improves Gas Utilization

The most sophisticated equipment still requires proper application techniques to maximize efficiency. Our specialized KnowHow™ in gas applications helps operators understand how to adjust parameters for optimal results with minimal waste.

In metal fabrication, we show welders how slight adjustments to torch angle and travel speed can maintain weld quality while reducing gas consumption. For heat treating applications, we help operators understand the relationship between gas flow, temperature uniformity, and part quality. These practical insights often yield immediate efficiency improvements.

Monitoring Systems That Maintain Optimization

Initial improvements can erode over time without proper monitoring. We help implement tracking systems that maintain visibility into gas consumption patterns. These systems establish baseline usage rates for different production scenarios and flag deviations that might indicate developing problems.

For bulk gas users, telemetry systems provide continuous consumption data that reveals operational anomalies before they become significant issues. For cylinder users, simplified tracking methods help maintain accountability across shifts and departments. This ongoing visibility helps sustain efficiency gains over time.

Training That Builds Internal Capability

Sustaining gas optimization requires knowledgeable personnel who understand proper procedures and their importance. We provide targeted training that builds this internal capability, focusing on practical techniques rather than theory alone.

From proper cylinder handling to sophisticated gas mixing, these training sessions help your team develop the skills needed to maintain efficient operations. By building internal expertise, you establish a foundation for continuous improvement that extends beyond our initial involvement.

Comprehensive Approach That Delivers Results

The most effective gas optimization programs address multiple factors simultaneously. Our approach combines assessment, equipment, application techniques, monitoring, and training into comprehensive programs that deliver meaningful results. This holistic method helps customers Forge Forward with gas efficiency initiatives that contribute directly to operational performance and profitability.

Optimizing industrial gas usage delivers benefits beyond direct cost savings. Reduced consumption means fewer deliveries, less cylinder handling, and smaller environmental footprint. Well-tuned gas systems often produce better quality outputs with greater consistency. By transforming gas from a fixed expense to a managed resource, you gain both immediate savings and long-term operational advantages.