Case Study: How nexAir Helped a Local Manufacturer Improve Productivity with Custom Gas Blends

A regional metal fabricator recently noticed a gradual decline in output. Weld quality had become inconsistent, post-weld cleanup was taking longer, and small defects were beginning to impact delivery timelines. The team had already ruled out equipment issues and retrained operators but the problem persisted.

When they reached out to nexAir, we took a closer look at the full welding environment, from the materials in use to the shielding gas supporting their process. What we found was simple: the gas blend they’d relied on for years no longer aligned with the way they were working today.

Realigning the Process

The fabrication team had evolved their operation over time—new base metals, faster throughput, tighter tolerances—but their gas hadn’t changed with them. While the standard blend had once performed well, it was now contributing to excessive spatter and unstable arcs, both of which slowed down production.

We spent time on-site reviewing their weld stations, watching operations firsthand, and speaking with leads and floor technicians. Based on that input, our team developed a custom gas blend tailored to their most common joint configurations and wire combinations. It didn’t require any new equipment, just a better fit for the work being done.

Within days of switching blends, the feedback was clear: cleaner welds, steadier arcs, and a noticeable reduction in downtime. Operators reported less grinding, fewer touchups, and more consistent results across shifts. That translated into more parts completed per day and less frustration on the floor.

Support Beyond Supply

Getting the right blend into production was only part of the solution. We also reviewed their gas delivery schedule, trained staff on best practices for flow rates and cylinder handling, and provided clear safety documentation for their updated setup. We stayed in contact through the rollout and made on-the-fly adjustments based on real-world feedback.

This hands-on approach reflects how we help our customers Forge Forward with practical, focused solutions backed by service that doesn’t stop at the delivery dock.

Practical Improvements, Lasting Impact

In this case, productivity didn’t improve because of a major systems overhaul. It improved because a small, overlooked piece of the process was brought into alignment. That’s the value of paying close attention and having access to expert KnowHow™ that helps identify what’s holding you back.

At nexAir, we believe every operation has opportunities to run better. Whether you’re managing a large production facility or a smaller fabrication shop, the right gas solution can play a direct role in quality, efficiency, and output.

Let’s talk about how we can help improve your process. Contact us to start the conversation.