Customer Success Stories: How nexAir Helped Companies Optimize Gas Supply for Increased Efficiency

From Challenge to Solution: A Metal Fabricator’s Journey

A southeastern metal fabrication company faced persistent challenges with their welding operations. Inconsistent gas flow led to quality variations in their finished products, creating bottlenecks in production and increasing rework costs.

“We knew something wasn’t right with our gas supply, but couldn’t pinpoint the exact issue,” their operations manager explained. After consulting with our team, we identified multiple inefficiencies in their delivery system and storage methods.

Our solution included:

• Redesigning gas distribution across their facility
• Implementing digital flow monitors at critical points
• Installing a microbulk system to replace outdated cylinder banks
• Creating backup protocols to prevent production interruptions

The results spoke for themselves. Within three months, their rework rate dropped by 42%, and production capacity increased by nearly a third. The company estimates annual savings exceeding $120,000, with additional benefits from improved worker productivity and reduced handling time.

This transformation showcases how optimized gas supply does more than just deliver a necessary input—it fundamentally changes production capabilities.

Healthcare Provider Improves Patient Care Through Supply Chain Excellence

When a regional healthcare network struggled with managing medical gas supplies across multiple facilities, the challenges went beyond logistics—patient care was at stake.

Their manual tracking system created unnecessary emergency deliveries and occasional supply concerns. Staff spent valuable time monitoring gas levels instead of focusing on patients.

Our approach centered on removing these worries entirely:

• Transitioning to telemetry-equipped tanks with remote monitoring
• Creating auto-replenishment schedules tailored to usage patterns
• Implementing safety redundancies beyond industry standards
• Providing staff training on efficient gas usage in clinical settings

With our expert KnowHow™, we created a system that essentially managed itself, allowing healthcare professionals to redirect approximately 900 hours annually toward patient care rather than supply management.

“The peace of mind alone would be worth the change,” noted their director of facilities. “But seeing our staff focus on patients instead of gas levels has been the real victory.”

Food Producer Reduces Waste While Expanding Market Reach

A specialty food manufacturer faced a common industry challenge: balancing product freshness with distribution reach. Their limited shelf life restricted sales to local markets, severely constraining growth potential.

Traditional packaging methods weren’t working, and product waste rates exceeded industry averages, particularly during summer months when temperature variations affected distribution.

Working collaboratively, we:

• Analyzed their current packaging atmosphere composition
• Conducted shelf-life testing with modified gas mixtures
• Redesigned their packaging equipment for optimal gas infusion
• Created quality verification methods for production staff

The customized modified atmosphere packaging solution extended product shelf life by 15 days—an improvement that immediately opened new market opportunities. Within six months, the company expanded distribution to three additional states while reducing product returns by 76%.

“We’re selling more and wasting less,” their CEO summarized. “That’s as straightforward as success gets in our business.”

Automotive Supplier Finds Efficiency Through Automation

An automotive parts supplier wanted to modernize their manufacturing process to remain competitive in a challenging market. Manual gas management created inconsistent results, especially during shift changes and peak production periods.

We helped this company Forge Forward by completely reimagining their approach to gas as a manufacturing input:

• Integrating automated gas delivery with their production scheduling system
• Installing digital mixers that adjust gas blends based on specific product requirements
• Implementing usage analytics that identified optimization opportunities
• Creating predictive maintenance protocols for gas delivery equipment

The new system eliminated human variables from the equation. Production quality metrics improved across all shifts, and the company achieved certification requirements that opened doors to new contracts with major automotive manufacturers.

The plant manager noted that the changes “transformed gas from a background utility to a strategic manufacturing advantage.”

These success stories demonstrate the substantial impact that optimized gas management can have across industries. Each company faced unique challenges, but all found that addressing gas supply strategically rather than as a simple commodity yielded benefits far beyond initial expectations.

Contact us today to discuss how we can create a success story for your operation through smarter gas supply solutions.