Gas Applications in the Plastics Industry
Gas Applications in the Plastics Industry
Plastics of all kinds are a regular part of life. They help us safely hold a cup of your favorite soda, they protect us of falls and collisions, and they aid us giving life-saving medical care each and every day. Yet, the role that industrial gases play in the making of plastic is somewhat overlooked. In most cases, our favorite products we use every day is dependent upon quality gases in the manufacturing process in order make the type plastics needed to form the solutions we seek.
Nitrogen Use in Plastic Production
A key factor in the use of nitrogen in plastics production is that it is both dry and inert. These two factors make nitrogen a favored gas to us as it maintains the quality and integrity of the process of forming as well as the molded product. This means that it will help maintain the desired color of the product due to the removal of oxidation while forming. Nitrogen also ensures that the polymer being molded has both its intended strength and integrity for a better finished product.
Benefits of Nitrogen Use in Different Types of Plastic Molding
There are some widely used methods of molding where nitrogen is used to great benefit. Here are some that nitrogen makes all the difference in:
Plastic Extrusions- Polymers are forced through a die to create long forms, like pipes. Nitrogen displaces the oxygen to reduce oxidation and helps maintain the health of molding die and machinery.
Injection Molding- When the polymer is injected into the mold, the chamber must be free of oxygen to ensure integrity of the piece part and reduce oxidation. Nitrogen is the perfect choice in this application.
Gas Assist Injection Molding- Known as GAIM to many in the industry, this process used in the formation of large products that have complex structures and need to maintain integrity over longer distances. Nitrogen aids in forming the desired product through a repeatable bubble that forces the polymer into the critical corners of the mold for tight tolerances and correctly finished parts. It is also used in forming hollow shapes due to the application of nitrogen in the molding process.
When looking for the right source of nitrogen for your plastic molding needs, turn to nexAir for the quality, purity, and reliability. Leverage the KnowHowTM of our collective team of gas professsionals to help you make the best decisions for your needs of your facility.
Ask the people with the KnowHowTM here at nexAir how we can apply and deliver your next propane-based solution in your facility.
Don't see what you're looking for?
Everything we offer is a click away and it will arrive before you know it.
Manufacturing downtime costs American companies billions annually. When production lines halt due to gas supply issues, every minute translates to lost revenue, missed deadlines, and frustrated customers. At nexAir, we've spent decades developing solutions that keep manufacturing operations running smoothly.
The Hidden Costs of Gas-Related Downtime
When manufacturers calculate downtime costs, they typically focus on labor and lost production. However, gas supply disruptions create cascading effects that multiply these losses:
- Production rescheduling that disrupts carefully optimized sequences
- Rush shipping fees to meet customer deadlines despite delays
- Quality inconsistencies when processes restart after interruptions
- Overtime costs to catch up after unplanned stoppages
- Reputation damage when delivery commitments are missed
For a typical mid-sized manufacturer, each hour of downtime represents $5,000-$10,000 in direct and indirect costs. Our analysis shows that gas-related issues cause 7-12% of total manufacturing downtime - a substantial opportunity for improvement.
From Reactive to Proactive: The Supply Continuum
Most facilities follow a predictable pattern in their gas management evolution:
Stage 1: Reactive Management At this stage, facilities order gas when they notice supplies running low or, worse, after running out. Emergencies are common, and disruptions are accepted as "part of doing business." One automotive parts supplier operating this way experienced 14 production interruptions in a single quarter.
Stage 2: Calendar-Based Management Facilities advance to scheduled deliveries based on estimated usage. While better than the reactive approach, this method still results in either excess inventory (tying up capital and space) or shortages when usage spikes occur. A plastics manufacturer following this model maintained 40% more cylinder inventory than necessary while still experiencing occasional stockouts.
Stage 3: Consumption-Based Management Our telemetry systems monitor actual gas consumption, automatically triggering orders based on usage patterns rather than calendar dates. This approach virtually eliminates both stockouts and excess inventory.
Stage 4: Integrated Supply Management The most advanced approach connects gas management directly to production planning systems. Upcoming production requirements automatically adjust supply parameters, ensuring resources are precisely aligned with needs. A medical device manufacturer using this approach reports zero gas-related downtime for 27 consecutive months while operating with minimal inventory buffers.
Our expert KnowHow™ in industrial gas applications allows us to guide customers through this evolution at a pace that makes sense for their operations.
Customizing Solutions for Maximum Uptime
Manufacturing environments vary dramatically in their gas requirements and operational constraints. We've developed flexible approaches that address these differences:
- For high-volume, consistent usage operations, our bulk systems eliminate the cylinder handling that frequently causes supply disruptions. Bulk installations include telemetry monitoring and automated ordering to prevent outages.
- For variable-demand environments, our microbulk delivery systems provide the benefits of bulk supply with lower volume commitments. These systems reduce handling requirements while maintaining the flexibility needed for changing production schedules.
- For specialized applications requiring multiple gas types, our gas management programs combine cylinder tracking, usage monitoring, and automated replenishment. This comprehensive approach ensures that specialty gases are always available when needed, regardless of how infrequently they might be used.
- For multi-site operations, our enterprise supply programs coordinate deliveries and optimize inventory across locations. By treating the organization's gas requirements holistically, we minimize both stockouts and excess inventory across the network.
This consultative approach ensures that manufacturers receive solutions aligned with their specific operational patterns rather than generic "one-size-fits-all" systems.
Beyond Traditional Supply: Integrated Services for Total Reliability
Maximum uptime requires more than just reliable gas delivery. Our integrated services address the full spectrum of gas-related reliability factors:
Equipment maintenance programs that prevent system failures before they impact production Technical gas specialists who resolve application issues that could otherwise cause production problems Safety training that prevents accidents leading to downtime events Emergency response capabilities that minimize impacts when unexpected events occur Supply chain redundancy that ensures continuity despite regional disruptions
These services complement our supply solutions to form a comprehensive reliability strategy. By addressing both everyday operations and exceptional circumstances, we help manufacturers Forge Forward with confidence that gas-related disruptions won't derail their production targets.
Measuring Success: The Results That Matter
The ultimate measure of any downtime reduction strategy is its impact on production metrics. Our manufacturing customers consistently report significant improvements after implementing our comprehensive gas management solutions:
Downtime reductions of 85-95% for gas-related issues Inventory cost decreases of 20-30% through optimized supply management Administrative time savings of 5-10 hours weekly through automated ordering and tracking Production schedule adherence improvements of 3-7% due to improved supply reliability
These performance gains translate directly to bottom-line benefits that typically deliver ROI within months rather than years. More importantly, they allow manufacturers to confidently make delivery commitments, knowing that gas supply issues won't compromise their ability to perform.
Don't let gas supply issues impact your productivity. Contact us today to explore our tailored solutions.
Looking out for your future
Get your career going on the right track with nexAir
Find out how nexAir KnowHow has impacted businesses all over the Southeast
Our expertise makes us more than a valuable partner, it makes us headlines