In the bustling heart of South Africa’s industrial landscape, Transerve-JHT Laser Cut (Pty) Ltd has been quietly revolutionizing its operations with a state-of-the-art skid-mounted nitrogen generator from Atlas Copco. For over six and a half years, this cutting-edge technology has been the backbone of their precision laser-cutting processes, earning high praise from the company’s Technical Director, Douw Meyer.
“This solution consistently provides transformative benefits to our operations,” Meyer enthuses. “Since implementing the nitrogen skid, the company has achieved a payback period of under two years, demonstrating substantial financial advantages along with enhanced operational efficiency.”
The innovative skid-mounted system is a marvel of modern engineering, comprising an Atlas Copco GA22VSD+FF compressor with integrated Variable Speed Drive (VSD), the LB15 air and nitrogen booster, and the NGP100+ PSA nitrogen generator, all complemented by nitrogen storage tanks. This on-site nitrogen generation solution has proven invaluable for Transerve-JHT’s laser cutting processes, which demand exceptionally high air purity for precision cutting of metal components ranging in thickness from 0.5mm to 4mm.
The success of this skid-mounted system hinges on two key factors: advanced VSD technology that delivers market-leading energy efficiency and seamless operations, and the NGP100+ Pressure Swing Adsorption (PSA) nitrogen generator that delivers on-site air with a purity level of up to 99.999%. This is further enhanced by the LB15 nitrogen piston booster system, which increases nitrogen pressure to a maximum of 40 bar.
“Our previous reliance on liquid nitrogen was not only proving to be costly but also inefficient in meeting our stringent requirements for exceptionally high air purity,” asserts Meyer. “The transition to the Atlas Copco nitrogen skid has addressed all these issues and has been a game-changer. This nitrogen system minimizes waste, enhances our cutting speed, and enables us to cut various steel thicknesses with unparalleled accuracy, leading to a consistent ‘burr-free’ output. This translates to less material handling and improved product quality, significantly bolstering our service delivery to customers.”
Initially, Transerve-JHT sought a high-pressure air compressor to support their new innovative 4 kW fibre laser cutting machine. Dean Adriaanse, Product Manager at Atlas Copco Compressor Technique, explains that the customer faced geographical constraints that limited the availability of liquid nitrogen. Instead of traditional solutions involving costly multi-cylinder packs (MCPs), Atlas Copco Compressor Technique offered a modular skid-mounted nitrogen generation system designed specifically for laser cutting applications.
“This advanced solution mitigates all the challenges associated with liquid nitrogen, including reduced operational costs, increased productivity, and the elimination of transport and handling issues, which also addresses worker safety enhancement, adding tremendous value for our customer,” Adriaanse elaborates.
The system’s robust performance has been crucial in meeting the demanding requirements of laser cutting, allowing Transerve-JHT to dynamically scale operations in response to market fluctuations. Atlas Copco’s dedicated after-market service has further solidified this success through the provision of ongoing support and proactive maintenance. “Their team has been exceptional in ensuring our equipment operates at peak performance, and their rapid response to our needs has been invaluable,” affirms Meyer.
The successful integration of the nitrogen generator skid has enhanced Transerve-JHT’s operational capabilities while solidifying Atlas Copco’s commitment to providing cost-effective and sustainable solutions tailored to the needs of its customers. This is a clear demonstration of how innovation and collaboration can drive operational excellence.
“Our innovative on-site nitrogen generation solutions empower customers like Transerve-JHT to achieve independence from traditional gas suppliers while ensuring superior performance and sustainability,” states Adriaanse. He concludes, “This project marks the first complete nitrogen system sold to the laser cutting industry in South Africa and has unquestionably set a benchmark for future installations.”
Transerve-JHT has been servicing the South African road haulage industry for the past four decades, stocking an extensive range of truck and trailer replacement spares for the haulage, mining, and industrial hydraulics markets. The company offers specialized precision in-house laser cutting services (up to 20mm) under customer drawings and specifications.
