From €4,200/month bottled nitrogen → €1,220/month on-site PSA. Weld rejection rate dropped from 4.7% to 0.8%. Payback in 8 months.
Industry: Automotive Parts Manufacturing
Location: Stuttgart, Germany
Operation: 8 fiber laser welding stations producing exhaust system components for European OEMs. 24/5 production, 300 working days/year.
Welding Materials: Stainless steel 304 & 316, titanium exhaust components.
€4,200/month spent on bottled nitrogen — the single largest consumable cost after electricity.
2–3 production stops per week due to bottle changeovers. Each stop cost ~15 minutes of production time across 8 stations.
4.7% weld rejection rate — purity inconsistency between bottle batches caused oxidation on stainless welds, requiring rework.
Logistics headache: 48 bottles/week delivery, storage space for 120 bottles, safety compliance for high-pressure cylinders.
System: Standard Factory Nitrogen Station — 30 Nm³/h, 99.99% purity, 5.5 kW.
Integration: Connected directly to existing compressed air line (already had oil-free compressor). Buffer tank for consistent delivery pressure to all 8 stations.
Installation: 2 days — pre-assembled skid mount. No production downtime.
Training: 4-hour operator training. Remote monitoring set up for German engineering team.
Remote video survey · 1 day
Manufacturing · 5 weeks
Sea freight to Hamburg · 4 weeks
On-site in 2 days · Zero downtime
Model: Standard Factory Station
Flow: 30 Nm³/h (adjustable 40–100%)
Purity: 99.99% ±0.1%
Power: 5.5 kW · 380V/50Hz
Buffer Tank: 3m³ · 0.8 MPa
Certification: CE · ISO 9001
The exact model used in this case study. 20–60 Nm³/h.
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