Background
ZSB Constructies is a well-established structural steel fabricator in the south of the Netherlands. The business has grown steadily based on the principles of expertise, quality, service, speed, collaboration and customisation. Amongst their many activities, ZSB provide welding services and are a certificated EN1090 fabricator – the harmonised European Standard that applies to all structural metalwork.
Challenge
As a busy fabricator, ZSB was consuming a high quantity of welding gas. Naturally, as their business was growing so was their demand for welding gas. ZSB had already switched from a standard M21 Argon/CO2 welding mixture to Air Products' high-performing Ferromaxx® 7 weld process gas for carbon steel MAG welding. However, the business was very keen to investigate further options for reducing both welding gas consumption and, therefore, costs. Furthermore, ZSB had to prepare a sustainability roadmap for their local government department and was looking for solutions to reduce their carbon footprint.
Solution
As an early adopter of new technology and processes, ZSB was invited to trial the new Integra® e2 cylinder from Air Products. This new digital cylinder combines integrated cost saving and technology features. The ground-breaking technology reduces welding gas consumption in four ways, all of which contribute to reducing costs and carbon footprint:
Leak detection
Leaks from the welding set-up are often the largest source of gas waste. With the Integra® e2 cylinder, leaks can be tested at the start and end of every shift with a touch of a button.
Flow control
Not only do many customers set flow rates too high, frequently there is a difference between the flow rate set at the regulator and at the end of the welding torch or nozzle. The Integra® e2 cylinder has a built-in regulator and uses an Integra® Flow Optimiser (IFO) with a pre-set flow rate to control gas flow and make connecting to the cylinder quick and easy.
Surge protection
At the start of every weld there is a rush of welding gas. The unique design of the Integra® e2 cylinder virtually eliminates any gas surge at the start of the weld, saving a significant volume of gas over each shift.
Flow consistency
Typically, as a gas cylinder empties, the pressure drops and the flow rate increases. Not so with the Integra® e2 cylinder, meaning the cylinder lasts longer.
The next step in the journey was for an Air Products welding specialist to demonstrate the Integra® e2 cylinder at ZSB alongside their existing welding set-up. Using calibrated equipment to monitor gas flow rates, gas consumption and welding time, the specialist was able to clearly produce data showing a 25% reduction of welding gas consumption.
Outcome
ZSB was so convinced by the demonstration they agreed to switch all their welding gas cylinders to the Integra® e2 cylinder. Within weeks, ZSB were then realising the gas consumption savings.
Eliminating wasted gas also has sustainability benefits. By using the Integra® e2 cylinder, ZSB was able to provide energy consumption saving data to the local authority and prove their ongoing commitment to reducing their carbon footprint.
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