Case study · Nitrogen generation
Eliminating MCP Bottle Banks with Turnkey Nitrogen Generation
A client recently partnered with Design Air to transition away from traditional delivered nitrogen and modernise their gas supply. We successfully completed the installation and commissioning of a fully enclosed, turnkey nitrogen generation system.
This new installation replaces the customer’s reliance on delivered gas, providing a continuous, high-purity on-site supply while drastically reducing their ongoing utility expenses.
372 l/min
nitrogen produced
99.999%
ultra-high purity
-40°C
pressure dew point
9 bar(g)
supply pressure
The challenge
The Challenge: The High Cost of Delivered Gas
Prior to this project, the customer was utilising Manifold Cylinder Pallets (MCP bottle banks) to meet their daily nitrogen requirements. This traditional method incurs high, continuous running costs for gas purchasing, bottle rental, and delivery transport.
It also introduces logistical complexities, safety hazards associated with moving heavy cylinders, and potential production downtime during changeovers.
The client needed a complete, self-contained solution to eliminate external supply chains and take control of their own gas generation.
The solution
The Solution: A Comprehensive Turnkey Installation
Design Air managed the entire project to deliver a robust, all-weather generation station. The new system efficiently produces up to 372 l/min of nitrogen at an ultra-high purity of 99.999%, with a -40°C Pressure Dew Point (PDP) and a pressure of 9 bar(g).
Our comprehensive scope of supply covered almost every aspect of the project, with the customer only needing to connect their supply to the internal distribution board. The turnkey package included:
Custom GRP Housing
A durable glass-reinforced plastic enclosure to protect the equipment from the elements and house the entire system outside the main factory floor.
Complete Fit-Out
Full project management including plant shifting, internal pipework, ductwork, and comprehensive electrical installation.
Advanced Safety Features
The housing is equipped with a dedicated oxygen analyser and oxygen exhaust vent pipes to prevent atmospheric enrichment and ensure a safe working environment.
Climate Control & Accessibility
The enclosure features built-in lighting and a thermostatically controlled heater to maintain optimal equipment operating temperatures during colder periods.
The results
The Results: Substantial Operational Savings
By bringing their nitrogen generation in-house, the customer has completely eliminated their reliance on MCP bottle banks. This strategic infrastructure upgrade will save the business a small fortune in ongoing running costs.
The fully automated system now guarantees a reliable, ultra-high-purity nitrogen supply on demand, completely removing the administrative and logistical headaches of managing delivered cylinders.
The Design Air standard
The Design Air Standard
Whether it requires custom external housing or complex internal ductwork, we provide end-to-end solutions tailored to your exact operational requirements. Our goal is to make the transition to self-generated utilities as seamless and profitable as possible for your business.
If you are currently using nitrogen gas supplied via bottles or a liquid bulk tank, get in touch with Design Air today. Contact our engineering team to discover the exact cost savings you could achieve by bringing your nitrogen supply in-house.