Johannesburg, South Africa: Transerve-JHT Laser Cut (Pty) Ltd, a leading provider of precision laser cutting services to the road haulage industry, has significantly enhanced its operational efficiency and slashed costs by implementing an Atlas Copco skid-mounted nitrogen generation system. Technical Director Douw Meyer lauds the solution, stating, “This system has been transformative for our business. We’ve seen a payback period of under two years, alongside significant improvements in our cutting speed, quality, and overall productivity.”
For over six and a half years, the state-of-the-art system, comprising an Atlas Copco GA22VSD+FF compressor with integrated Variable Speed Drive (VSD), an LB15 air and nitrogen booster, and an NGP100+ PSA nitrogen generator, has been the backbone of Transerve-JHT’s laser cutting operations. The system also includes nitrogen storage tanks, ensuring a consistent and readily available supply.
Transerve-JHT specializes in precision cutting of metal components, ranging from 0.5mm to 4mm in thickness. These processes demand exceptionally high air purity, a requirement that the Atlas Copco solution has consistently met and exceeded.
“Our previous reliance on liquid nitrogen proved both costly and inadequate for our stringent purity requirements,” explains Meyer. “The switch to the Atlas Copco nitrogen skid has been a game-changer. It has addressed all our previous pain points.”
The system’s success hinges on two key technological advancements: the advanced VSD technology within the GA22VSD+FF compressor, which delivers market-leading energy efficiency and seamless operation, and the NGP100+ PSA nitrogen generator, which provides on-site nitrogen with an exceptional purity level of up to 99.999%. Complementing these components is the LB15 nitrogen piston booster system, which elevates nitrogen pressure to a maximum of 40 bar, ensuring optimal performance for the laser-cutting process.
The benefits of this on-site generation system are manifold. Meyer highlights the elimination of waste, a key advantage over the previous liquid nitrogen setup. Furthermore, the increased cutting speed has enabled Transerve-JHT to enhance its throughput and responsiveness to customer demands. The system’s precision has also resulted in consistently “burr-free” cuts across various steel thicknesses, minimizing material handling and improving product quality. These improvements have directly translated into enhanced service delivery and increased customer satisfaction.
Dean Adriaanse, Product Manager at Atlas Copco Compressor Technique, explains the genesis of the solution. “Transerve-JHT initially approached us seeking a high-pressure air compressor to support their new 4 kW fibre laser cutting machine. However, the geographical limitations of their location presented challenges with liquid nitrogen availability. We therefore proposed a modular, skid-mounted nitrogen generation system specifically designed for laser cutting applications.”
This innovative approach sidestepped the logistical and cost challenges associated with traditional liquid nitrogen supply methods, including the use of multi-cylinder packs (MCPs). “Our solution effectively mitigates all the drawbacks of liquid nitrogen,” continues Adriaanse, “offering reduced operational costs, increased productivity, and the elimination of transport and handling issues, which also enhances worker safety.”
The system’s robust performance has allowed Transerve-JHT to scale its operations dynamically, adapting to market fluctuations with ease. Atlas Copco’s commitment to after-market service has further solidified the partnership, providing ongoing support and proactive maintenance to ensure the system operates at peak performance. “Atlas Copco’s service team has been exceptional,” affirms Meyer. “Their responsiveness and expertise have been invaluable in keeping our operations running smoothly.”
The successful integration of the nitrogen generator skid has not only enhanced Transerve-JHT’s capabilities but also reinforced Atlas Copco’s commitment to providing cost-effective and sustainable solutions tailored to its customers’ specific needs. “This project demonstrates how innovation and collaboration can drive operational excellence,” says Adriaanse.
“Our on-site nitrogen generation solutions empower customers like Transerve-JHT to achieve independence from traditional gas suppliers while ensuring superior performance and sustainability,” concludes Adriaanse. “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, with four decades of experience serving the South African road haulage industry, stocks a comprehensive range of truck and trailer replacement spares for the haulage, mining, and industrial hydraulics markets. The company’s specialized in-house laser cutting services, capable of handling thicknesses up to 20mm, adhere to customer drawings and specifications, ensuring precise and high-quality results.
