COMPRESSED AIR, VACUUM, AND GENERATORS As pressure mounts on manufacturers to reduce emissions and contain operating costs, attention is turning to longestablished processes, including how industrial gases are sourced and supplied. In laser cutting, nitrogen is critical to both edge quality and process speed, but the traditional reliance on bottled or bulk deliveries is beginning to shift. H&P spoke to Andrew Butler, Business Development Manager for Industrial Gases at Atlas Copco, to explore why an increasing number of metalworking firms are switching to on-site nitrogen generation and how new purification technologies are helping manufacturers meet changing demands. Why is nitrogen so critical to laser cutting? Nitrogen is widely used as an assist gas in laser cutting because it prevents oxidisation during the cutting process. The result is a clean, oxide-free edge that is ideal for applications where surface finish and downstream compatibility are important, for example, when parts will be powder-coated, welded, or assembled directly after cutting. While oxygen can be used as an alternative, particularly on mild steel, it tends to leave a carbon-stained edge and can reduce the speed and precision of the cut. Nitrogen, by contrast, allows faster cutting speeds on certain materials and supports a broader range of applications, including non-ferrous metals. That versatility has made it the gas of choice for manufacturers working across different product types and thicknesses. Why are companies now looking to generate nitrogen on site? Rising costs, supply chain disruptions, and sustainability goals are prompting many firms to reassess how they source industrial gases. Bottled or liquid nitrogen typically comes with delivery fees, rental charges, and price volatility, not to mention logistical risks. By switching to on-site generation, 34 HYDRAULICS & PNEUMATICS October 2025 www.hpmag.co.uk Is it time to rethink nitrogen supply in laser cutting? As manufacturers face rising energy costs and tighter sustainability targets, attention is turning to industrial gas supply. In laser cutting, on-site nitrogen generation is helping firms cut emissions, improve reliability, and gain control over costs while supporting cleaner, faster production and more flexible, scalable manufacturing operations. H&P spoke to Andrew Butler, Business Development Manager for Industrial Gases at Atlas Copco. manufacturers can take control of their nitrogen supply. The benefits go beyond cost savings. Generating gas at the point of use reduces transport-related emissions and allows users to produce only the purity they require, rather than relying on a standardised product. For sites already using renewable electricity, it also opens the door to near-zero carbon nitrogen production. Just as importantly, on-site systems are scalable. As manufacturers add new laser machines or increase their production volumes, they can expand their gas generation capacity accordingly. That flexibility is harder to achieve with thirdparty supply contracts. What technical considerations come into play? For manufacturers already using on-site nitrogen generation, it is worth reassessing whether existing systems are still fit for purpose. Many older generators were designed around less efficient air-tonitrogen ratios, meaning they require more compressed air to produce the same output. Newer systems can deliver higher flow rates, improved purity control, and better consistency using significantly less energy. They also tend to feature more advanced pressure swing adsorption (PSA) technology and refined Carbon Molecular Sieve (CMS) packing techniques, which improve separation efficiency and extend service life. Upgrading can be particularly worthwhile when nitrogen demand has increased, for example after adding new laser machines. In some cases, a modern generator of the same size can produce substantially more nitrogen, helping to avoid the need for additional equipment or expensive external supply. While supporting elements like variable speed drive compressors and integrated dryers contribute to overall system efficiency, it is the improvements in generator design - from flow optimisation to automated purity monitoring - that make the strongest case for replacement. These developments not only improve performance but also reduce maintenance intervals and help operators
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