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We're here to help you plan and implement the fill plant that is right for you now and far into the future. From simple filling stations to fully palletized and automated fill plants, your options are endless. Our process ensures that your new fill plant will exceed all of your expectations, from planning through full operation, and for the long-term. And we'll be with you every step of the way. |
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1. Plan
2. Build
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3. Install
Note: Electrical and piping must be completed by a third-party before Start-Up can begin. |
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4. Start-Up
5. Training
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| Long Term Support We support you in many ways long after your new fill plant is up and running. Your weldcoa team is always available to answer questions. We offer remote monitoring services for our automated solutions that enables us to detect and often resolve issues before you are even aware an issue has occurred. Our Precision University provides professional, continuing education throughout the year for you and your employees. |
Weldcoa is the recognized leader in independent manufacturing of Fill Systems. The Weldcoa Modular Filling Equipment is designed for rapid, minimal cost, installation into new or existing facilities. Our process has been developed over the last 45 years and continues to be refined. Building the equipment in the controlled environment of the Weldcoa plant prior to delivery reduces labor, engineering and overall planning costs dramatically.
When we looked at Weldcoa’s system and compared it to others in the market, we all found it to be extremely impressive, in particular the ability to provide service using remote diagnostics. Their technicians can receive instant notification of any messages from the equipment and access our control systems to diagnose and address issues. Downtime is practically eliminated, and the customers don’t experience any delays. While these instances are few and far between the ability to address them quickly and flawlessly sets Weldcoa apart from the others.”Pat Dalton, Operations Manager for WestAir Gas & Equipment, Inc.
Since the island was commissioned, whenever we pick up the phone for support, within a few minutes we’re talking to the person that either programmed the equipment, designed the equipment or installed the equipment.”Mike Zeilman,Sales/Operations Manager for S.J. Smith Company
Mike Schwarz, Plant Manager for A-OX Welding Supply Co.We know that Weldcoa is constantly watching over us. Their remote monitoring and troubleshooting proves extremely valuable. They’ve called and alerted us to issues before we even knew about them. Now that’s good service.”
Sonny Knotts, Manager of Operations and Production for Norco, Inc.Without fail, Weldcoa comes through when we need them, from design to installation to support. We consider Weldcoa part of our family, part of our team— a necessary partner as we look to continue to support our customers with timely delivery of high-quality products.”
Their level of experience was unbelievable; their depth of knowledge and technical abilities was deeper and wider than everyone else we talked to. Competitors were not near the same level.”Ken Goicoechea, Plant Manager of the new Boise Fill Facility for Norco, Inc.
Available Options and Benefits within:
Turnkey, modular design can grow by adding new modules or automation
Professionally interpipped and interconnected
Operator friendly which makes it easy to use and to quickly train personnel
Can be remotely supported by Weldcoa for any updates, changes, new personnel training or trouble-shooting
Reduces cylinder handling
Safer filling
Increased productivity
Measurabel employee activity
Each unit is shipped fully assembled and pre-tested.
Made in the USA
Key Modular Design Options for Palletized Systems:
Traversing Fill Heads
A Traversing Fill Head is traverses to the left and to the right. The main benefit of a traversing head is that once a pallet of cylinders has been filled you can quickly move the head over to another pallet that is prepared to be filled, thus maximizing your capitol expense of fill head and cryogenic pumps. Operation is simple; the leads pull down and when released, recoil back into the Fill Head. Several key features are integrated into the fill head design including a cylinder cap rack, isolation valves for situations that require less than pallet load fills, swivel connectors to eliminate the hassle of cylinder valve orientation, a connection for air tools, durable aluminum housing, and independent heavy-duty retractors on swivels for long work life operation. Weldcoa’s retractable lead fill heads are delivered complete and ready for installation. The installation process takes approximately 15 minutes. The traversing fill head is by far our more popular and recommended option.A Fixed Fill Head is permanently positioned over a designated fill station. A fixed fill head is generally only recommended for smaller facilities filling one particular product, when the need for flexibility and possible volume growth is not desired.
Standard Pallet Height Deck
With this popular island-style design, the pallets and the deck are the same height so the cylinders can easily roll off the pallet and on to the island. With this setup, the filler can sort and inspect their cylinders on the deck itself. Over 90% of Weldcoa’s Palletized Fill Systems have a standard pallet height deck due to the improvements it provides with cylinder flow and management.
Raised Pallet Deck
The big benefit towards this design is that the deck is at a raised level, providing an ergonomically friendly height for the filler to attend to the cylinders. This eliminates the filler to having to reaching up above their shoulders to handle the cylinders. Please note this option is only good if their filler is doing the cylinder sorting and inspection at another location, not on the island. This happens to be Weldcoa’s most popular deck preference for its customers outside the US.
With No Deck
This is an economical option that allows more of the capital investment to be used towards automation and/or additional equipment verses the deck structure and aesthetics itself. This erector set-design can still obtain many of the key filling system featuring traversing fill heads, being automated, etc. but keep in mind that this can only be a one-sided unit.
Single Sided Palletized System
The two main benefits to a single-sided design is that the unit can be placed against a wall in order to maximize space or the non-filling side can be designated specifically for the filler to perform the cylinder sorting and inspection.
Double Sided Palletized System
A double-sided design is an economical, efficient layout allowing the operator to fill large volume in a manageable, safe space.What to Expect From Weldcoa
All Weldcoa Palletized Fill Systems are fully built and piped 100% at Weldcoa. They are operationally tested, oxygen cleaned and then bagged, tagged and broken down into modules for delivery. Once on the customer site, the system can generally be set up in 1 to 1 ½ days. All piping is cleaned and capped at one end of the island for ease of piping in the field. The ease of installation dramatically cuts down the costs of the installation. Weldcoa guarantees all of our structures to be free of manufacturing defects for life.
All electrical control panels for our systems are made in-house with a UL listed shop. All automation, if any, is fully tested and proven prior to shipment. Electrical schematic wiring drawings are provided for the local electrical contractor and a meeting is held with the contractor prior to the installation. Our electrical engineer, to ensure proper installation, inspects all final wire connections. These steps greatly minimize any start-up and operational issues with the system, which is another significant cost savings.
Engineering/Mechanical drawings for the piping (P&ID’s) for each gas system are provided to the customer as well. Cut sheets for all equipment components are also provided for repair and spare parts information. All of this is stored on the HMI operator screen for ease of use and to find readily if automation is included.
Start-up & Training
Because of the preliminary work done already on the electrical and mechanical side of the project, along with the system already cleaned, inspected and tested in the shop, the start-up is easy to implement and usually only takes 2 – 3 days to get everything functional. At least one of our elite Engineers and Automation Programmers will be on-site during this time to make sure all the programming meets your satisfaction and your specific SOP’s. We will train your operators on all phases of the systems. The HMI is user friendly with very simple easy to read screens with touch screen operation. Thus your system is up and running fully in no time at all.
For any questions on what is offered, please feel free to contact us at (630) 806-2000 or email us at solutions@weldcoa.com.
