“With Weldcoa’s automated setup, variability is completely removed. We get consistent product down to the gram level. In the challenging biotech market, that’s critical.”

- Austin Romesberg, Vice President of Operations for WestAir Gases & Equipment, Inc.

Sur-Fill™Automation

Modular Gas Filling Automation for any size budget. 

 Weldcoa’s automation was designed by seasoned people who filled cylinders for a living. The touchscreen PLC automates all  of the responsibilities of the traditional human cylinder filler creating a safer environment, uniform product fill, maximum production and new levels of management control/simplification of training. Our automated cylinder fill systems have been validated by some of the largest gas manufacturers in the world.

Four levels of automation are available to fit every size gas cylinder filling operation. Systems can be installed into new or existing facilities. The Sur-Fill is a highly efficient, cost effective alternative to conventional filling methods.

The Benefits of Using Weldcoa's Sur-Fill™ Automation 

  • Increases safety and productivity by establishing a more organized, safer filling environment
  • Measurable employee activity is gained
  • A more unified, consistent SOP (Standard Operating Procedures) is put in place
  • Improved and consistent product quality levels
  • Instantaneous fill report capability
  • Frees operators to multi-task
  • Simple user-friendly screens prompt users through the filling process
  • Every system is Bilingual (Spanish-English)
  • Designed with field configurable parameters and set points to meet each and every customer specific filling requirements and market needs
  • Delivered as self contained, turn key units that are ready to operate once the existing gas lines have been connected to them
  • All units are built and tested at Weldcoa prior to shipping to the customer work site. This assures that the unit is fully operational upon receipt. The units are highly adaptable to various environments and reside within a NEMA enclosure.
  • Built, Programmed and Tested in the USA

Choose from any of our 4 lines of automation. Automation can make the difference in your business profits today.

Weldcoa Sur Fill Graph

We continue to work with Weldcoa primarily for their experience and expertise with automation. We’ve found their systems to be extremely reliable. And, we really appreciate how Weldcoa can monitor their systems remotely, and identify and correct any issues in a timely fashion—often before our local guys know there are issues."

John Rogstad, COO for Gas and Supply

We did a lot of research. Weldcoa listened to what we wanted and came up with an affordable package that allowed us to do automated filling. We knew automation was available, but it had been cost-prohibitive in the past.” 

Fred Seminik, General Manager of American Welding & Gas

The accuracy and efficiency of our new automated fill island and lab has enabled us to expand into the beverage and specialty gas markets with great confidence and immediate success.”

Jim Weiler, Co-Owner of Weiler Welding Company, Inc.

Being customer-driven and known for our quick response to customer requirements, we believed it was time to invest in a new, state-of-the-art automated fill island. Now, our completely modernized fill operations have optimized consistency, accuracy and purity for our customers.””

Kevin Kimker, Director of Gas Operations at Cee Kay Supply, Inc.

Added Value within Weldcoa's Automation

ElectricalAll electrical control panels for our systems are made in-house with a UL listed shop.  All automation 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.  All final wire connections are inspected by our electrical engineer to ensure proper installation.  These steps greatly minimize any start-up and operational issues with the system which is another cost savings.

Mechanical – Drawings for the piping (P&ID’s) for each gas system are provided to the customer.   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. 

Our palletized automated fill islands are pre-assembled in our shop including mechanically and electrically.   They are operationally tested prior to shipment and then prepared for shipping.  Once on the customer site the island can be set up in 1 – 1-1/2 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.

Pumps & Controls – The heart of any pumping system is the pump itself.  If the pump fails for any reason then your production is down and that is costly.  For that reason Weldcoa’s automation provides a number of checks for the proper operation and will send you alarm email alerts of any pump issues.  It also tracks the performance and utilization.  With the remote support set-up, we are proactive in keeping your pumps operating and eliminating as much unplanned down time as possible.

Weldcoa is the only company that predominantly uses variable frequency drives (VFD’s) on the pumps.  This allows our automation to control the pump speed at any time.  This is one of the keys to the success of the system with its accuracy for mixtures.    Besides mixtures this allows us to slow the pump down when filling smaller type cylinders including CO2, control the speed for heat of compression, use a higher capacity pump when needed for filling tube trailers or large volumes, to ramp up the speed of the pump instead of instantaneous start-up.

We also include electrical boxes out at the pump pad that houses the thermocouples used for monitoring the pumps.  This allows for simple electrical installation for these devices which can add up to real savings. 

Start-up & Training – Because of the preliminary work done for the electrical and mechanical along with it already tested in the shop, the start-up is easy to debug and usually only takes 2 – 3 days to get everything functional.  Our automation programmer is 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.

Technology – Weldcoa constantly reviews new products on the markets that could enhance our systems.  For that reason our systems are always current state-of-the-art.  Our automation staff is all in-house and with 20 years of systems in operation, the staff is very knowledgeable on overall cylinder filling plant operations.  So with this understanding the logic that is built into each system is very thorough. 

It is like someone, who fully understands the ins and outs of cylinder filling, is standing there and operating the system.  Which is exactly what is happening.  Weldcoa has a number of engineers on staff who have worked in fill plants for the major gas companies.   They have worked with our automation programmers to ensure that this logic is built into the system.

It is easy for anyone to say they offer automation.  However, you really need to look at what you are actually getting and understand what the automation will do for you.  This can have a tremendous impact on the efficiency of the system.  

Security – Because many companies have a concern with an outside company having access to the computer system for the automation, Weldcoa has recently come up with a solution.  This system provides Weldcoa remote access without going through any of the company’s channels or systems.  Thus security is guaranteed and companies can be assured of no breaches into their systems. 

There are many reasons why to choose a Weldcoa automated fill plant.   The primary reason though is that they work and perform.  We have a long, proven track record of successful systems and satisfied clients. Don’t be misled by a cheaper price on the bottom line of a quote for the equipment.  Make it a point to fully understand the overall costs.

LOOKING FOR REFERENCES?  CLICK HERE - CHECK OUT OUR CASE STUDIES AND SEE HOW SUR-FILL WORKS FOR OTHERS IN OUR INDUSTRY.

“With the automation in the new fill plant in Tulsa, variability is removed and process repeatability is ensured. For example, doing cylinder prefills on a scale provides perfect accuracy and eliminates any chance for human error. The operators are hooking up and pushing buttons, and don’t have to worry about following specified fill procedures—the computer manages that process.”

Harry Fite, Owner of Gas & Supply's Oklahoma Facility

“Automation has enabled us to save labor, increase quality and consistency, and preserve raw materials.”

Robert Parsons, Plant Manager for Holston Gases facility in Knoxville, TN

“We’ve grown tremendously on the back of the new Weldcoa fill plant. Automation allows one operator to run the five fill heads simultaneously. He connects the cylinders to the pigtails, opens the valves, punches in the job information into the touchscreen control panel to call up the program (what we’re filling, how many cylinders we’re filling and the grade) and he’s done. The computer controls the vent cycle, vacuum cycle and fill cycle automatically—no operator involvement.”

Dave Messina, Plant Supervisor for WestAir Gases & Equipment's National City, CA facility

“Our sales guys are much more confident in our product than ever before. We’re ready to take on other gases now, which we have been outsourcing. The new Weldcoa equipment gives us the confidence to consider moving that work inhouse. There’s a lot of room to grow.”

Curt Towne, Owner of Depke Welding Supplies in Danville, IL