Pallet Fill System with a 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 set-up, the filler can sort and inspect their cylinders on the deck itself - all while being protected from potential fork-lift loading and unloading traffic hazards.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. Also it is important to note that our systems can be designed to fit and accommodate the pallet style you use at your facility, whether it is a Weldcoa pallet or another from a different supplier. 

Pallet Fill System with am Ergonomically Raised 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 there 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 of the US.

Pallet Fill System with No Deck

This is an economical option that allows more of the capitol 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 features like the fill head assembly however keep in mind that this can only be a one-sided unit and you loose the safety and sorting benefits the deck provides. 

Traversing Fill Heads:

A Traversing Fill Head traverses (slides) to the left and to the right. The main benefit of a traversing head is the once a pallet of cylinders has been filled you can quickly move the fill head over to another pallet that is prepared to be filled, thus maximizing your capitol expense of the fill system and cryogenic pumps. This, by far, is our most popular option simply due to the efficiencies alone.

Fixed Fill Heads:

A Fixed Fill Head is permanently positioned over a designated fill station. A fixed fill head is generally only recommended for smaller volume facilities filling one particular product. This is for situations when the need for flexibility and possible volume growth is not desired. 

Single Sided System:

The two main benefits to a single-sided design is the the unit can be placed against the wall on 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 System:

A double-sided design is an economical, efficient layout allowing the operator to fill large volume in a manageable, safe space.  

Sur-Fill™ Automation:

Our Sur-Fill™ Automation is a highly efficient, cost effective alternative to manual conventional Filling methods. Weldcoa has several levels of automation to choose from allowing the operator to be freed up to do more operations during a fill cycle. 

Sur-Fill™ Reports Software:

Make better management decisions with Weldcoa's revolutionary reporting software. This data can be used for production scheduling, to identify productivity by employee, productivity by pump, cylinder utilization and more.

Manual Control Panel System:

A minimal cost option that will increase productivity and efficiency.   

Bank Filling Station Add-On:

We can provide customized bank filling stations with isolated flexible leads (pigtails).   

HEAR WHAT YOUR PEERS HAVE TO SAY:

Holston Gases Tells Their Fill Plant Story

Encore Welding Talks About Their Weldcoa Experience

WestAir Tells Us How Their UpGrade Transition Has Been

ClIENt CASE STUDY TESTIMONIALS:

Cee Kay Supply Increases Purity, Accuracy and Consistency

B&J Welding SupplY Capitalizes on Tremendous Market Potential

General Air makes the Right Move at the Right Time.

WestAir Gases & Equipment: Filling Quality and Accuracy Automation Keeps WestAir on Top of Biotech Market.

Holston Gases: Benchmarking Uncovers Best Practice

THERE IS A SIGNIFICANT ADDED VALUE WHEN TRUSTING WELDCOA WITH YOUR FILL PLANT NEEDS

ELECTRICAL BENEFITS:

All 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 BENEFITS:

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.  

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.

Building the equipment in the controlled environment of the Weldcoa manufacturing plant prior to delivery reduces labor, engineering and overall planning costs dramatically as well.

PUMPS AND CONTROLS BENEFITS:

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.

SECURITY BENEFITS:

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.

START-UP AND TRAINING BENEFITS:

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.  If you fill island has automation included, our automation programmer 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.  Your system will be up and running fully in no time at all.