How On-Site Nitrogen Generation Reduces Costs and Downtime in Industrial Applications

In modern industry, reliability and cost control are inseparable. From food packaging lines to metal fabrication plants, nitrogen plays a vital role in preserving product quality, preventing oxidation, and maintaining stable production. Yet for many businesses, bottled or bulk nitrogen supply remains a hidden drain on operational budgets — and a source of unwanted downtime whenever deliveries fall behind schedule.

On-site nitrogen generation offers a smarter, self-sufficient alternative. Using clean, dry compressed air and advanced Pressure Swing Adsorption (PSA) technology, businesses can now produce their own nitrogen — at the exact purity, pressure, and flow required for their process — without relying on third-party supply chains.

The Shift Towards Self-Sufficiency

Industries across the UK are increasingly moving away from traditional cylinder or liquid nitrogen deliveries. The reasons are practical and financial in equal measure: rising gas prices, logistical uncertainty, and sustainability goals are prompting plant managers to reassess the long-term value of bulk supply contracts.

Installing an on-site nitrogen generator transforms this model completely. Once installed, the system continuously separates nitrogen from the surrounding air using compressed air as the feed source. No refills, no deliveries, no waiting — simply a steady, reliable flow of high-purity nitrogen on demand.

For businesses running 24-hour operations, that consistency translates directly into fewer interruptions, lower running costs, and a faster return on investment.

How PSA Nitrogen Generators Work

Mikropor’s MNG Series PSA Nitrogen Generators use a proven, energy-efficient process known as Pressure Swing Adsorption. Each unit contains twin adsorption towers filled with Carbon Molecular Sieve (CMS) material. When compressed air passes through one tower, the CMS adsorbs oxygen and moisture molecules, allowing only nitrogen to pass through as product gas.

While one tower is in adsorption mode, the other regenerates under reduced pressure — ensuring a continuous nitrogen supply. The system is fully automatic, controlled by a PLC interface and designed for long, maintenance-free operation.

Depending on the requirement, the MNG series can deliver nitrogen purity from 95% up to 99.999%, making it suitable for a wide range of industrial applications — including food packaging, plastics, electronics, pharmaceuticals, and metal processing.

Achieving Ultra-High Purity with the MDX Nitrogen Purifier

For processes that demand ultra-pure nitrogen — such as laser cutting, electronics production, or pharmaceutical packaging — Mikropor’s MDX Series Nitrogen Purifier System can be added downstream of the generator.

The MDX uses a catalytic reaction between residual oxygen and a small, controlled amount of hydrogen to achieve 99.999% nitrogen purity, with oxygen content reduced to as little as 10 parts per million (ppm). The only by-product of this reaction is water, which is safely removed by the integrated dryer.

Crucially, this purification stage allows plants to produce ultra-pure nitrogen using smaller compressors and lower overall air consumption, significantly reducing energy costs. The combined MNG + MDX system is compact, fully automated, and capable of 24/7 operation with minimal maintenance.

Key Benefits of On-Site Nitrogen Generation

1. Major Cost Savings
Producing nitrogen on site can cut gas costs by up to 70% compared to bottled or liquid supply. Once installed, the main running cost is simply the electricity required to power the air compressor.

2. Continuous Supply, Zero Downtime
Eliminating external deliveries removes the risk of production stoppages caused by late cylinders or empty tanks. The generator provides nitrogen whenever the plant is operating.

3. Adjustable Purity and Flow
The PSA process allows the purity level to be adjusted according to need. For example, 99% purity may be sufficient for some applications, while others require 99.999%. The operator can balance purity with efficiency for optimal running costs.

4. Environmental Benefits
On-site generation reduces CO₂ emissions by removing the transport and production footprint associated with delivered gas. Mikropor systems are also engineered for low energy consumption and long service life.

5. Minimal Maintenance
Aside from periodic filter element changes and compressor servicing, PSA systems require very little attention. Mikropor’s durable piston valves, integrated PLC control, and modular design ensure reliable, long-term operation.

Example: How a Food Packaging Plant Could Benefit

To illustrate the potential benefits, consider a typical food packaging facility in the West Midlands that relies on bottled nitrogen to preserve product freshness during sealing. Such businesses often face fluctuating gas prices, delivery delays, and occasional production interruptions when supply runs short.

By installing a Mikropor MNG Series PSA Nitrogen Generator paired with an MDX Purifier and an energy-efficient rotary vane compressor, the plant could generate nitrogen on site at 99.999% purity, entirely independent of deliveries.

This approach would reduce nitrogen-related costs by more than half, eliminate the risk of downtime caused by late deliveries, and improve environmental performance by removing gas transport emissions. The system’s fully automated operation and minimal maintenance requirements make it ideal for continuous production environments.

Integrating Compressors, Pipework and Installation

An on-site nitrogen generator is only as reliable as the air system behind it. That’s why every installation should begin with a correctly sized air compressor, suitable filtration, and well-designed pipework.

At West Midlands Compressors Ltd, we supply and install complete turnkey systems — from the air compressor and air treatment equipment to the Mikropor generator and stainless-steel or aluminium pipework. Each project is designed to achieve maximum efficiency with minimal pressure loss, ensuring consistent nitrogen output and energy-optimised operation.

Our engineers also provide ongoing servicing and maintenance, so clients can focus entirely on production, confident that their nitrogen system will perform day and night.

Why Choose Mikropor Nitrogen Systems

Mikropor has been manufacturing advanced air and gas treatment solutions since 1987, now serving customers in more than 140 countries. The company’s MNG and MDX product lines reflect decades of innovation in compressed-air and gas separation technology.

Their systems are known for:

• Compact, modular construction.

• Low air-to-nitrogen ratios for better efficiency.

• Fully automated PLC control.

• Long service life and high reliability.

• Proven results in industrial environments worldwide.

Combined with the expertise of a dedicated installation partner, Mikropor systems provide a dependable and cost-effective nitrogen supply for any production facility.

Contact Us

If your business depends on nitrogen, switching to an on-site generation system could transform your operation — lowering costs, improving reliability, and giving you complete control over gas quality.

West Midlands Compressors Ltd supplies, installs and maintains high-performance nitrogen generation systems for industrial clients across the UK.

Contact us today to discuss your nitrogen requirements or arrange a site visit.