South Africa’s first locally manufactured nitrogen generator system NitraWeld, developed by nitrogen generator supplier Nitralife, allows for a “new level of flexibility and efficiency in laser-welding operations”.

The system, developed in response to feedback from laser cutting and welding clients, makes nitrogen gas on site. This provides a cost-effective, self-sufficient alternative to traditional nitrogen or argon cylinders, while allowing for broader adoption of laser-welding technologies in a challenging skills environment.

The creation of NitraWeld was a “natural progression” from the company’s successful NitraCut system, and has become a “first mover” in this specific space, says Nitralife MD Tom Sowry.

“We noticed that our laser-cutting clients had begun using their NitraCut units to supply laser-welding applications. These fabricators, already familiar with the benefits of on-site nitrogen, requested adaptations.”

These requests demonstrated a clear market need for a dedicated nitrogen solution optimised for laser welding.

Bridging Skills Gap

Laser welding is increasingly regarded as a practical solution to South Africa’s shortage of skilled welders. The technology allows for high-precision welding that is easier to learn and conduct than traditional techniques, supporting operators with limited experience.

Sowry notes that, instead of lamenting the loss of skilled labour, Nitralife has taken a proactive approach by supporting technologies that help bridge the skills gap.

“Laser-welding systems are far quicker and easier to implement. The systems have enabled new operators to become productive, faster.”

Importantly, this shift is also gaining support among engineers who approve weld procedures – a key step in driving broader industry acceptance of laser welding as an effective technique for thin stainless and mild steels.

He notes that nitrogen is widely recognised as a preferred shielding gas to argon for laser welding, as a result of its ability to produce cleaner, faster welds.

However, it is typically used at higher flow rates (about 25 ℓ/min) compared with argon (around 10 ℓ/min to 15 ℓ/min)making cylinder-based nitrogen an expensive option for sustained use.

“NitraWeld eliminates the recurring cost of bottled gas and transforms nitrogen from a premium gas into a cost-saving solution. This is particularly beneficial for high-volume users and those without reliable supply chains.

This independence is also vital for operations where supply interruptions could cause costly downtime.

The NitraWeld system is designed for ease of use, with its ‘plug-and-play’ design, requiring no electricity and connecting directly to a compressed air line. Sowry adds that this simplicity is deliberate, making it ideal in skills-constrained environments.

He explains that even minor design choices (such as using a ball-and-tube flow meter, rather than a digital one) are made with end-users in mind: “This is what traditional welding set-ups have, and our customers understand them well.”

A key feature of the NitraWeld system is its modular scalability, with base units that are made to supply up to three laser welders, with larger systems custom-built.

“The system can be configured for anything – from a single welder to dozens of robots. Every installation is tailored with custom-built panels, flow meters and digital monitoring tools for flow rate and gas purity monitoring.”

NitraWeld aligns with the principles of Industry 4.0 and 5.0 by supporting automation, real-time monitoring and self-sufficient manufacturing.

The nitrogen generators can be integrated into smart factory environments, reducing complexity and operational costs while lowering manufacturers’ carbon footprints.

For industries that rely on thicker structural steel, Nitralife can design systems to meet those gas flow requirements, ensuring value across various fabrication needs.

Sowry highlights that speed, availability and adaptability are the hallmarks of Nitralife’s local manufacturing approach, adding that “even small adjustments to meet a specific requirement can make a large impact on performance and productivity”.

Alongside smaller fabrication shops, NitraWeld is being adopted by larger manufacturers as a more cost-effective solution. The elimination of cylinder supply and delivery issues is especially attractive to these customers, as it makes operations leaner and more sustainable.

Sowry advises that “even greater than the financial benefit is the guarantee of production independence. NitraWeld gives local manufacturers the tools to compete more effectively, with the confidence that their nitrogen supply is secure, scalable and sustainable.”