Production Process
At Euro Cylinder, we take great pride in our cylinder making production process. Our process is designed to ensure that our products are manufactured to the highest standards of quality and accuracy. Below is a brief overview of our production process:
Our final product is tested at appropriate KGF/CM2 pressures. Random Bust Test, Bonfire Test, and Bullet penetration Test are conducted to meet statutory safety standards.
1. Steel Tubes
2. Cutting to Length
3. Induction
4. Bottom Spinning
5. Bottom Milling
6. Neck Induction
7. Neck Spinning
8. Neck Machining
9. Heating Quenching and Tempering
10. Ultrasonic Testing
11. Hardness Testing
12. Neck Threading
13. Hydro Testing
14. Air Leakage Test
15. Hot Air Drying Operation
16. Internal Shot Blasting
17. External Shot Blasting
18. Cylinder Marking
19. Cylinder Painting
20. Final Inspection
21. Cylinder Accessories
22. Packing & Dispatch
1. Steel Tubes
STEEL TUBES are also used specifically in the manufacture of high-pressure gas cylinders. They are used as the raw material for the production of cylinders in various sizes and designs. The steel tubes are cut to the correct length and then heated, spun, and shaped to form the cylinder. The cylinder is then subjected to various quality control and testing procedures, including hydro-static testing, ultrasonic testing, and other inspections, to ensure that it meets safety standards and can withstand the intended pressure and temperatures. Steel tubes are used in the production of CNG Cylinders, Oxygen Cylinders, Industrial Cylinders, and Hydrogen Cylinders. They are preferred because of their strength, durability, and ability to withstand high pressures and temperatures. The steel tubes are used in the production process are of high quality and are specially treated to meet the standards of the cylinder industry.
2. Cutting to Length
TUBE CUTTING refers to the process of cutting tubes to specific lengths using specialized machines and tools. This process is often used as the first step in the manufacturing of cylinders, as it ensures that the tubes are the correct size for the cylinder.
The process of tube cutting can be done using a variety of machines, such as a saw, a shear, or a laser cutting machine. The specific machine used will depend on the type of tube being cut, the size and shape of the tubes, and the desired precision of the cut.
The tubes that are cut to the correct length are then used as the raw material for manufacturing cylinders, they can be used as is or they can be subjected to further process such as, spinning, necking, induction heating, and bottom pressing.
3. Induction
INDUCTION HEATER : An induction heater is a device that uses electromagnetic induction to heat a conductive material. In the case of heating tubes, the tubes are typically made of metal, such as steel, and are placed in an induction coil. An alternating current is passed through the coil, which creates an oscillating magnetic field. The magnetic field induces an electrical current, called eddy currents, in the tubes, which in turn generates heat in the tubes.
The induction heating process is a fast and efficient way to heat tubes for the spinning process. It heats the tubes uniformly and accurately without any direct contact with the heating source, which reduces the risk of damage to the tubes and allows for precise temperature control. The tubes can be heated to a specific temperature quickly and uniformly, which is essential for the spinning process to ensure the tubes are malleable enough to be formed into the desired shape.
Induction heating is widely used in various industries, such as the manufacturing of cans, bottles, pipes, and other cylindrical parts. It is also used for heat treating, brazing, and soldering.
4. Bottom Spinning
BOTTOM SPINNING is a metal forming process that is used to create a flat, circular bottom on cylindrical parts such as cans, bottles, and other containers. The process involves spinning a cylindrical piece of metal at high speeds while a tool, called a punch, is pressed against the bottom of the spinning metal. The punch is shaped to match the desired final shape of the bottom, and as the metal spins, it is forced against the punch, forming it into the desired shape.
The metal is heated to a certain temperature before spinning, to make the metal more malleable and easier to form. The spinning process can also be performed cold, depending on the material and the desired final shape.
Bottom spinning is similar to neck spinning, but it is used to create the bottom of a container instead of the neck. The process can create parts with tight tolerances and can be used to form parts with complex shapes that are difficult to create using other metal forming processes. It is widely used in the manufacturing of cans, bottles and other containers.
.
5. Bottom milling
BOTTOM MILLING is a machining process used to create a flat bottom surface on a cylindrical or other shaped workpiece. The process involves using a milling machine, which is a machine tool that uses a rotating cutting tool to remove material from the workpiece.
In bottom milling, the workpiece is mounted onto the milling machine and a rotating cutter is used to remove material from the bottom surface of the workpiece. The cutter is moved in a specific pattern, typically in a spiral or circular motion, to create a smooth, flat surface.
Bottom milling can be performed on a variety of materials, including metals, plastics, and composites. The process is often used in the manufacturing of parts for machinery, vehicles, and other industrial applications. It can also be used to create a smooth surface on the bottom of a cylinder for example in the manufacturing of cylindrical containers. This process can be performed either manually or CNC(Computer numerical control) machine which can be programmed for a specific pattern or shape.
6. Neck induction
NECK INDUCTION: Neck induction refers to a process that is used to heat and shape the neck of a cylinder. It typically involves using a specialized machine that uses electromagnetic induction to heat the neck of the cylinder. Once the neck is heated, it can be reshaped by using a mandrel or other shaping tool.
The process of neck induction is typically used in the manufacturing of gas cylinders, such as those used for storing and transporting gases like propane, butane, or oxygen. The process is used to create a specific shape or size for the neck of the cylinder, to match the specifications of a particular application or to fit with other equipment. It can also be used to improve the surface finish of the neck and to remove any burrs or sharp edges, which can enhance safety and reduce the risk of injury or damage.
The process of neck induction heating is considered a critical process in cylinder manufacturing, and it is typically performed by trained and certified professionals. The process generates hazardous debris, and proper safety and personal protective equipment must be worn. The process is also required to meet the safety standards and the finished product must be tested and inspected to ensure it meets the required specifications.
7. Neck spinning
NECK SPINNING: Neck spinning refers to a manufacturing process that is used to shape and finish the neck of a cylinder. It typically involves using a specialized machine that spins the cylinder at high speeds and applies a cutting tool to the neck to shape and finish it.
The process of neck spinning can be used to create various shapes and sizes for the neck of the cylinder, such as conical, tapered, or stepped shapes. It can also be used to improve the surface finish of the neck, remove any burrs or sharp edges, and make the cylinder neck compatible with other devices such as, cylinder valves, regulators or couplers.
The specific tools and techniques used in neck spinning will depend on the type of cylinder, the desired shape or size of the neck, and the desired surface finish. It can be performed using a variety of tools such as a lathe, milling machine, or grinding machine, and the process may involve multiple stages of cutting and finishing.
Neck spinning is considered a critical process in cylinder manufacturing, and it is typically performed by trained and certified professionals. The process generates hazardous debris, and proper safety and personal protective equipment must be worn. The process is also required to meet the safety standards, and the finished product must be tested and inspected to ensure it meets the required specifications.
8. Neck Machining
NECK MACHINING: Cylinder neck machining refers to the process of cutting, shaping, or finishing the neck of a cylinder, typically using a specialized machine or tool. This is often done for a variety of purposes, including:
To create a specific shape or size for the neck of the cylinder, to match the specifications of a particular application or to fit with other equipment.
To remove any burrs or sharp edges on the neck of the cylinder, which can improve safety and reduce the risk of injury or damage.
To improve the surface finish of the neck of the cylinder, which can enhance its appearance, reduce the risk of leakage, or improve the seal between the cylinder and other equipment.
To make the cylinder neck compatible with other devices such as, cylinder valves, regulators or couplers.
The process of cylinder neck machining can be done using a variety of tools and machines, such as a lathe, milling machine, or grinding machine. The specific tools and techniques used will depend on the type of cylinder, the desired shape or size of the neck, and the desired surface finish.
9. Heating Quenching and Tempering
HEATING QUENCHING AND TEMPERING : Heating, quenching, and tempering is a process used to heat treat cylindrical parts made of steel or other metals. The process is typically used to improve the mechanical properties of the material, such as increasing its strength and toughness.
The heating process involves heating the cylinder to a specific temperature, typically above the critical temperature of the material, in order to change its microstructure.
Quenching process is where the cylinder is cooled rapidly in order to lock the microstructure in a specific state. It typically involves immersing the cylinder in a liquid, such as oil or water, or using a high-pressure stream of air or gas. This rapid cooling process causes the material to harden.
Tempering process is where the cylinder is heated to a lower temperature, typically below the critical temperature, in order to relieve internal stresses and improve the toughness of the material.
The combination of these three processes heating, quenching and tempering improves the mechanical properties of the cylinder such as strength, toughness, ductility and fatigue resistance.
10. Ultrasonic Testing
ULTRASONIC TESTING: Ultrasonic testing (UT) is a non-destructive method used to evaluate the integrity of materials, such as a cylinder, by measuring the time it takes for sound waves to travel through the material and reflect back. It is a form of non-destructive testing that uses high-frequency sound waves to detect internal and surface defects, such as cracks, porosity, and inclusions.
For a cylinder, an ultrasonic probe is placed on the surface of the cylinder, and sends high-frequency sound waves into the material. The sound waves travel through the material, and if they encounter a defect, they will be reflected back to the probe. The time it takes for the sound waves to travel through the material and reflect back is used to determine the location and size of the defect.
Ultrasonic testing is a widely used method for the inspection of cylindrical components like pipes, pressure vessels, and aerospace components. It’s popular for its high accuracy, and the ability to detect small defects that other testing methods may not detect.
11. Hardness Testing
HARDNESS TESTING: Hardness testing is a method used to evaluate the hardness of a material, such as a cylinder. Hardness is a measure of a material’s resistance to indentation, abrasion, and penetration, and is an important mechanical property for many industrial materials. There are several different methods for measuring hardness, each of which is suited for different types of materials and applications.
The most common methods for testing the hardness of a cylinder are:
Rockwell hardness test: This test measures the depth of penetration of a diamond cone or a hardened steel ball into the surface of the material. A Rockwell hardness number is then assigned to the material based on the depth of penetration.
Brinell hardness test: This test uses a steel ball that is pressed into the surface of the material with a specific load. The diameter of the indentation is then measured and used to calculate the Brinell hardness number.
Vickers hardness test: This test uses a diamond pyramid-shaped indenter that is pressed into the surface of the material with a specific load. The diagonal of the resulting indentation is then measured and used to calculate the Vickers hardness number.
Knoop hardness test: This test uses a diamond pyramid-shaped indenter that is pressed into the surface of the material with a specific load. The long diagonal of the resulting indentation is then measured and used to calculate the Knoop hardness number.
Hardness testing is a commonly used method for evaluating the quality and consistency of materials, and is often used as a part of quality control and material selection processes in manufacturing and other industries.
12. Neck Threading
NECK THREADING: Cylinder neck threading is a process of cutting threads onto the neck of a cylinder, such as a bottle or a can, so that it can be sealed with a screw-on cap. This process is typically done using a thread-cutting machine, which uses a cutting tool to remove material from the neck of the cylinder and create the threads.
The thread-cutting machine can be manual or CNC (Computer Numerical Control) operated. CNC machines are programmable, which allows for precise control of the thread cutting process, including the depth, width, and pitch of the threads.
The thread-cutting process is typically done after the cylinder has been formed and the neck has been spun to the desired shape. The cylinder is then loaded into the thread-cutting machine, and the cutting tool is positioned to start cutting the threads. The cylinder is then rotated while the cutting tool is moved along the length of the neck, removing material and creating the threads.
13. Hydro Testing
HYDRO TESTING: Cylinder hydro testing is a process used to test the strength and integrity of gas cylinders. The process involves filling the cylinder with water and pressurizing it to a specific level, which is typically higher than the cylinder’s maximum working pressure. The cylinder is then examined for leaks, cracks, or other defects that could compromise its safety and integrity.
The hydro testing process is typically done on new cylinders before they are put into service, and on older cylinders at regular intervals to ensure they are still safe to use. The frequency of hydro testing is determined by the regulations and safety standards of the industry in which the cylinder is used.
During the process, the cylinder is filled with water and pressurized to a specific level, then the cylinder is examined for leaks, cracks, or other defects that could compromise its safety and integrity. Any defects found during the hydro test will typically result in the cylinder being taken out of service and either repaired or scrapped.
14. Air Leakage Test
AIR LEAKAGE TEST: Air leakage test is a process used to test the integrity of a cylinder or other pressure vessel, by checking for leaks in the cylinder or other pressure vessel. The process involves pressurizing the cylinder with air or another gas, and then checking for any leaks or drops in pressure.
The air leakage test is typically done on new cylinders before they are put into service, and on older cylinders at regular intervals to ensure they are still safe to use. The frequency of air leakage test is determined by the regulations and safety standards of the industry in which the cylinder is used.
During the process, the cylinder is pressurized with air and checked for leaks using a variety of methods such as, visual inspection, ultrasonic testing, and mass spectrometer leak detection. Any leaks found during the air leakage test will typically result in the cylinder being taken out of service and either repaired or scrapped.
It’s important to note that the air leakage test process must be performed by trained and certified professionals, and in compliance with safety and industry standards. The process is also required to meet the safety standards, and the finished product must be tested and inspected to ensure it meets the required specifications.
15. Hot Air Drying Operation
HOT AIR DRYING OPERATION: Hot air drying operation is a process used to dry or remove moisture from materials such as, gas cylinders, valves, and other components. The process involves blowing hot air over the surface of the material, which causes the moisture to evaporate.
Hot air drying is typically used in the manufacturing and maintenance of gas cylinders, to remove any moisture that may have accumulated on the surface of the cylinder during the cleaning process. Moisture can cause corrosion, rust and can affect the integrity of the cylinder, so it’s important to dry the cylinder before storing or transporting it.
The process of hot air drying is typically performed using specialized hot air drying equipment, such as an industrial hot air blower or a hot air gun. The temperature of the hot air and the duration of the drying process will depend on the type of material being dried, the amount of moisture present, and the desired level of dryness.
It’s important to note that the hot air drying process must be performed by trained and certified professionals, and in compliance with safety and industry standards. The process is also required to meet the safety standards, and the finished product must be tested and inspected to ensure it meets the required specifications.
16. Internal Shot Blasting
INTERNAL SHOT BLASHTING: Internal shot blasting is a process in which a cylinder or other object is blasted with small, abrasive particles in order to remove surface defects and create a smooth finish. This process can also be used to prepare the surface for further processing or coating.
17. External Shot Blasting
18. Cylinder Marking
CYLINDER MARKING:The cylinder is then stamped with the required information such as serial number, manufacturing date, and test pressure. Cylinder marking refers to the process of labeling or marking cylinders used to store and transport gases or liquids. These markings are typically used to identify the contents of the cylinder, its owner, and any relevant safety information. The markings are usually applied to the cylinder using stencils, labels, or paint.
19. Cylinder Painting
CYLINDER PAINTING: Cylinder marking refers to the process of labeling or marking cylinders used to store and transport gases or liquids. These markings are typically used to identify the contents of the cylinder, its owner, and any relevant safety information. The markings are usually applied to the cylinder using stencils, labels, or paint.
20. Final Inspection
CYLINDER PAINTING: The inspection process typically includes a visual examination of the cylinder’s surface, threads, valves, and other components to ensure that they are free of defects and meet the required specifications. The cylinder is also checked for proper markings and labeling, such as the manufacturer’s name, serial number, and test date. Additionally, the cylinder is tested for its strength and integrity by performing hydrostatic and pneumatic tests.
21. Cylinder Accessories
CYLINDER ACCESSORIES: Cylinder accessories refer to various items that can be used in conjunction with cylinders to enhance their functionality, safety, or ease of use. Some examples of cylinder accessories include:
Cylinder valves: These are used to control the flow of gas or liquid out of the cylinder and can come in various types such as, pressure-reducing valves, needle valves, and flow control valves.
Cylinder regulators: These are used to control the pressure of the gas or liquid flowing out of the cylinder and can come in various types such as, single stage and two-stage regulators.
Cylinder carts and stands: These are used to safely transport and store cylinders, and can be made of various materials such as, steel, aluminum, or plastic.
Cylinder cap protectors: These are used to protect the cylinder valve and keep it free of dirt and debris.
Cylinder pressure gauges: These are used to monitor the pressure in the cylinder and ensure that it is at the correct level.
Cylinder safety relief valves: These are used to release pressure from the cylinder in case of overpressure and protect it from bursting.
Cylinder couplers: These are used to connect cylinder to other equipment such as, regulators, hoses, or other devices.
Cylinder labels and stencils: These are used to mark the cylinder with important information such as, the cylinder’s contents, pressure rating, or expiration date.
22. Packing & Dispatch
PACKING & DISPATCH: Cylinder packing and dispatch is the final step in the manufacturing process of a cylinder. It involves preparing the cylinder for shipment or storage and getting it ready for delivery to the customer.
Packing typically involves cleaning the cylinder, inspecting it for any defects, and then wrapping it in protective material such as plastic wrap, bubble wrap, or foam. This is done to protect the cylinder from any damage during transportation.
The cylinder is then placed in a cardboard or wooden box that is also filled with protective material. The box is then sealed and labeled with the appropriate shipping information, such as the destination address, weight, and handling instructions.
After packing, the cylinder is then dispatched to the customer, either by shipping it through a carrier such as a trucking company or by loading it onto a pallet for storage or transport. Dispatch process also includes preparing the necessary paperwork such as invoice, bill of lading, and packing list for shipment.
The cylinder might be dispatched to a warehouse for storage, or directly to the customer’s facility. Dispatch process is done in such a way that the cylinder is delivered on time and in perfect condition.