Patented Gas Saver System (GSSTM)
and Patented Flow Rate Limiter and Lock
(FRLL) Have Quick Paybacks
for Industrial Shops.
The following are quick calculations with more detailed
information below showing how to use your own cost/payback data.
NOTE: If paying more than $50
for a cylinder of shielding gas the
will pay for itself in about 2 cylinders and improve weld starts!
Cost of MIG Shielding Gas =
$5/100 cubic feet
Note: If using CO2 there are 8.74 CF/lb of
of Wire Deposited per Welding Hour = 6 lbs per hour:
On average a MIG welder deposits
8 lb/hr of wire or more. 6 lbs/hr is a conservative assumption.
Typical Arc Time per Work Day =
Conservative 30% Used
8 work hrs/day x 30% = 2,4 hours per day x 5 days = 12 hours per week of
actual arc on time.
Cubic Feet of Gas /Lb of wire = 20 CF
of wire used.
30 CF of gas /lb of wire was quoted by a
Praxair engineer in a published article as being their shop survey findings.
This is supported by a second article
in the Fabricator Magazine. We find it varies from 20 to over 30+ CF/lb
of wire. These
calculations use a conservative 20 CF/lb.
Crunching the Numbers for a
6 lbs/hr wire deposition x 12 hrs/week of arc on time =
72 lbs wire used/week/welder.
20 CF of Shielding Gas used/lb wire = 20 CF X 72 lbs
wire/week = 1440 CF gas/week/welder.
Gas Cost = $5/100 CF or $5 x 1440/100
= $72/week (If using cylinders gas cost is much higher)
Typical Shielding Savings Reported by
our customers varies from 40 to 50+% (note some report a 60% savings)
Using 40% the savings will be
$72/week gas cost X 40% savings with GSS
= $29 Gas Savings/week
GSS needed is 25 feet long. A 25 foot
GSS cost less than $110.
Payback is $110/$29 savings = <4 weeks.
Crunching the Numbers for a
A patented Flow Rate Limiter and Lock
save even more if you find welders have the flow ball pinned to the top of
the flow tube.
The Flow Rate Limiter and Lock sells for
Assume the same 40% savings and
therefore the savings = $29/week
Payback = $50 Cost/$29 Savings/week / =
Neither product has any
wear parts or needs any adjustment. They will delivery cost savings
year after year.
maintain focus on Saving NOT
Selling shielding gases our patented products
are NOT available in "Stores" - - as the saying goes!
You can purchase directly from
our site. We manufacture the product all from US made components like
our custom extruded, very heavy wall hose and CGA brass fittings with
a special peak flow limiting orifice. CLICK on
the picture to go to the GSS
can place orders with a credit card using PayPal or email for other options.
Gas Saver System
Flow Rate Limiter
CLICK Picture for Details of FRL
MIG Shielding Gas Waste?
What Users Say About GSS
What % of Total Welding Cost is Shielding Gas?
It Could Be as High as
The shielding Gas Saver System (GSSTM)
costs about the same or less than a Heavy Duty
standard gas delivery hose (SEE NOTE 1) When your
adding a new welder, the decision to purchase a GSS
is an easy one - - "JUST DO IT" !
If your using any Helium in your gas mixture the "Just Do It"
approach works for any situation! Just replace all you gas
delivery hoses before you get a 80% of last years usage allocation!
It's in short supply and is finite resource it doesn't come from the air!
When replacing an existing 12 foot or 25 foot gas delivery hose with a GSS
the tables below provide an estimate of the weeks it will take to payback the
Installing New Welding Machines? The GSS may be less expensive
than a quality conventional Gas Delivery Hose! See Notes Below for
Retail Price Comparison of fitted GSS
compared with Heavy Duty fitted gas hose from a major welding manufacturer (Brand name and part
numbers available on request), The Heavy Duty hose was selected for comparison
rather than cheap vinyl hose since it at least has fiber reinforced, abrasion
resistant construction like the GSS
hose, even though it provides none of the gas waste or surge reduction
benefits. The GSS
hose also has a better OD to ID size
ratio than conventional hoses providing greater resistance to restriction when
the hose is subjected to crushing, pinching or being stepped on.
* Brand name 12 1/2 foot HD
prefitted hose = $63.10 (no gas saving or weld quality benefits)
12 foot prefitted hose = $65.00 (Slightly higher but payback is
* Brand name 25 foot HD prefitted
hose = $114.30 (no gas saving or weld quality benefits!)
25 foot prefitted hose = < $110.00 (The GSS is less expensive
Do It!" -Want Brand Name, Part Number?
Very Conservative Assumptions
used in calculations:
* Shielding gas savings estimated
at only 25% when all reported results are between 30 to 63%
* Gas usage assumed to be 2 1/2
times theoretical with published data showing a range from 2 1/2
to 5 times is what is used in industry
* Flow rate set for 35 CFH
* One shift operation and 40 hour
* Price of
GSS based on 12 & 25 foot systems as noted; however longer
hoses waste more gas which usually offsets their higher price.
* Short welds and/or the use of
many tack welds will increase waste reduction beyond 25%,
decreasing payback time.
* Reduced time to change cylinders
not included in calculations.
*All weekly payback values rounded
up to higher number.
% Arc Time = amount of time in a
work day welding is actually occurring versus the 8 hour work day -- stated as a
Cost Savings also result from fewer
cylinders being used over a fixed period of time. A recent
article by a manufacturer of shielding gases defined the benefits of using
what is referred to as Microbulk gas distribution. It commented on the extra
cost associated with cylinder use.
One cost benefit defined was less cylinder handling. It mentioned
cylinder handling can result in 20 minutes of extra labor per change-out. It
also mentioned each cylinder often has residual gas left in it, up to 20%.
That is gas paid for and not used.
If the GSS reduces gas usage
by 50% these cost for these items will also be cut in half.
Purchase Gas Saver
Calculations for Flow Rate Limiter
WAT-FRL (Without Lock) &
WAT-FRLL (With Lock)
- Work week = 40 hours for 1 shift
- Welding has 40% duty cycle; i.e. arc is on 40% of the time
- Shielding Gas Flow Desired = 35 ft3/hr
- Without Flow Rate Limiter flow is set 15 ft3/hr higher
than needed or at 50 ft3/hr.
- Shielding gas cost $5.00/100CF = $0.05/ ft3
Gas Waste Calculation:
Waste = (50 ft3/hr - 35
ft3/hr) x 40 hr/week x 40% arc-on-time x $0.05/ ft3 =
$12.00/week gas waste per welder
Payback for WAT-FRL
unit cost / $12.00/week savings = 2.9 weeks Payback
Payback for WAT-FRLL = $47.50
unit cost / $12.00/week savings = 3.9 weeks Payback
|BOTTOM LINE-With Average
Assumptions, Payback is Less Than 1 Month
Purchase Training Aids
Purchase Orifice Flow Control
Flow Rate Limiter
Purchase Wire Feeding Aids