Gas Filling Machines - Home - Profill

PGS-Profill Gas Station is a highly secure and portable unit that can be set up in any secure yard, enabling you to start filling LPG cylinders almost immediately.

If you are looking for more details, kindly visit gas refilling machine.

To begin, you need at least one 48Kg LPG supply cylinder and a 220 Volt 10amp electricity supply via a cable with an earth wire.

We provide the PGS with one or two filling machines, either the certified-for-trade Econo 60 MP with a mechanical scale or the Econo 60 EP with an electronic scale. The PGS offers secure lockable storage space for 8 x 48Kg LPG cylinders and some shelter from wind and rain for the operator during the filling process.

This is the quickest method to get an LPG cylinder filling business operational. The filling machines are certified for use in Ex Zone 1.

**Check with your local authority/fire department for approval.

Two Approaches

LPG gas cylinders can be refilled in two ways:

Decanting: In service stations, LPG cylinders are often refilled by transferring gas from the source container until it vents excess gas. This venting occurs because a small vent screw allows excess gas to escape, preventing overfilling.

By Weight: In this method, LPG cylinders are placed on a scale, and the operator inputs the tare weight. The electronic filling scale then transfers gas into the cylinder and shuts off as soon as it reaches the desired full weight.

Gas bottles and cylinders are typically made of welded steel, aluminum, and composites. Their robust nature and high-pressure capacity make them refillable and reliable for various applications.

ELGAS LPG cylinders come in portable sizes ranging from 3.7kg to large industrial sizes, such as 210kg and more. All these sizes are refillable, but gas refilling should only be conducted by professionals, as untrained attempts can lead to severe incidents due to improper filling methods.

Refill by Weight

In several ELGAS service locations, LPG cylinders are refilled using an electronic filling scale. These scales have a filling hose connected to a solenoid valve, which closes when the LPG reaches the desired weight.

Pros:

Accuracy: Filling by weight is more precise since the LPG's gross weight is continuously measured electronically. This helps prevent underfilling and overfilling of cylinders.

Safety: A properly calibrated and maintained scale ensures operations are within safety standards.

Compliance: Electronic scales have higher accuracy and precision compared to decanting. They meet most regulatory standards as they provide a clear and standardized way to perform gas bottle refills.

Efficiency: Automating the filling process speeds up the refilling process, eliminates human error, and maximizes efficiency.

Cons:

Cost: Using electronic scales and automatic filling systems require service stations to invest in expensive equipment. Maintenance of this equipment can also add to the overall expenses.

Technical Requirements: Operating an electronic filling scale demands thorough training and skilled personnel for operation, routine maintenance, and annual calibration.

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Infrastructure: Refilling a gas bottle by weight should only be performed in a controlled environment because fluctuations in temperature and pressure can affect the scale's accuracy.

Refill by Decanting

When refilling a gas bottle by decanting, the service station transfers gas from a larger supply tank into smaller consumer gas bottles. Decanting relies on the pressure difference between the supply tank and the empty cylinder to transfer the gas.

Pros:

Simplicity: Decanting uses less equipment compared to filling by weight and is relatively straightforward. It also requires less automation, as human operators manually close the valves.

Lower Initial Investment: Since decanting requires fewer pieces of equipment, service stations can start filling empty tanks with less capital investment and achieve quicker turnarounds.

Flexibility: Decanting can be performed in various locations, including remote areas.

Cons:

Less Accurate: Decanting heavily relies on visual indicators to close the valve, particularly the venting of excess gas via the vent screw. As a result, the gas quantity transferred can vary significantly, leading to underfills or overfills.

Safety Risks: Overfilling beyond the required ullage (20% of the volume) increases pressure inside the gas bottles. Exposure to direct heat or higher ambient temperatures can further increase internal pressure, raising the potential for leaks.

Skill Requirement: Decanting requires operators to have adequate training and certifications to refill and handle gas bottles safely. The lack of automation means higher expertise is needed and increased reliance on operator skills.

Environmental Factors: Ambient pressure and temperature slightly influence gas behavior during transfer, complicating the operation and affecting accuracy.

See VIDEO (Disclaimer: This video on how to Fill a Gas Cylinder is only a supplement and refresher for trained individuals and professionals. Untrained individuals must not attempt LPG decanting.)

No matter which LPG gas cylinder refill method is used, the cylinder must have a current inspection date. The refill technician must check the inspection date stamped into the gas cylinder's neck ring before refilling it.

Out-of-date gas cylinders cannot be refilled until re-inspected and stamped with a new inspection date.

Using digital scales ensures the proper and safe refill of LPG gas cylinders based on weight. When the total weight equals the empty weight plus the appropriate refill weight, the gas cylinder refill is complete.

Scales are set for each individual refill based on its empty (tare) weight and the full desired weight.

The cylinder manufacturer stamps the tare weight (empty weight) into the neck ring. The operator inputs this tare weight into the scale's keypad. After inputting the weight, the technician connects it to the LPG supply to fill the gas cylinder. The digital scale automatically stops the refill once the target weight is reached, ensuring an accurate refill and preventing dangerous overfilling or underfilling.

A side benefit of using scales for gas cylinder refills is speed. The LPG supply line can be pump-driven to fill a gas cylinder more quickly. This isn't possible with decanting, as the operator might be too slow to stop the refill process, leading to overfilling.

Digital scales and pump-driven LPG also allow for the use of high-speed carousels, like the SWAP'n'GO carousel, to fill gas cylinders.

In fully automated plants with gas cylinder refill carousels, even the keypad step can be automated. The carousel digitally reads an RFID chip on the cylinder containing the tare weight and other manufacturing specifications.