“MCA” is engaged in the project design, manufacturing, and installation of turnkey plants for the production of all types and sizes of steel LPG / Propane / Refrigerant cylinder & Autogas tank & LPG / Propane cylinder valve according to all relevant international standards, particularly EN, DOT, BS, KS.
The blanks are cut by the hydraulic press & blanking toolset or by the rotary shear from the steel coil to the required dimensions automatically. The blanks are loaded manually / automatically to a specific hydraulic deep drawing press to be formed as upper and lower halves of LPG cylinders & Autogas tanks.
Then deep-drawn parts are trimmed and joggled on trimming and joggling machine before welding to have matching upper and lower pieces when assembled together.
Various types and sizes of guard rings and foot rings can be produced in a flexible production line. The line consists of decoiler – straightener – feeder, blanking & forming & stamping presses and related toolsets, round bending machines, serial number punching unit, MIG/MAG welding machines which are designed and produced by “MCA”.
The guard rings and foot rings are welded onto upper and lower cylinder halves by automatic MIG/MAG welding machines. The valve boss (neck ring) is welded onto the upper cylinder half and then the upper and lower halves are welded together by automatic SAW circumferential welding machines. For three pieces LPG cylinders are welded by specific automatic SAW longitudinal and circumferential welding machines. All welding machines are equipped with well-known welding rectifiers to achieve uncompromising welding quality.
Since the welding requirements and process steps of forklift cylinder and refrigerant gas cylinders with multiple bungs are special, it is necessary to use appropriate welding processes and welding equipment. Bungs and pipe pre-welding processes are completed with specially designed welding apparatus. Afterwards, bungs are welded onto the tube halves with highly skilled robotic MIG/MAG welding solutions. Once the robotic bung welding process is completed, the body and attachment welds are automatically performed by using special welding apparatus, respectively, and welding processes are completed.
All welded LPG cylinders and Autogas tanks will be heat treated for normalizing after the deep drawing and welding process. The cylinders pass through the high-tech oven from entry to exit side on the conveying system for the proper heat treatment process with preheating, heating and cooling steps. All cylinders are heated up to 930 ⁰ C and are kept that temperature for a curtain time.
All cylinders which are cooled gradually after heat treatment process will be hydrostatically tested under 34 bars to visual check of the forming and welding defects. If requested, full automatic in-line hydrostatic test unit can be used for reducing handling and increasing productivity.
All LPG cylinders and Autogas tanks will be shot blasted to remove all rust after heat treatment and to prepare a surface for metallization and painting. After that, all LPG cylinders conveyed on the overhead conveyor are zinc coated by automatic arc spray metallization guns & painted automatically by electrostatic powder painting method by the spray guns and cured in the tunnel type modern paint curing oven. If requested, the second color wet painting can be applied on the same line.
By using high-tech manipulators which are developed and produced by “MCA”, cylinders can be loaded & unloaded to shot blasting machine and painting line overhead, conveyor automatically.
The tare weighing and ink-jet printing, valve thread cleaning & valve screwing air leakage testing, and vacuuming processes are performed in in-line finishing and air leakage testing line automatically.
Single color logos and labels are printed by serigraphy machine and multi-color logos are printed by tampography machine automatically.
To preserve and maintain product quality according to related international standards in LPG cylinder and Autogas tank production, “MCA” provides reliable quality control equipment and laboratory systems.
