How to Select the Right Nitrogen Generator for Your Industry

Choosing the right nitrogen generator is one of the most important decisions you’ll make when upgrading your facility’s gas supply. Whether you’re in food packaging, electronics manufacturing, pharmaceuticals, plastics, metal fabrication, or any other nitrogen-dependent industry, picking the correct system can improve product quality, reduce operational costs, and eliminate the headaches of cylinder deliveries.

But with multiple technologies, purity requirements, flow rates, and pressures to consider, how do you know which nitrogen generator is right for your industry?

Below is a clear, practical guide to evaluating your needs—and selecting a nitrogen generator designed to support your production, efficiency, and long-term growth.

1. Start by Identifying Your Nitrogen Requirements

Before choosing a N2 generator, you need to understand exactly how your operation uses nitrogen. This includes three core factors:

✔ Purity

Different industries require different nitrogen purity levels.

• Food packaging (MAP): 95–99%
• Laser cutting: 99.995%+
• Electronics & semiconductor manufacturing: 99.99%+
• Pharmaceutical production: 99–99.9%
• Chemical processing: varies widely based on application

Knowing the minimum purity ensures the generator you choose can maintain your standards consistently.

✔ Flow Rate (SCFH or Nm³/hr)

Calculate your total nitrogen consumption per hour or per shift.

Think about:

• Peak demand periods
• Multiple machines using nitrogen simultaneously
• Future expansion plans

A generator that meets today’s needs and tomorrow’s growth delivers long-term value.

✔ Pressure Requirements

Some processes—like laser cutting or high-pressure blanketing—require significantly higher PSI. Selecting a system with integrated compressors or booster options ensures smooth operation without bottlenecks.

2. Understand the Two Main Nitrogen Generator Technologies

Most on-site nitrogen generation relies on one of two proven technologies. Choosing the right one depends on your industry’s purity and flow requirements.

Pressure Swing Adsorption (PSA) Nitrogen Generators

Best for high-purity applications. PSA systems use carbon molecular sieve (CMS) media to separate oxygen from nitrogen, delivering purity levels up to 99.9995%.

Ideal for industries such as:

• Electronics manufacturing
• Pharmaceuticals
• Laser cutting
• Food processing requiring ultra-high purity

Benefits:

• Extremely high purity
• Reliable, continuous production
• Long media life

Membrane Nitrogen Generators

Best for medium-purity, high-flow applications. Membrane systems push compressed air through specialized fibers that separate nitrogen molecules from oxygen and moisture.

Ideal for industries such as:

• Food packaging (MAP)
• Fire prevention systems
• Chemical processing
• Oil & gas
• Tire inflation

Benefits:

• Compact and energy-efficient
• High flow rates
• Minimal maintenance
• Fast startup times

3. Match Your Industry to the Right System

Different industries demand distinct nitrogen specs. Here’s how to align your selection:

Food & Beverage Production

• Key priorities: purity, reliability, low oxygen levels.
• Best fit: PSA for high-purity MAP applications, or membrane for moderate purity needs.

Electronics & Semiconductor Manufacturing

• Key priorities: extremely high purity (99.99–99.999%).
• Best fit: PSA nitrogen generation. PSA systems prevent oxidation and protect moisture-sensitive components.

Laser Cutting

• Key priorities: very high purity & high pressure.
• Best fit: PSA nitrogen generators with booster options. Purity > 99.995% is typically required to achieve clean, oxide-free edges.

Metal Fabrication & Heat Treating

• Key priorities: consistent purity to prevent oxidation.
• Best fit: PSA for high purity or membrane for moderate purity.

Pharmaceutical & Lab Environments

• Key priorities: purity, sterility, clean operation.
• Best fit: PSA nitrogen generators. PSA systems meet strict quality and compliance standards.

Oil & Gas / Chemical Processing

• Key priorities: safety, inerting, blanketing.
• Best fit: membrane nitrogen generators for high flow and efficiency.

4. Consider Total Cost of Ownership (Not Just Upfront Price)

The cheapest generator isn’t always the best investment. Evaluate long-term savings:

• Electricity usage
• Maintenance schedules
• Media replacement cycles
• Downtime risks
• Cylinder delivery elimination
• ROI over time (often 6–24 months)

On-site nitrogen generation often reduces nitrogen costs by up to 80%, making lifetime operating cost a key advantage.

5. Choose a Manufacturer with Proven Industry Experience

When selecting a nitrogen generator, the partner behind the system is just as important as the technology itself.

With On Site Gas Systems, you get:

• 40+ years of engineering excellence
• Custom-built systems for every industry
• U.S.-manufactured, military-validated equipment
• Expert installation and ongoing support
• Systems designed for longevity and reliability

A generator isn’t a one-size-fits-all purchase—your industry deserves a system built around your specific application, purity, and output needs.

6. Plan for Scalability

Your production may grow, and your nitrogen system should grow with it.

Look for features such as:

• Modular expansion
• Multi-bank PSA configurations
• Ability to add compressors or boosters
• Remote monitoring and diagnostics

Scalable designs help you avoid replacing entire systems down the line.

7. Schedule a Professional Sizing Consultation

Even with clear guidelines, the best way to select the right nitrogen generator is to work with an expert who can analyze:

• Current nitrogen consumption
• Application purity requirements
• Facility environment
• Equipment load
• Budget
• Long-term goals

On Site Gas Systems engineers will review your specs in detail and design a system tailored specifically to your operational needs.

Need Help? Contact On Site Gas Today!

Selecting the right nitrogen generator can transform your facility—reducing costs, boosting efficiency, and giving you complete control of your nitrogen supply. By understanding your purity, flow, and pressure needs—and choosing the right technology for your industry—you ensure long-term performance and reliability.

If you’re ready to explore the best nitrogen generator for your application, our engineering team is here to help. Contact On Site Gas Systems today for a customized quote and expert guidance.