Whether used for welding or food production, keeping track of all the gas cylinders that enter and exit a business’s operations can be difficult. Once gas cylinders are delivered, teams need a reliable system to log and track their activity — if a cylinder rental is lost or returned without a record, that could mean paying an unexpected late fee.

As a result, any company requiring gas cylinders must have a strategy for tracking them. An effective tracking system helps your business improve safety and reduce waste while keeping gases replenished on schedule.

What Is Cylinder Tracking?

Cylinder tracking involves monitoring gas cylinders through their life cycle. Companies use bar codes or Radio Frequency Identification (RFID) technology to track unit location, use and fill status. It’s a highly efficient strategy for maintaining accurate inventory records and adjusting operations as needed to meet demand.

How Cylinder Tracking Works Step by Step

Gas cylinder tracking uses technology to improve inventory management accuracy and regulation compliance. Once you have a system established, you should follow it consistently to make it effective. The tracking process generally involves:

Cylinder tagging: Each unit is assigned an identifier with a barcode or RFID tag. Each step in the tracking process involves scanning this code to keep the cylinder visible.
Scanning: When users return, fill or deliver cylinders, they’re scanned. The database logs the data for record-keeping purposes.
Monitoring: As the cylinder travels through its life cycle, the system may provide real-time monitoring data. Instead of periodic check-ins, real-time tracking constantly reports on cylinder locations and status. This information makes finding and replacing units easier.
Use and maintenance tracking: After being tagged and delivered, the cylinders are scanned to record fill level, gas type and maintenance. Businesses can keep cylinders in good condition and avoid overuse with maintenance tracking.
Reporting: Finally, all the data is automatically sent for report generation. Reports record cylinder use, expiration dates and compliance to keep businesses safe and efficient.

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Technologies for Cylinder Tracking

The two primary methods for tracking cylinders are RFID tags and barcodes.

RFID uses radio waves to transmit data from a tag attached to the cylinder. The data goes to a reader, which records all the relevant information. RFID tagging is quick and contactless. Tags record data automatically, even if cylinders are stacked or in transit. It eliminates manual scanning errors and improves inventory accuracy.

Barcoding is another common tracking method. It’s slower and more labor-intensive than RFID, but it’s also cheaper. Cylinders have a unique barcode on the unit. During transportation and use, the barcode is scanned to provide a record of cylinder movement. Barcoding works well, but it lacks the real-time monitoring RFID tags offer.

For best results, look to solutions that combine barcode and RFID monitoring. With both tools, you can gain a comprehensive overview of cylinder movements and conditions. If one tracking area is skipped, the other technology will close the gap. A combined solution gives you the strengths of both technologies so you can maximize cylinder management efficiency.

Benefits of Effective Cylinder Management and Tracking

A cylinder tracking system is essential for any business working with compressed gas. With advanced tracking tools, your company can improve inventory accuracy and optimize your supply chain. When all cylinders are accounted for and monitored, you can reduce waste costs and increase overall efficiency.

1. Improved Inventory Accuracy

Inconsistent tracking methods can quickly lead to errors and supply challenges. If your business is working off of manual logs, it’s easy to misplace cylinders or experience shortages and overstocking. You need to know cylinder inventory numbers at all times to make the best calls for business demands. An automated tracking system eliminates these issues by making it easier to record and track gas cylinder data.

RFID and barcoding technology can help your business maintain precise inventory records, reducing discrepancies. With barcode or tagging systems, you minimize manual errors. Additionally, leaving manual processes behind means your team can monitor cylinder patterns to optimize cylinder ordering. You can make sure your team has the right gases on hand when needed with cylinder tracking tools.

2. Gas Cylinder Compliance and Safety Protocols

Many industries must follow safety regulations set by OSHA, the Department of Transportation (DOT) and the Environmental Protection Agency (EPA). For example, cylinders used in welding must not be tampered with and should be handled carefully according to OSHA guidelines. Failing to follow relevant regulations can lead to safety violations and fines that put your business at risk. Gas cylinders are no exception to these standards.

Cylinder tracking systems help your operation meet relevant regulations by providing:

Automated records: Digital tracking systems log serial numbers, gas types, expiration dates and other critical information. Businesses can use accurate records to prove compliance during audits.
Maintenance alerts: Regular maintenance and inspections are critical for preventing safety hazards. Tracking systems make it easier for businesses to schedule maintenance. They can also set maintenance reminders, preventing issues before they lead to downtime.
Hazard monitoring: More advanced tracking tools can monitor environmental conditions, like temperature and pressure, to prevent dangerous situations and alert employees before they become hazards.

3. Supply Chain Optimization

Gas cylinder management also influences your supply chain efficiency. Lost cylinders can delay production, increase costs and affect overall productivity. Investing in a reliable tracking system smooths out these bumps so your operation can move along efficiently.

If you’re using an RFID system, your business gets real-time cylinder visibility. Track gas units from the moment they leave the supplier’s facility to arrival at their final destination. Whether you need to improve cylinder return rates or inventory tracking, real-time monitoring can help.

Real-time information and barcode scanning also help optimize delivery routes. Monitor your cylinder usage patterns to make sure you’re scheduling deliveries as needed without overstocking. You’ll cut wasted expenses and ensure everyone gets their gas supply on time.

Part of optimizing your supply chain is reducing waste and expenses. Over-ordering drives up costs while wasting units. In comparison, losing cylinders raises rental fees unnecessarily. Your business can use tracking technology to monitor all your cylinders and avoid wasting resources.

Find a Partner Near You

Optimize Stock Monitoring With Gas Cylinder Tracking From Meritus Gas Partners

You need reliable gas cylinder management to keep your operation safe, compliant and profitable. Meritus Gas Partners offers businesses advanced cylinder tracking solutions. We provide real-time visibility, so you always have the right gases where you need them. Our system integrates barcode and RFID tracking for more accurate inventory and waste reduction.

Choose us for expert support and local services across the country. Meritus Gas Partners combines the capabilities of a national supplier with the personalized service of independent distributors. Our expertise, advanced solutions and commitment to customer support ensure reliable, efficient gas management and supply. Find a Meritus Gas Partner near you to start elevating your tracking capabilities!

Gas has unique properties that make it versatile and practical for many applications, but these same unique properties mean you have to be careful when you work with gas. Improper disposable of gas cylinders poses a significant risk to the health and safety of people, animals, property and the environment. You can take steps to ensure your business discards empty gas cylinders safely.

The Importance of Proper Gas Cylinder Disposal

There are many practical, economic, environmental and ethical reasons to properly dispose of gas cylinders. 

Safety is at the top of the list — for you, the surrounding public and neighboring property. Incorrect disposable methods are hazardous and can lead to explosions or leaks that can be dangerous to people and natural resources or cause severe property damage. Implementing proper disposal methods shows your business practices are ethical and your business is reliable, responsible and conscientious — all of which are excellent for your business’s reputation.

Safe disposal benefits the environment by reducing the impact gas and gas cylinders can have on your surroundings. If not disposed of properly, gas cylinders can end up in landfills, posing a risk to water and soil. Additionally, most cylinders are made from materials that can take years to decompose. Discarding cylinders correctly can also help reduce unnecessary costs. Improper methods may lead to potential liabilities, including fines and penalties.

Understanding Gas Cylinder Markings

Gas cylinders are specialized equipment, so understanding the markings on cylinders is important for safety. Generally, manufacturers will mark gas cylinders with the following information:

Specific color coding to classify and identify different gases and cylinders
Cylinder specifications include information about the cylinder type, material and pressure
Serial number
Date of manufacture
Neck ring identification, which shows the name of the cylinder’s owner
Retest markings to show the retest date if the cylinder qualifies for a 10% overfill and fulfills the requirements for a 10-year retest rather than a five-year retest
Bar code label
Manufacturer’s inspection marking that will show the cylinder has undergone inspection
Tare weight, which is the cylinder’s weight when it is empty

Safety Precautions and Handling Guidelines

It is essential to follow all safety guidelines when handling cylinders regardless of the type of cylinder, gas, application or other factors:

Always wear complete personal protective equipment (PPE) when handling gas cylinders. Ensure anyone who handles gas cylinders in your business has access to and wears the right eye and face, hand, and foot protection.
Know the manufacturer’s instructions for handling, transporting, storing and using the gas cylinder. 
Move gas cylinders by tilting and rolling them on their bottom edges. If using powered equipment to transport them, ensure they are secured vertically. 
Always store cylinders upright and secure them to prevent them from accidentally toppling.
Keep cylinders away from flames, heat sources or reactive materials.
Conduct regular inspections to ensure the gas cylinders aren’t damaged and that all safety measures are secured.
Handle cylinders carefully so they do not drop or hit anything.
Never tamper with a compressed gas cylinder’s pressure valves.
Always lift cylinders carefully and correctly. Do not lift cylinders by their caps or use magnets or makeshift objects to lift cylinders.
Call emergency services if you suspect or detect a gas leak and evacuate the area immediately.
Always dispose of cylinders per local regulations.

How to Know if a Gas Cylinder Is Empty

If you have the correct equipment for lifting and weighing gas, going by the cylinder’s tare weight is the most efficient way of knowing if the cylinder is almost empty.

All cylinders have a disk showing the tare weight, which is the weight of the cylinder when it is entirely empty. You can carefully place the cylinder on a scale and calculate how much gas is left by subtracting the tare weight from the cylinder’s current weight.

 Another method involves pouring warm water down the side of the cylinder:

Use warm water — not boiling water.
Pour some of the warm water down the side of the cylinder and wait a few minutes.
Use your hand to feel down the side of the bottle.
The cylinder will feel cool where there is still gas, or a condensation line may form that indicates the remaining gas level.

Checking for Damage or Leaks

A cylinder with signs of damage or wear can pose a safety risk. You can always contact the manufacturer if your cylinder is defective.

Check for these signs of a defect:

Cracks
Corrosion or rust
Dents
Bulges
Extreme heat while busy with a job
Fire damage during a job

You can also test for acetylene leaks by following these steps:

Get a trusted leak detection spray.
Spray the leak detection spray into the cylinder’s connections and joints.
Ensure regulators are set to zero outlet pressure and all torch valves are closed.
Open the acetylene cylinder valve carefully and slowly to avoid damaging the regulator.
Set the outlet pressure to 50 to 60 kPa.
Open the torch valve for under five seconds and close it again to purge hoses of air.
Apply the spray to all acetylene connections. The spray will foam where there are leaks.
You may correct a leak by tightening the joint or spindle nut.
Shut the acetylene valve, open the torch valve and set the outlet pressure to zero. 
Close the torch valve.

You can also follow this procedure to test for oxygen leaks. If leaks persist, contact the manufacturer for a replacement.

How to Dispose of Gas Canisters

Improperly discarded containers are a safety hazard, as they may explode, and the contents of cylinders can be toxic and contaminate water and soil. The best approach to disposing of your gas containers is to recycle them, which can create a more positive impact on the environment. You can establish a recycling program by contacting your local recycling facility to discuss if they recycle gas cylinders.

If everything is in order, the recycling facility will make arrangements to collect your gas cylinders and then dispose of them. Some facilities are also equipped to recycle gas cylinders with some gas left in them, so be sure to locate a facility that does this if applicable to your needs. If your local recycling facility does not take gas cylinders, you may be able to work with a scrap metal recycling company to achieve the same result.

Hazardous Waste Classification

If your business operates in a state that classifies gas cylinders as hazardous waste, you should consider hiring an environmental consultant. The consultant can help you find recycling facilities that deal in commercial hazardous waste and provide other guidance to ensure you dispose of your cylinders correctly.

It’s important to note that if you’re unsure of what materials are in a gas cylinder, you must treat it as if the cylinder contains the most hazardous gas you work with at your facility. In some cases, you can work with a disposal facility to determine what the cylinder contains.

Preparing Gas Cylinders for Recycling

Facilities may vary slightly in their requirements for preparing gas cylinders for recycling, but you can generally incorporate the following steps into your preparations:

Check the cylinder’s labels or contact your gas supplier to determine if the tanks are recyclable. 
Look into your local laws and regulations regarding the disposal of gas cylinders.
Ensure gas cylinders are empty before recycling. If your chosen facility takes cylinders with some gas left, you can skip this step.
Remove the valve or render it inoperable by the safest means possible. Some facilities will also ask you to cut the cylinder in half before they accept it.

In the case that your gas cylinder is damaged or leaking, you likely won’t be able to recycle it. If you come across this situation, contact the cylinder’s manufacturer to discuss next steps.

Return or Exchange Programs Offered by Gas Suppliers

Gas suppliers often have exchange programs in place. You can always speak to your supplier when purchasing gas and ask about the terms and conditions of their exchange program. These programs allow you to exchange cylinders for a like-for-like replacement.

These programs ensure safety, as they can eliminate the need for you to dispose of empty gas cylinders by yourself. You can often contact your supplier and arrange for them to collect empty cylinders or those you no longer need. The supplier will have procedures in place for reusing and recycling unwanted cylinders.

Gas Cylinder Disposables and Gas Services With Meritus Gas Partners

Following approved methods for compressed gas cylinder disposal should be standard practice in your business for your and your staff’s safety. You can contact your gas supplier or a recycling facility to set up a return or exchange program and integrate the relevant disposal process into your business’s procedures.

At Meritus Gas Partners, our partners are reputable distributors in the industry that you can trust for your gas and welding supplies. Each of our partner businesses provides top-quality gas and welding solutions that streamline your operations with the supplies, equipment, services and support you need. You can count on efficient and reliable service from a partner near you.

Feel free to visit any of our branches or contact us today with any questions.

Mishandling compressed gas cylinders can be extremely disastrous. Compressed gases can cause fires, explosions, oxygen deficient atmospheres, toxic gas exposure and more hazards. To use compressed gas cylinders safely, it’s vital that they are stored and handled properly.

How to store gas cylinders

When storing gas cylinders, follow these safety guidelines:

Storing cylinders upright and securing them with a chain, strap, or cable to a stationary building support or to a proper cylinder cart to prevent them from tipping or falling. Restraints must be fastened on the upper half of the cylinder above the center of gravity.
Ensuring valves are completely closed and securing any protection devices.
Storing cylinders in a dry, well-ventilated area at least 20 feet from combustible materials. Avoid keeping cylinders in lockers. If they leak, a buildup of flammable or other types of gases can occur inside the locker.
Mark the storage area with proper precautionary signs, such as flammable, oxidizer, or toxic.
Placing them in a location where they will not be subject to mechanical or physical damage, heat, or electrical circuits to prevent possible explosion or fire. Do not let indoor temperature exceed 100°F.
Keep cylinders away from vehicle traffic.
Keeping empty cylinders away from full cylinders.
Limit access to storage area to authorized personnel.

How to handle and transport gas cylinders

Did you know that most accidents or injuries involving cylinders occur when moving or handling the gas cylinders? When moving gas cylinders, observe the following safety tips:

Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders to avoid personal injury and cylinder damage.
Do not handle more than one cylinder at a time unless a cart that is designed for such purpose is utilized
Wear protective footwear, safety glasses, and heavy gloves.
Securely install the valve protection devices, such as caps or guards.
Keep cylinder vertical, except for short periods of time while cylinders are being hoisted or carried
Secure cylinders upright to a proper hand truck or cylinder cart designed for the purpose. Don’t drag or roll them – use a properly designed cart or hand truck!
When using a crane, be sure to use proper cradles, nets, boats, or special platforms designed for this purpose to prevent cylinders from falling.
Handle them carefully to avoid dropping or banging them.
Avoid lifting them by the protective cap/guard or using magnets or slings to lift or move them since valves may be damaged or sheared off.

The above cylinder safety guidelines are based on recommendations from the Compressed Gas Association and American Welding Society.  

Contact Atlas Welding Supply

For the safety of your team and business, establishing policies that promote safe cylinder storage and handling is essential. But, when in doubt, contact your gas supplier to send a qualified representative to take care of the problem or refill your cylinders.

With decades of experience in gas and welding applications, we are confident we can be your trusted partner for everything from supplying the appropriate gas, troubleshooting equipment and providing customized solutions that guarantee safety and efficiency.