The human eye is incredible in many ways, but also prone to distractions, tiredness, or overwhelm. That’s why, on many filling plants and other LPG sites, the human eye is being replaced or assisted by automatic vision systems that offer lower error rates and greater efficiency.  

Reading and inputting of tare value (the cylinder’s empty weight, usually stamped on the cylinder) is one of the most obvious functions to automate, and there are now many such solutions on the market, including MAKEEN Energy’s automatic vision systems.

But we also see new technologies that use QR codes to enable full data storage and tracking of individual cylinders – not just their tare weight, but also their physical condition. In the EU, QR-coded cylinders are becoming increasingly standard, encouraged by laws promoting product traceability and transparency.  In the US, QR codes are being used to identify cylinders that are due for recertification, before they start the filling process. Using QR codes to identify the individual cylinder also provides the LPG marketing company with a channel to communicate safety instructions and commercial information to the end-consumer.  

Cylinders are not the only objects caught by the new electronic eyes. There are emerging camera technologies that can automatically check whether staff members working in a hazardous zone are wearing the correct PPE, heightening safety awareness on potentially dangerous sites.

Automatic leak detection is standard in many filling plants, but most technology so far has only focused on leak detection around the valve of the cylinder. Now there is a growing awareness of the potential for leaks in the cylinder body. Traditionally, checking for cylinder body leakage is done by immersing the cylinders in water and having an operator look for bubbles – a relatively slow and inconsistent method. New technologies, like the MAKEEN Body Leak Detector, offer a reliable and highly efficient alternative. 

When a cylinder arrives at the filling machine, and the filling head automatically attaches to the valve, there is always a small risk that the head does not connect perfectly. This can be due to poor cylinder conditions, faulty or missing valve gaskets, etc. In those few cases, the release of LPG can be considerable as the liquid LPG that is supposed to be filled into the cylinder will evaporate and expand violently. 

When that happens, an operator has to approach the affected machine and manually stop the filling process. This creates a potentially dangerous situation, as even a small build-up of static electricity in the operator’s body/clothing can cause a spark that ignites the leaking gas. In addition, it requires an operator to be present for no other purpose than this, thus affecting the OPEX for the equipment negatively.

MAKEEN Energy recently released a solution to this problem by installing pressure sensors in LPG filling heads, allowing the machine to automatically register the pressure increase caused by a bad connection and cut off the flow of gas before it becomes a hazard. The sensor system can be integrated into new filling machines, and it can also be retrofitted to existing Kosan Crisplant, Siraga, or MAKEEN Energy heads. In this case, automation is a safety measure, not just an efficiency booster.

Often, this is due to a lack of standardisation in cylinder sizes and types, which means that an LPG filling plant might have cylinders of varying dimensions coming through in a single batch, making it impossible to fit them on the same pallet. In other cases, the trucks themselves are too different to make palletisation a possibility, or the CAPEX involved in the introduction of a cylinder palletiser is simply not affordable by the operator. In these markets, it’s typical to use telescopic conveyors that extend into the bed of a truck, where a person manually loads the cylinders.

But manual loading comes with its downsides. Aside from inefficiency, it also places a strain on the body of the person who has to lift hundreds of heavy cylinders per day.

The industry has been crying out for solutions that can alleviate the physical strain on personnel for years, and now we see emerging solutions that can meet the need. One such solution may be to use robotic truck loaders, although these still require a certain degree of standardization in truck sizes.