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Smart Gas Monitoring for Mechanical Engineering & Manufacturing

TSRAI NANOZ MEMS MOX sensors deliver real-time monitoring of process gases, coolant emissions, welding fumes, and VOCs across CNC machining, welding, and metal fabrication — ensuring worker safety, process quality, and regulatory compliance.

12+
Gases Simultaneously
<3s
Response Time
ppb
Detection Level
🔧

CNC Machining

Coolant & Oil Mist Monitoring

⚡

Welding

Fume & Shielding Gas Control

🔩

Metal Fabrication

Process Emissions Detection

🛡️

Worker Safety

Exposure Limit Monitoring

Manufacturing Challenges

Hidden Hazards in Metal Manufacturing

CNC machining, welding, and metal fabrication generate hazardous emissions that impact worker health, product quality, and regulatory compliance

💨
Welding Fumes
Hexavalent chromium, manganese, nickel — known carcinogens in stainless steel welding
🛢️
Oil Mist
Metalworking fluids create aerosols linked to respiratory disease and skin irritation
🧪
VOCs
Volatile organic compounds from coatings, adhesives, and cleaning solvents
⚠️
CO/NOx
Combustion gases from cutting, brazing, and thermal processes
Applications

Where TSRAI NANOZ Transforms Manufacturing

Comprehensive gas monitoring across all mechanical engineering and fabrication processes

🔧

CNC Machining

Turning, Milling, Drilling

Oil Mist Coolant VOCs Formaldehyde Aldehydes
  • Coolant condition monitoring
  • Oil mist concentration tracking
  • Ventilation optimization
  • Worker exposure alerts
⚡

Welding & Joining

MIG, TIG, Arc, Laser Welding

Ozone (O₃) NOx CO Metal Fumes
  • Shielding gas flow verification
  • Fume extraction efficiency
  • Ozone level monitoring
  • Weld quality correlation
🔩

Metal Fabrication

Cutting, Bending, Forming

Cutting Gases Metal Oxides Smoke CO
  • Plasma/oxy-fuel monitoring
  • Smoke extraction validation
  • LEL detection for fuel gases
  • Area air quality mapping
🎨

Surface Treatment

Coating, Painting, Plating

VOCs Isocyanates Solvents HCl/HF
  • Paint booth monitoring
  • Solvent recovery optimization
  • Plating bath emission control
  • LEL safety monitoring
💥

Laser Processing

Cutting, Engraving, Sintering

Metal Vapors CO Polymer VOCs Particulates
  • Assist gas purity verification
  • Fume extraction monitoring
  • Process chamber atmosphere
  • 3D printing off-gas detection
📊

Quality Control

Testing & Inspection

Leak Detection Outgassing Contamination Cleanliness
  • Weld integrity testing
  • Material outgassing analysis
  • Cleanliness verification
  • Process gas quality check
Process Monitoring

Real-Time Process Gas Intelligence

Optimize manufacturing processes through continuous gas composition monitoring

🔧

CNC & Metalworking Fluids

Coolant health & air quality monitoring

🛢️
Oil Mist

Aerosol concentration

🧪
Aldehydes

Coolant degradation

🦠
Biocide VOCs

Bacterial growth indicator

💨
Ammonia

Coolant pH shift

Coolant life extension Dermatitis prevention OSHA compliance
⚡

Welding & Thermal Processing

Shielding gas & fume monitoring

🌐
Ar/CO₂/O₂

Shielding gas mix

⚡
Ozone (O₃)

UV-generated oxidant

🔥
NOx

High-temp combustion

☁️
Metal Fumes

Cr, Mn, Ni oxides

Weld quality optimization Fume hood efficiency TLV monitoring
💥

Laser Cutting & Additive

Chamber atmosphere & emissions

🌬️
N₂/O₂ Purity

Assist gas quality

🔬
Metal Vapors

Condensate detection

🧱
Polymer VOCs

Plastic cutting fumes

🛡️
O₂ Depletion

Inert chamber safety

Cut quality correlation 3D print atmosphere Filter saturation
🎨

Coating & Surface Finishing

VOC emissions & LEL safety

🎨
Total VOC

Paint/coating emissions

⚗️
Isocyanates

2K paint sensitizers

🔥
LEL Solvents

Explosion risk monitoring

🌡️
Curing Off-Gas

Oven emissions

Booth airflow optimization Solvent recovery EPA/TA Luft compliance
Worker Safety

Protecting Workers in Manufacturing Environments

Real-time monitoring against occupational exposure limits (OELs) and threshold limit values (TLVs)

⚠️

Welding Fume Hazards

  • Hexavalent Chromium (Cr VI) — Carcinogen
  • Manganese (Mn) — Neurological damage
  • Nickel (Ni) — Respiratory sensitizer
  • Ozone (O₃) — TIG/MIG byproduct
  • Nitrogen Oxides (NOx) — Lung irritant
🛢️

Metalworking Fluid Risks

  • Oil mist inhalation — Respiratory disease
  • Biocide exposure — Skin sensitization
  • Bacterial endotoxins — Hypersensitivity
  • Formaldehyde release — Carcinogen
  • Amine vapors — Eye/skin irritation
🎨

Coating & Solvent Hazards

  • Isocyanates — Occupational asthma
  • Toluene/Xylene — CNS effects
  • MEK/Acetone — Eye/respiratory irritation
  • Chromate primers — Carcinogen
  • Solvent LEL — Explosion risk
Use Cases

How Manufacturers Benefit from TSRAI NANOZ

Real-world applications across CNC, welding, and metal fabrication

🔧
CNC Machining
Coolant degradation detection before quality issues
⚡
Welding Cells
Fume monitoring & shielding gas verification
🎨
Paint Booths
VOC & LEL monitoring for safety compliance
💥
Laser Cutting
Assist gas purity & fume extraction control
Return on Investment

Proven ROI within 18-24 Months

Measurable savings across sensor costs, energy consumption, and CO₂ emissions

🔬
-15%
Sensor & Maintenance Costs
Fewer sensors needed (1 vs. 6-12)
No calibration gas bottles
Longer sensor lifespan (3+ years)
Reduced maintenance effort
⚡
25-40%
Energy Cost Reduction
Demand-controlled ventilation
Optimized fume extraction
Lower sensor power (<100mW)
Reduced HVAC load
🌍
25-40%
CO₂ Emission Reduction
Direct result of energy savings
Less e-waste (fewer sensors)
ESG reporting data included
Sustainability compliance
Typical Payback Period
18-24
Months

📊 5-Year ROI Calculation

Sensor & Maintenance Savings -15%
Energy Cost Reduction 25-40%
CO₂ Cost Savings (Carbon Tax) 25-40%
Total Combined Savings + Worker Safety & Compliance

Want a customized ROI calculation for your facility? Contact us for a free assessment.

📧 Request ROI Assessment
Technology

Swiss Precision for Industrial Environments

TSRAI NANOZ MEMS MOX sensors engineered for harsh manufacturing conditions

🔬

Multi-Gas Detection

Simultaneously detect 12+ gases including VOCs, toxic gases, and combustibles. AI algorithms separate overlapping signatures in complex industrial atmospheres.

🛡️

Industrial Hardened

IP67 protection against oil mist, coolant spray, and metal particles. Operating range -40°C to +85°C for foundry to cold storage applications.

🧠

AI Cross-Sensitivity Correction

Machine learning compensates for interfering gases in complex mixtures. Accurate readings even with 50+ VOCs from mixed metalworking operations.

📡

Wireless Mesh Networking

Deploy sensors across large facilities without cabling. Real-time data to SCADA, PLC, or cloud dashboard for centralized monitoring.

🎯 TSRAI NANOZ Industrial Specifications

<3s
Response Time (T90)
12+
Simultaneous Gases
ppb
Detection Limit
3+ years
Sensor Lifespan
IP67
Protection Class
-40/+85°C
Operating Range
ATEX
Zone 2 Certified
4-20mA
Analog + Modbus
Technology Comparison

TSRAI NANOZ vs. Traditional Sensor Technologies

See why leading manufacturers are switching from legacy gas detection to AI-powered MEMS MOX technology

Parameter TSRAI NANOZ MEMS MOX Electrochemical (EC) PID Detector Catalytic Bead IR / NDIR
Simultaneous Gases 12+ gases 1-2 gases 1 (Total VOC) 1-2 gases 1-4 gases
Detection Limit ppb level ppm level ppb level % LEL only ppm level
Response Time <3 seconds 30-90 seconds 1-3 seconds 10-30 seconds 10-60 seconds
Sensor Lifespan 3+ years 1-2 years 2-3 years 1-3 years 5+ years
Calibration Frequency AI Self-Learning Monthly Monthly Weekly-Monthly Quarterly
Cross-Sensitivity AI Compensated High (H₂S, CO, etc.) No gas ID Silicone poisoning Water interference
Power Consumption <100 mW 50-200 mW 500-2000 mW 500-1500 mW 200-500 mW
Maintenance Effort Minimal High (monthly cal.) Medium High (poisoning) Low
Calibration Gas Required ❌ No (AI self-learning) ✓ Yes (expensive) ✓ Yes ✓ Yes ✓ Yes
Multi-Gas Capability 1 sensor = 12+ gases Need 6-12 sensors No gas identification Need 6-12 sensors Need 3-6 sensors
💡 Key Advantage: One Sensor Replaces Many
To monitor a typical welding station for CO, NOx, O₃, and metal fumes, traditional systems require 4-6 separate sensors — each with its own calibration schedule and replacement cycle. One TSRAI NANOZ sensor detects all these gases simultaneously with AI-powered pattern recognition. No calibration gases needed. No sensor poisoning from silicone or other contaminants.
Your Benefits

Why Manufacturing Leaders Choose TSRAI NANOZ

Measurable improvements across operations, safety, and sustainability

🔬
12+ Gases
One Sensor
vs. 6-12 traditional sensors
🧠
AI Self-Cal
No Gas Bottles
vs. monthly calibration
⏱️
3+ Years
Sensor Lifespan
vs. 1-2 years (EC sensors)
⚡
<3 sec
Response Time
vs. 30-90 sec (EC sensors)

⚙️ Operational Benefits

  • ✓ Fewer sensors to install & maintain
  • ✓ No calibration gas bottles needed
  • ✓ No sensor poisoning from silicones
  • ✓ Longer replacement intervals
  • ✓ Less downtime for maintenance
  • ✓ Real-time data for process optimization

🛡️ Safety Benefits

  • ✓ Faster detection = earlier warnings
  • ✓ Multiple hazards with one device
  • ✓ Continuous TLV/OEL monitoring
  • ✓ Personal exposure documentation
  • ✓ Zone-based air quality mapping
  • ✓ Compliance reporting built-in

🌍 Sustainability Benefits

  • ✓ Lower power consumption (<100mW)
  • ✓ Fewer sensors = less e-waste
  • ✓ Demand-controlled ventilation possible
  • ✓ Optimized extraction = energy savings
  • ✓ ESG data automatically collected
  • ✓ Reduced VOC emissions monitoring

📊 Want to Know Your Specific Savings?

Every manufacturing environment is different. Contact us for a free assessment of your current gas monitoring setup and a customized ROI calculation for your facility.

📧 Request Free Assessment