When you last snacked on some almonds, you may not have given much thought to how they were harvested and made ready for your consumption. However, like almost all food and beverages, on their journey to your snack bowl they encountered some stainless steel bearing equipment.

Australia is a dominant producer of almonds, with the Murray Darling region accounting for almost a third of production. Kooba, located a few kilometres south of Griffith in south-central New South Wales and off the Murrumbidgee River, is the site of a large almond orchard having received significant recent investment.

Irrigation is critical to growing almonds, and water usage can reach up to 14ML per hectare. ASSDA Member Custom Built Stainless, through their sister company and installer Irribiz, was commissioned to fabricate a range of dam water delivery systems for the efficient growth of these almonds. The scope of works included on-site valve banks, pump stations and fertigation (a process of delivering dissolved fertiliser through irrigation supply) systems, with stainless steel featuring heavily as a material of construction.

ICI Industries’ (parent company of Custom Built Stainless and Irribiz) Engineering Manager Vernon Green said, “A key element of supporting the business case for using stainless steel versus PVC and Poly Ethelene was the long-term value, with other factors taken into consideration including the aesthetic appearance and environmental sustainability”.

Around 7 tonnes of grade 304 and 316 stainless steel pipe in sizes ranging from 50mm to 600mm diameter was supplied by fellow ASSDA Member A&G Engineering. Welding was completed in accordance with AWS D18.1: Specification for Welding of Austenitic Stainless Steel Tube and Pipe Systems in Sanitary (Hygienic) Applications and AS 4041: Pressure Piping. Walkways were also manufactured from grade 316, with all stainless components pickled and passivated prior to installation. 

As the world continues to work through severe drought conditions and water supply issues, projects being designed to be as efficient as possible in water use will continue to rely on the longevity, durability and life-cycle benefits of stainless steel.

 

This article is featured in Australian Stainless Magazine Issue 76 (2022).

Stainless steel has delivered the lifeblood for the evolving brewery operation  of one of Australia’s largest independent beer businesses.

Brick Lane was founded by 25 shareholders in 2017 with the vision to grow a sustainable, more inclusive, independent brewery focused on quality, flexibility, and sustainability. Delivering its own craft beer, ciders, seltzers and other drinks, Brick Lane extends its facilities to the wider brewing community, offering its brewing and packaging services to like-minded partners to encourage and support the growth of independent and craft beer in Australia.

Critical to Brick Lane’s success was the design and construction of a state-of-the-art brewery, combining global-leading technology with local stainless steel technical expertise and fabrication. Located in Victoria’s Dandenong South on a 5,000sqm site, Brick Lane partnered with German-based brewery equipment supplier BrauKon to deliver the original 50hL 4 vessel brewhouse in 2018, which was later expanded in  2020 with an additional 110hL 4 vessel brewhouse.

ASSDA Member and Accredited Fabricator Total Piping and Mechanical (TPM) was engaged both locally and by BrauKon to deliver the equipment installation and assembly, and process and service piping. TPM used 316L grade stainless steel to AS 1528 (Stainless steel tube and tube fittings for food processing and hygienic applications) pipe and fittings for the process pipework lines, and 304 grade AS 1528 stainless steel for the service pipework lines.

With most of the equipment supplied from Europe, the connections were delivered in DIN sizes, presenting some challenges in transitioning from DIN to locally sourced AS 1528 sized tube. TPM addressed this by supplying custom-made transition pieces.

TPM’s highly skilled team of welders performed all the hand welding of process pipework to AS/NZS 3992:2020 (Pressure equipment – Welding and brazing qualification), AS 4041:2006 (Pressure piping) and ASME Section IX (Boiler and pressure vessel code: Welding and brazing qualifications). TPM also deployed one of its specialised orbital welding machines on site which completed more than 2,500 welds alone. 

In addition, TPM completed the high-pressure steam installation, all of which were weld mapped, NDT and hydrostatically tested in accordance with AS 4041:2006. 

Brick Lane’s Head Brewer Jon Seltin said TPM’s quality in the pipe fittings and welding was exemplary. ‘Their approach to hand-selecting their labour force ensured workers with validated welding skills, experience, attention to detail, efficiency, and quality. In periods of high pressure and tight deadlines, TPM’s management and staff always remained courteous, positive, and practical, contributing to a great on-site culture.’

Brick Lane was the first Australian brewery to adopt thermal load wort boiling and crossflow filtration technology, reducing its energy and water usage, improving beer output quality and eliminating the need to use non-renewable filtration aids. With sustainability and efficiency at the forefront of its design, the brewery also houses a vapour condenser, which reclaims energy from steam produced during the brewing process.

2021 Major Cellar Expansion

A multi-million-dollar investment in equipment to expand the brewery saw the construction of a major cold-block rolled out in 2021, increasing the operation’s annual production capacity to approximately 20 million litres. The expansion saw Brick Lane further adopt world-leading technologies in yeast propagation, fermentation management, automated liquids handling, centrifugation, high-gravity brewing, thermal storage/energy recovery and keg packaging.

ASSDA Member and Accredited Fabricator Furphy Engineering was engaged to design, fabricate, test, and deliver thirteen stainless steel tanks, including ten 400hL beer fermenters, two 450hL bright beer tanks, one 610hL hot water tank, plus an upper-level stainless steel access platform system. 

Approximately 100 tonnes of stainless steel was used for the project, including grade 304 for the fermenters, bright beer tanks and access platforms, and grade 316 for the hot water tank. The material used was a mix of stainless steel sheet and plate from 2mm to 10mm, 250NB Sch40 and 300NB Sch40 pipe, and various sizes of AS 1528 tube. Stainless steel materials were supplied by ASSDA Members Atlas Steels and Vulcan.

The fermenters and bright beer tank were designed and constructed to AS 1210:2010 (Pressure vessels). The fabrication of the fermenters, bright beer tanks and hot water tank was undertaken using a plasma arc welding (PAW) process. PAW produces excellent weld quality with the introduction of minimal heat and with no removal of parent material required for weld preparation. This system was pioneered in Australia by Furphy Engineering in 2006, and today they operate five PAW machines for tank and vessel welding.

The cooling jackets on the fermenters and bright beer tanks employ Furphy Engineering’s Dimple-Q, a laser-welded dimple plate that delivers efficient temperature control and achieves brew cooling from the exterior. Dimple-Q is the only Australian made laser-welded dimple plate and is manufactured in-house by Furphy Engineering in Shepparton.

Jon Seltin said Furphy Engineering was an excellent local partner for the major cellar expansion, with the team proactively involved throughout the project cycle while seamlessly collaborating with other project vendors. ‘The quality of the supplied tanks was excellent and their on-time delivery during difficult COVID restrictions was critical for the overall success of the project. Their reliability coupled with their flexibility, quality design and fabrication capability are no doubt why they enjoy such a good reputation in their industry.’

TPM’s team of welders was brought back on-site to perform the mechanical installation of the Furphy Engineering supplied tanks. From the time of the original build through to the completion of the third cellar expansion, TPM has delivered more than 5,000 welds and installed over  5,000m of stainless steel tube.

Brick Lane continues to have its eyes set on the future, with its site well-positioned to grow with the Australian craft beer market while setting the benchmark for sustainability and efficiency in brewing.

This article is featured in Australian Stainless Magazine issue 75, 2022. 

Australia is in a craft beer renaissance. The materials used in beer production has evolved over the years, and today, stainless steel is the material of choice and industry standard in modern brewing. Let’s look at some of the benefits...

Corrosion resistant

Stainless steels are excellent combatants of corrosion. This resistance to attack is due to the naturally occurring chromium-rich oxide film formed on the surface of the steel, which self-repairs in the presence of oxygen.

With the correct selection of alloys and application of good design principles and proper fabrication practices, stainless steel equipment will perform successfully. 300-series stainless steels are commonly specified in brewing equipment, and passivation is a chemical surface treatment that is often performed to enhance the steel’s corrosion resistance. The process removes contaminants and promotes the formation of the steel’s passive film.

Better taste

Beer ranges broadly in acidity and has live micro-organisms which can cause biofouling and biocorrosion in the tanks and fluid lines used in the brewing process. This can deliver a metallic taste in beer, even with tiny iron concentrations. Stainless steels’ corrosion resistance offers the best insurance against any unusual and unwanted flavours.

Easy to clean and maintain

Compared with other materials, stainless steel is a hygienic, low maintenance product that’s easy to clean and sanitise. Chemical cleaning is an effective method for maintaining stainless steel brewing equipment. Typically, both an alkaline wash (often sodium hydroxide based) is used to remove organic materials. It is followed by an acidic treatment with phosphoric acid (with a dash of oxidising nitric acid) or, increasingly in hard water areas, a peracetic acid formulation for mineral scale removal. Beerstone removal may require warm solutions.

It’s important to never use bleach on stainless steel! It can cause staining, pitting corrosion and permanently damage the steel’s surface and protective layer.

Durable and sustainable

Stainless steel delivers structural strength and integrity, and with a proper maintenance regime, stainless steel brewing equipment can deliver a lifetime of use. In addition, stainless steel is 100% recyclable and is actively repurposed without any significant loss of material quality.

Sleek good looks

Today, many breweries are opening their venues as a vibrant place to eat, drink and socialise. Its popularity has gained momentum in the Australian market with stainless steel brewery equipment and processes showcased as part of the patron experience, delivering style, substance, and aesthetics.

This article is featured in Australian Stainless Magazine issue 75, 2022. 

Water quality plays a crucial role in the decontamination and reprocessing of reusable medical devices, and stainless steel has helped facilitate the standard required for their sterilisation. 

The release of AS/NZS 4187:2014 Reprocessing of reusable medical devices in health service organisations requires hospitals across Australia to comply with a range of stringent new requirements consistent with European and global standards for sterilisation processes. Its aim is to ensure reusable medical devices are adequately cleaned, disinfected and sterilised to protect patients and prevent infection.

Water quality is critical for sterile processing, and one requirement of the revised standard includes the replacement of non-compliant cleaning, disinfecting and sterilising equipment. There are minimum water quality requirements for pre-cleaning, cleaning and the rinse(s) prior to final rinsing. These include water hardness no greater than 150 mg/L and chloride no greater than 120 mg/L. AS/NZS 4187:2014 also specifies water quality requirements for the final rinse stages of sterile processing across Tables 7.2, 7.3 and 7.4, including final rinse water for manual cleaning and washer-disinfectors, and feed water for a dedicated steam generator.

Despite the Australian water quality guidelines, water supplies are variable in chemical impurities and the microbiological purity may also be a challenge. Therefore, water used for the final rinse of the disinfection process and the generation of steam for sterilisation must undergo treatment to achieve the water quality requirements. Reverse osmosis technology delivers a solution to meet the physical, chemical and microbial water quality required for the final rinse.

Reverse osmosis (RO) is a water treatment process that uses a semi-permeable membrane and applied pressure as the final step to filter out ions, unwanted molecules and large particles. The process is effective for the removal of micro-organisms and both organic and inorganic chemical components. ASSDA Member and Accredited Fabricator J&T Mechanical Installation have delivered stainless steel bioprocessing equipment for over 25 hospitals across Queensland, New South Wales and Victoria to meet the new specification and requirements of AS/NZS 4187:2014. The ongoing work includes the fabrication and installation of new equipment and replacement of non-compliant ring mains, water distribution networks and RO water treatment systems.

The RO water treatment systems must accommodate the required regular thermal disinfection to mitigate bacterial endotoxins and deliver a high level of microbial water quality. The treated water is reticulated to central sterile services departments (CSSDs) where surgical instruments and other reusable medical devices are sterilised. Continuous bacteria control is critical to supplying the required microbial water quality and the use of ultraviolet (UV) light in the ring mains to treat return water delivers compliance with AS/NZS 4187:2014. UV sterilisation is 99.99% effective in killing microbiological substances, and  is a safe, chemical-free process.

Stainless steel is the standard material of construction in water treatment applications, offering hygienic properties, durability, and optimum long-term performance. With excellent corrosion resistance and hydraulic conductivity characteristics, stainless steel is the first-choice material for best overall water system design.  

In addition, plastic materials are not viable in high water purity applications due to potential leaching, and copper may also be an issue because of cupro-solvency in soft water. 

Grade 316 stainless steel material has been specified for works as per the standard, including the use of 51mm tube, 20mm three-piece ball valves,  and 45^o and 90^o bends as specified in AS 1528 and supplied by ASSDA Member Atlas Steels.

J&T Mechanical Installation’s expertise has ensured the highest quality of work continues to be delivered to meet the current and future requirements of water supply systems complying with AS/NZS 4187:2014. Orbital welding is used on site during installation, with bioprocessing equipment requiring high quality welds to ensure water supply remains free of bacteria, rust and other contaminants. Orbital welding ensures full penetration welds with no overheating occurring that could undermine the corrosion resistance of the final weld zone.

The J&T team also performs hydrostatic testing and weld traceability to confirm mechanical integrity, as part of AS/NZS 4187:2014’s requirement for all equipment to undergo installation qualification (IQ), operational qualification (OQ) and performance qualification (PQ) tests.

As the roll out of AS/NZS 4187:2014 continues across Australia, hospitals and other health organisations are required to have a documented plan for implementation in place by December 2021, with the deadline for full compliance by December 2022.  Critical hospital infrastructure demands long-term compliance, structural integrity and quality fabrication, all of which are being delivered using stainless steel and superior workmanship by J&T Mechanical Installation.

  

Photo credits: J & T Mechanical Installation

This article is featured in Australian Stainless Magazine issue 73, 2021. 

Stainless steel continues to be the material of choice for commercial kitchen equipment, meeting and exceeding the rigorous demands of busy food service operations.

Dubbed as the ‘Home of Sport in Western Sydney’, Bankwest Stadium opened in April 2019 in the heart of Parramatta. The 30,000-capacity, multi-purpose rectangular stadium features a steep tiered seating arrangement across five levels, offering the best viewing quality of live events. Sport matches including rugby league, rugby union and soccer are some of the arena’s main events. To complement the unparalleled live event experience, the stadium’s clever design ensures spectators are never more than 30 metres away from onsite food outlets and amenities. 

The stadium features 16 food and beverage outlets, 11 kitchens and five bars. ASSDA Member and Accredited Fabricator Stoddart delivered a bespoke solution for the 32 food and beverage areas with the fabrication, supply and installation of an extensive range of stainless steel commercial kitchen and food service equipment.

The major kitchen fit outs by Stoddart included the supply of Halton ventilation exhaust hoods manufactured under license at their Karawatha site in Brisbane. Food service equipment supplied included commercial combi-steamer ovens, Adande refrigerated drawer systems and Anets deep fryers, brands exclusively imported and distributed by Stoddart in Australia.

Stoddart’s own Culinaire range of commercial kitchen equipment was custom fabricated, manufactured, supplied and installed. This included vertical and standard hot cupboards, bain-maries, hot food slides and cold food displays. In addition, wash basins, work benches, counters, shelves, wall sheeting and spine walls were also manufactured and supplied.

TIG welding techniques were used across the different goods and services provided. As an ASSDA Accredited Fabricator, Stoddart’s strong expertise in stainless steel design and fabrication ensured the strict requirements of food equipment manufacture were met. Correct surface finish, avoiding cross-contamination of materials, and hygiene and cleanability of stainless steel food equipment are some important considerations in delivering quality products expected to perform in busy food operations.

Overall, a significant amount of 304 grade stainless steel was used for the project, including 8,500m2 of coil, 3,987 linear metres of tube, 158 flat sheets (1.2mm thick, 914mm and 1219mm wide sheets in various lengths) and perforated sheets (1.2mm thick, 500mm wide in various lengths). Stainless steel coil and tube was supplied by ASSDA Member Dalsteel Metals, while the stainless steel sheet was supplied by ASSDA Member Midway Metals.

Stainless steel is a versatile and attractive material offering corrosion and heat resistant properties. It has  a non-porous surface, therefore it is less reactive and does not affect the taste of food. 

Commercial kitchens are the busiest places in the hospitality industry, and stainless steels meet the high-level standard for delivering excellent hygiene, cleanliness and durable equipment. In addition, stainless steel delivers a long service life of over 10 years for food service equipment and over 20 years for fabricated goods including exhaust hoods, benching and wall sheeting.

Bankwest Stadium is now a distinctive landmark for Western Sydney, and with the use of stainless steel, offers an exciting range of food options highlighting the flavours of local operators.

  
 
Copyright: Stoddart

This article is featured in Australian Stainless Magazine issue 73, 2021.

World-class processing systems demand high quality products, innovative features, and long-term yield increase, all of which have been delivered through superior workmanship, engineering, and the use of stainless steel.

ASSDA Member, INOX Australia, was engaged by a Melbourne based stock and soup manufacturer to design the integral process, fabricate, install, and commission a beef, chicken, seafood, and vegetable stock processing system. The processing system is entirely fabricated in stainless steel as it has been essential to the project design and fabrication, being the material of choice in demanding hygienic environments that involve high heat. 

Exceeding their client’s expectations, INOX supplied a processing system that provided multiple innovative features, winning the 2019 Food & Beverage Industry ‘Innovative Technology of the Year’ Award, and being nominated for ASSDA’s 2019 Fabricator Project of the Year Award. This extraordinary processing system features a single user operational interface, safe and ergonomic handling of the product during the process from start to finish and hygienic design of the process including zero wastage at end of production. It also improved the yield of raw materials by pressure processing instead of traditional atmospheric process.

The system works by depositing 1000kg of raw materials into a stainless steel basket which is lifted by an electric hoist into the automatically opened pressure vessel. The touchscreen operational interface is used to set and supply the water volume. The process is fully automatic to the set parameters and then alarms when the process is completed. Following the cooking procedure, the CIP (Clean In Place) water is circulated through the heating jacket of the vessel which serves two purposes. The first is to cool the cooking vessel to a temperature that allows the product to be discharged, and the second, to use the heat recovered from the cooking vessel to heat up the cleaning water. This reusable use of heating allows for no external heating of the cleaning water.

The liquid stock produced is then pumped through a specially designed filtration system, to a holding tank which is then ready for the product to be received by the external filling line. The stainless steel basket is then removed from the vessel and the waste product is dumped into a hopper underneath the basket, ready to be removed to a disposable waste bin. The basket is then cleaned within the vessel during the CIP process and does not exit the food processing room at any point, ensuring the equipment is cleaned and cannot be contaminated externally. 

An impressive 5000kg of 304 and 316L grade stainless steel was used to complete the project. All stainless steel material was supplied by ASSDA Members, Midway Metals, Vulcan Stainless and Tubesales Stainless. This included stainless steel tube, pipe, plate and sheet with 3mm to 12mm thickness. Several components (with thicknesses up to 75mm) required a large amount of specialised machining. The material was mechanically polished where required to achieve a better than 0.8 µm R_a surface finish. This superior material of choice meets the project’s sanitary requirements, offers structural integrity and excellent corrosion resistance in high temperature applications. 

 

This article is featured in Australian Stainless Magazine issue 71, 2021.

 

The aim of AS 1528: Stainless steel tubes and tube fittings for food processing and hygienic applications is to standardise hygienic tube and fittings for use in dairy, food and beverage manufacturing. It has been successful in maintaining the required food safety standards in Australia and New Zealand.

AS 1528 was first issued in 2001 and developed by an ASSDA group of stakeholders in the manufacture, supply, fabrication and use of stainless steel tube and associated fittings in the food manufacturing industries.

Changing industry practice, some existing errors, internal consistencies and expansion of sizes required a revision of the standard. The drafting journey to bring AS 1528 up-to-date began in 2015 and has been a challenge, but its successful outcome is significant for the industry and a testament to everyone involved.

The new edition of AS 1528 was published in four parts by Standards Australia in October 2019:

Part 1: Tubes

Part 2: Screwed tube couplings

Part 3: Butt weld tube fittings

Part 4: Clamp tube fittings

The revision of the AS 1528 suite of standards from the 2001 edition has brought the documents' technical coverage up to current practice and recognised the target industries in which hygienic tube is used. The suite is easier to understand and use, and facilitates verification of product compliance so that it achieves the required hygienic conditions.

 

What the revision achieved

The 2019 edition achieved all of the original aims, except one (see below). The suite of four standards now presents as a consistent coverage of all the tube and fittings regularly supplied in Australia.

1. Addition of a consistent set of pressure ratings across all parts of AS 1528. Useful for designers.
2. The wall thickness tolerance for tube has been changed. Previously it was +nil/-0.10mm for all sizes of tube. Widening it out to ±10% brings it into line with most other tube specifications and makes it more economical to manufacture without compromising product quality. It also then matches the tolerances of the fittings in other parts.
3. The title now includes 'hygienic applications' in addition to food processing. This recognises the wider range of applications in which these products are already used.
4. The reference to duplex stainless steels has been removed. In practice all tube and fittings referenced by these standards are austenitic.
5. All tube and fittings can be produced without grit polishing the internal surface. Internal surface finish is specified by measurable roughness for hygiene cleanability.
6. Inner tube surface roughness has been set as 0.8µm R_a maximum; this is consistent across all four parts of the standard and is also consistent with US and European specifications. From a gleanability perspective this is adequate. In addition there is now a specified maximum roughness for the inner weld bead, specified as 'Rt'. This is an unusual specification but it does address directly the requirement for cleanability of the remnant weld line.
7. For the first time there is a stated limit for inner weld surface heat tint (no more than Level 3 in AWS D18.1M, commonly referred to as 'pale straw'). Again this aligns with US and European standards and much research work promoted by ASSDA and others.
8. Consistent working pressures and temperature ranges have been given for all tube and fittings, with the exception of clamp fittings above 152.4mm.
9. The range of sizes has been expanded generally up to 304.8mm or 12" diameter, but lesser maximum sizes for certain fittings, depending on market availability. Smaller diameter tubes have also been included as these have some niche applications. Additional wall thickness have been added. It is not anticipated that there will be a sudden move ways from the usual 1.60mm WT and the common OD range, but there were some industry requests for the expanded size range.
10. Part 2 covering screwed couplings has been completely restructured. The two fundamental types - RJT and IDF/Trapezoidal - are clearly separated, with all dimensional specifications included in Sections 2 and 3. Section 1 deals with the requirements common to both types.
11. Fittings not previously recognised have now been included. This includes both RJT blank hexagonal nut and an IDF blank cap in screwed couplings (AS 1528 Part 2). Butt weld fittings (Part 3) has addition of crosses, equal radius tees and 45 degree tees. In clamp fittings (Part 4) an end cap has now been included.
12. The branch lengths of reducing tees and crosses (Part 3) have been clarified. The previous edition have a specification for this dimension that was in some cases contradictory and in all cases confusing. The new requirement is that the branch length, measured as the extension beyond the run surface, is the same as the branch OD.
13. Reducers, both concentric and eccentric (Part 3), now include the option of a short extension to enable orbital welding.
14. Reducers are now standardised as 'short reducers', with the 'full flow' reducers still specified but in the absence of request the standard type is short.
15. New appendices in Part 4 cover a very useful description of clamp conditions for correct installation (App C), specification of grooves for expanded-type clamp liners (App D) and the method for expanding (App E).
16. Correction of a long list of typos and inconsistencies in dimensions.

 

What was not achieved

The New Zealand market is already using AS 1528 and keen to have it branded as their own, but early discussions between the committee, Standards Australia and Standards New Zealand revealed the cost imposed by Standards Australia to make the project a joint cross-Tasman effort was prohibitive. As a result, the project became simply Australia, but the committee was able to co-opt a New Zealand member, and a tube manufacturer active in both Australian and New Zealand was also included as a Drafting Leader. The project therefore included New Zealand input, even though the document is branded Australian. The committee was mindful that there is substantial cross-Tasman movement of tube and fittings, of manufactured processing equipment, of engineering expertise and of food product, so joint output was essential to maximise all-round benefits.

 

Why this revision was important

The AS 1528 suite is the only fully integrated set of standards to the Australian industry's traditional dimensions for stainless steel tube and tube fittings for hygienic applications.

The Australian food manufacturing industry is critical both because of our high standards for domestic consumption and also as a very significant export earner. Australia has a clean and green reputation that only thrives if we can guarantee freedom from contamination. 

All the commonly used and some niche tube and fitting products are covered and all are consistent.

Food manufacturing plant is getting bigger, so this edition includes provision of larger size tube and fittings. The applications are also increasingly diverse, so an expanded range of products is appropriate.

This revision presents manufacturers of tube and fittings with a clear, consistent and measurable standard for these critical products. The standard offers a pathway to economical outcomes for tube and fittings manufacturers, designers, installers and asset owners.

 

This article was written by Technical Consultant and AS 1528 Committee Chairman, Peter Moore.

This article is featured in Australian Stainless Magazine issue 68, 2020.

A growing demand for quality wines in China has seen its third-largest winemaker venture onto Australian soil with a new state-of-the-art winery incorporating over 800t of stainless steel. 

Weilong Wines’ winery in Red Cliffs, Northern Victoria is the first Australian winery development of its magnitude for many years, and the company’s investment in the Murray-Darling region is a testament to the strong reputation and quality of Australian wine. Grape crushing for the export-only wine has already commenced following the completion of the winery’s construction in March 2019 and is expected to have wine bottled before the year-end in time for the Chinese New Year celebration in January 2020.

ASSDA Member and Accredited Fabricator A&G Engineering designed, manufactured, delivered and installed all stainless steel storage and processing vessels for the new winery. The project scope was to achieve a vintage intake of over 26,000t capacity of grapes, equating to 21 million litres of wine.

Stainless steel was selected as the material of choice for the wine production equipment because of its excellent corrosion resistant properties, durability and ease-of-cleaning. Furthermore, the use of stainless steel does not impart additional flavour to the wine, preserving the original palates offered in the grape.

A total of 180 stainless steel tanks in grade 304/304L were delivered - 124 storage vessels ranging from 30kL to 1200kL, 42 fermentation vessels and 14 general processing tanks - plus associated stair towers, platforms, catwalks, support structures and connections.

Over 700t of 2mm-6mm stainless steel coil was supplied for the project by ASSDA Member, Outokumpu. In addition, the A&G Stainless Steel Sales Department was engaged to supply over 15km of primarily 304 grade tube in sizes ranging from 20mm to 300mm, plus all associated fittings.

Two 1200kL storage vessels were manufactured by A&G on site, using their own fully automated Plasma TIG welding process for tank manufacture, Site PAM (Precision Automated Manufacturing). The unique system was designed with a focus on large-capacity stainless steel vessels being constructed in the field, giving A&G the capability to custom build vessels that hold in excess of 5 million litres. 

Site PAM’s automatic planishing system compresses the weld with high pressure to ensure there are no peaks inside or outside of the tank, providing an aesthetically pleasing finish and a flat surface for the automated polishing application. All vessels were passivated for added corrosion resistance.

With safety and logistical considerations managed, 24-hour shifts were undertaken to fabricate the two 1200kL tanks to minimise downtime and maximise the efficiency of the project planners and estimators’ time on site.

The fabrication of the remaining 178 stainless steel storage vessels were spread across A&G’s three workshop premises, including Griffith in New South Wales, Mildura in Victoria and Angaston in South Australia. The extensive logistical challenges were managed with diligent project management, forward planning and transparency across the three sites and different production teams.

Transportation of the larger storage vessels required National Heavy Vehicle Regulator road permits, allowing only small pre-set time windows and significant planning to ensure loading and unloading occurred as planned to meet the scope of the permit. All vessels were delivered on A&G’s specialised tank trailers, and the larger vessels were transported on trailers specifically designed for the operation to comply with road regulations and permit requirements.

A&G was also appointed as the WH&S Principal Contractor for its portion of the works, taking responsibility and liability for all safety aspects on those parts of the site under its control. With the complexity of works being undertaken day-to-day, including the use of cranes up to 100t, heavy materials, working at heights, hot works, traffic management, job safety analysis requirements and standard operating procedures, the breadth of safety considerations were significant. Zero injuries or notifiable incidents were recorded over the duration of the ten-month project on site, a fantastic result given the magnitude of the project.

The end result is a technologically-advanced, modern winery with state-of-the-art stainless steel equipment and infrastructure built to last. With China continuing to drive growth and demand for wine imported from Australia, Weilong Wines plan to expand production each year, with the potential for future capacity to reach 168,000t per annum.

World-class infrastructure demands high quality products and long-term asset performance, both of which have been delivered through superior workmanship and the use of stainless steel.

Fuchs Lubricants Australasia opened its new $33 million purpose-built plant at Beresfield, New South Wales in February 2018. Operating in Australia since 1979, Fuchs’ expanded and relocated from its original factory in Newcastle due to strong business growth, now being the only major lubricants company to still manufacture products in the country.

Fuchs’ new plant is a blending operation, features two highly-developed laboratories and is three times larger than the old factory, producing 10,000 lubricant products for applications in industries ranging from mining and automotive to transport and food.

Stainless steel has been integral to the plant expansion project design and construction, being the material of choice in demanding environments that involve high heat and aggressive substances. Offering structural integrity and excellent corrosion resistance in high temperature applications, stainless steel is vital in the construction of tanks, pressure vessels, valves and pipework. 

The Myriad Connections ASSDA Member and Accredited Fabricator TFG managed the 12-month stainless steel installation project. This included 9km of 304L grade AS1528 tube ranging from 25mm to 101mm in diameter, 1km of pipe, 33 tanks, and the specialised fabrication of a blending platform and pipe racks for a purpose-designed traffic flow system to move and process raw through to final product oils and lubricants around the 25,000m2 plant. The stainless steel materials were supplied by ASSDA Members Prochem Pipeline Products and Stirlings Australia. After receiving the process design and piping and instrumentation diagrams from Fuchs, TFG’s Foodline Projects division mechanically designed and installed the pipe routes and pipe racks, increasing production capacity from 30 million to 90 million litres per year. Foodline Projects was integral in the success of the project through designing and incorporating 3D models of the pipe routes and racks which improved performance and efficiencies. Foodline Projects also completed the piping and installation of a custom loading arm. TFG’s Austline Fabrications division designed and completed 3D drawings of the 35-tonne blending platform and pipe racks, and included 40 per cent extra capacity for future expansion. The 40-metre-long and three-tier platform was pre-fabricated in their Perth workshop, then flat packed, transported, assembled and installed on site.

Processing and Vessels ASSDA Member and Accredited Fabricator Furphy Engineering designed, fabricated and supplied 33 grade 304 stainless steel tanks ranging in size capacities of 16kL to 180kL, with material including processed plate supplied by ASSDA Member Vulcan Stainless. The tank designs were produced by Furphy’s in-house engineering team, accommodating for both heat exchange and agitation requirements to ensure that Fuchs were confident in the ability of the tanks and vessels to perform the required manufacturing operations going forward, all of which were completed to AS1210. The manufacture of the designs heavily utilised a range of innovative technologies in Furphy’s state-of-the-art workshop, including plasma welders, automated strake manufacturing and seam polishing systems, full undercover hydrotesting and QA/QC sign off, as well their own in-house laser welded cavity plate. While widely embraced in Europe, Furphy Engineering is currently the only manufacturer with laser welded cavity plate technology in Australia, a key part of the heat exchange design on this project. The heat exchange loading on the pressure vessels was high given the materials and size of the equipment, and the laser welded cavity plate system enabled additional heat exchange surfaces to be included on the cones, increasing the active thermal exchange area and optimising the efficiency of the system to ensure effective operation.

The successful collaboration of TFG Group and Furphy Engineering resulted in the project being completed on time and within budget, each using their in-house stainless steel design and technical expertise to deliver a world-class facility supporting Fuchs’ continued expansion and investment in the Australian lubricants market.

  

This article featured in Australian Stainless magazine - Issue 62 Winter 2018.

The new facility in Merrifield Estate on Melbourne's outer northern fringe will allow Dulux to step into the next generation of paint manufacturing technology and innovation. Dulux's aim was to design and construct a state-of-the-art facility, so using quality products was essential to achieve this. Stainless steel in 300 series grades was an integral part of the project design, including storage vessels and over 10,000m of food grade, quality tube complying with AS1528.

CONCEPT STAGE

In 2015, Dulux announced its decision to construct the new state-of-the-art, highly automated paint factory at an investment of $165m.

The Dulux plant, the first of its kind, is approximately 20,000m², built on 17 hectares of land and is due for completion towards the end of 2017. For a project of this large scale, it was crucial that a strong collaborative relationship was set up between Dulux and its chosen suppliers. In relation to the tubing, supply flexibility, reliability and quality was a key requirement and ASSDA Sponsor Prochem Pipeline Products stepped up to the mark and was the successful tenderer. At the outset the total amount of tube was unclear and would only become apparent as the building process unfolded.

Working together with the client, Prochem executed a strategy to provide more than 10,000 metres of stainless steel tube over a nine-month period to complete the project.

Whilst the original engineering design specified pharmaceutical standard ASME BPE, Prochem worked with the client and design team to have this changed to AS1528 due to its suitability for the application and also due to availability of this stainless steel standard compliant product in the Australian market.

THE DESIGN

The design included a number of large and small storage vessels which were fabricated locally and supplied by ASSDA Members and Accredited Fabricators A&G Engineering and J Furphy & Sons. 

A major part of the design involved the supply and fabrication of the AS1528 tubing and included stainless steel fitting and flanges. The fabrication work was contracted to ASSDA member John Beever Australia who worked closely with Prochem to ensure a continuous supply of materials was made available as required. 

The project consumed over 10,000 metres of AS1528 tubular products in a size range from ½” to 8” in outside diameter with the bulk being 2”, 3” and 4”. The fittings used in the project included BSM fittings, tri-clover ferrules and clamps and also a significant amount of ANSI flanges which were all supplied by Prochem and fabricated by John Beever. The overall project quantities were significant and as such a large degree of co-ordination and co-operation was required with numerous manufacturers to meet the project schedule. 

An innovative technique was designed to match the tri-clover ferrules and clamps to the tube and machinery to enable a correct fit-out at site. 

With good co-operation and education, the project also allowed the flexibility to use both stainless steel grades 304 and 316 if availability became an issue. 

With an innovative and co-operative approach involving many ASSDA members, this project was completed on time and within budget, and will support the Dulux paints business for decades to come.

 

This article is featured in Australian Stainless Magazine Issue 60 (Summer 2017/18).

Wave Discs Revolutionises Traditional Drying Process

In the search to find a more efficient way of manufacturing industrial disc dryers for the meat-rendering industry, Melbourne-based engineering company Pinches Group has developed a new technology called Wave Disc.

THE CHALLENGE

Traditional rotary discs comprise of a series of stainless steel discs, welded back-to-back and attached to a centre pipe. Together, the pipe and discs make up the shaft, which operates under steam pressure and rotates within a stainless steel shell.

Employed throughout the world in a wide range of industries, disc dryers are commonly used to dry materials such as coal, sand, sludge, paper pulp and animal waste.

There are significant inefficiencies in the manufacturing of disc dryers:

• Discs are cut from industry standard rectangular plate, with the centres and corners of the donor material often wasted;
• Flat discs rely on pressure-welded pins for structural support. A typical two-metre diameter disc requires ninety-six support pins pressure welded with full penetration on both sides of the disc. Pressure welds are not only labour intensive, but due to the proximity of discs with the drum, they are difficult to repair once the dryer is in operation.

ASSDA Member Pinches Group began investigating designs that could overcome the need for support pins and reduce raw materials waste. Rather than cutting the discs, Pinches discovered that using specific rectangular sections of material discs could be formed through a series of folds along one edge of the plate. This enable all supplied materials to be used in the formulation of the disc.

BENEFITS

Because folds occur consistently and consecutively around the disc, the folds reinforce the structure of the discs and eliminate the need for added support.

Removing the pins not only improves manufacturing time, it eliminates the chance of weld failure around the support pins, which can cause equipment faults in traditional disc dryers.

Additionally, the natural waves of the discs provide increased agitation to drying material, which can improve evaporation rates.

One design flaw with flat discs is a tendency for product to stick and build up between discs. With Wave Disc, the waves in the disc massage the product and keep it moving within the drum, preventing build up and ensuring that all raw materials are exposed to heat.

Wave Disc also provides greater surface area. Any indirect drying processes (where the heat source doesn't make direct contact with the product) is reliant on the surface area to transfer heat.

With the addition of the folds, Wave Disc provides a surface area at least thirteen per cent larger that conventional discs within the same footprint. This means that existing disc dryers can replace their current shaft with a Wave Disc shaft and increase the capacity of the dryer.

AWARD WINNING DESIGN

In 2012, the Wave Disc concept received top level funding from the Australian Federal Government's Commercialisation Australia program.

In 2014, the first Wave Disc unit was installed at animal by-product processor, Australian Tallow, in Brooklyn, Victoria. Since then, further units have been exported to by-product processors in New Zealand.

As Australia's leading supplier of processing equipment to the animal rendering industry, Pinches Group developed Wave Disc to overcome specific inefficiencies within the meat processing industry.

Now that this innovative new technology has been tested and proven in the rendering industry, Pinches has plans to expand their focus to heating and cooling processing technologies in the food and agricultural sector.

Pinches Group own and operate a testing facility in Melbourne which incorporates an operational Wave Disc pilot unit used by prospective clients and educational institutions for running trials on a range of raw materials.

Among other metrics, the pilot units can provide clients with evaporation rates and in-an-out moisture levels for specific products.

PATENT

The Wave Disc design is protected by Provisional Patent Number 593495.

This article in Australian Stainless Magazine Issue 59 (Winter 2017).

Over 17 tonnes of stainless steel has been used for the upgrade of a premier meat processing plant to support the growing local and global demands of Australian red meat supply.

The Australian Lamb Company (ALC) currently exports lamb to more than 60 countries worldwide, and recently secured a 10-year contract to process lamb for Coles supermarkets in eastern Australia.

ALC’s multi-million dollar investment to support demand and increase production capacity included the expansion and upgrade of its meat processing operation in Colac, Victoria.

ASSDA Member and Accredited Fabricator Stainless Steel Associated Fabricators (SSAF) Australia was engaged to design, manufacture and install 65 box conveyors spanning 400m, three access walkovers and 30 production tables for the plant’s re-engineered automated boning room.

The conveyor system was designed by SSAF Australia with input from the ALC’s production team to achieve optimum process flow. The main criterion for the mechanical design was excellent product transfer, mechanical reliability and optimal hygiene through easy cleaning of the conveyor’s belt and frame.

The box conveyors are a semi-modular design using the latest SEW-EURODRIVE MOVIGEAR® SERVO motors and gearboxes. Compared with conventional motors and gearboxes, SSAF Australia’s Managing Director Chris Stacey said these systems are significantly more efficient in reducing power usage and allowing a wider speed range without loss in torque.

Grade 304 stainless steel with a 2B finish was specified and used for the upgrade, supplied by ASSDA Sponsors Atlas Steels, Midway Metals and Vulcan Stainless.

Grade 304 stainless steel is a standard requirement in the food industry where acid and salt are not present in the production process. With rigorous standards in food safety and hygiene to adhere to, the boning room must be washed down daily and to this end, the conveyors incorporate CIP (clean in place) systems.

Stacey said that grade 304 2B stainless steel with a PVC protective coating is the material of choice for their food grade equipment. ‘By taking care during manufacture and polishing welds to 320G, 2B is superior to a No 4 or bead blasted finish. The smoother grain structure is much better than No 4 in inhibiting the growth of microorganisms and is easier to clean. Our equipment is regularly swabbed for surface cleanliness and this is critical to our customers’ Quality Assurance (QA) requirements.’

With the full scope of works completed within a 6-month timeframe in early September 2016, the increased capacity of ALC’s Colac operation has delivered significant benefits for the Australian lamb industry and a boost in the Victorian economy.

This article is featured in Australian Stainless Issue 57 (Spring 2016).

Images courtesy of SSAF Australia.

Connections are vital

Any visit to a dairy, beverage or food processing plant will drive home the critical importance of the connections between the tanks, mixers, driers, pumps, etc. The image above (courtesy of TFG Group) showing an image of a brewery is a typical example. These tubes and/or pipes carry the process materials, the heating or cooling or wash water, gases, and also dispose of the wastes.

 

Getting the right standard

Except for high pressure or very aggressive environments, most tube is rolled into shape and welded longitudinally. For mechanical or structural service such as columns or handrails, the weld must penetrate and be sound although to perform its mechanical function, it may not need to provide a seal. This is reflected in the basic test requirements of standards such as ASTM A554 ‘Welded Stainless Steel Mechanical Tubing’ and is a reason why it is cheaper and is sometimes used, in error, for fluid transport. Despite these restricted requirements, the external finish is often critical for aesthetic reasons as seen on the handrails in the figure on the right.

Verification of leak tightness is the reason why tubing standards for carriage of fluids, e.g. AS 1528.1 or ASTM A269 or ASTM A270, all include either hydrostatic or 100% eddy current testing. Section 8.4 of the ASSDA Reference Manual summarises the test requirements of the plethora of tubing (and piping) standards commonly used in Australia. However, the food and sanitary industries also require surfaces that are readily cleanable. Hence, in addition to a lack of leaks, there are also requirements on the profile of the weld bead in the tubing, potential crevices in fittings and the surface finish of product contact areas. 

System design and installation

Quite apart from the manufactured components, the system design must include adequate slope for self draining (including across welded joins), simple cleaning procedures, velocities above ~0.5m/sec for low solids streams, at least double that for high solids content and avoidance of design features permitting stagnant zones or dead legs. Excess velocity (at least below about 40m/second) is not a concern for stainless steel, although it may increase noise and pumping costs. These are matters for another place.

Material selection

There are quite complete sets of corrosion resistance data for single corrosives (and some mixtures) at a variety of temperatures and concentrations but they are usually for continuous exposure.  For some acidic, hot and salty fluids or slurries such as sauces, high alloy stainless steels or even nickel-based alloys may be required and such components are rarely “off-the-shelf”. However, for apparently aggressive fluids processed in batches, the intermediate cleaning will arrest the initiation of attack and restore the passive layer so that standard 316(L) material is usually adequate especially with the highly polished finish often used to enable cleanability. One operational issue is that cleaning chemicals can be quite aggressive and the procedures must ensure that residues from cleaning do not remain and are not able to be concentrated and cause corrosion or hygienic issues.

Food tube and fittings – AS 1528

The weld bead is a potential source of crevices and for food tube, its effect must be removed without causing additional surface defects. AS 1528.1 requires the weld bead to smoothly blend without harmful markings. It also sets a nominal surface roughness (0.3 μm Ra) for the rest of the interior by requiring the use of fixed (1.6mm) thickness 2B material. ASTM A270 ‘Seamless and Welded Austenitic and Ferritic/Austenitic Stainless Steel Sanitary Tubing’ assumes a sophisticated specifier as it lists a mill finish as well as multiple alternative mechanical or other finishing techniques. Acceptance of minor surface imperfections is by agreement. The specifier may require a surface roughness (Ra) limit – which, of course, would override a grit size specification.

The manufacturing tests (eddy current or hydrotesting) ensure that food tube will hold pressure. For the essential quality assurance purposes, AS1528.1 requires line marking of tube. Finally, food grade tube requires a complementary set of fittings that will fit together. The AS 1528 suite achieves this with screwed couplings (Part 2), butt welding fittings (Part 3) and clamp liners with gaskets (Part 4). Aesthetics may be important and is in the hands of the specifier as the exterior of AS1528.1 tube may be as-produced or “buff polished as agreed”, i.e. polished with grit of a specified size.

The AS 1528 suite started life in 1960 as AS N32, was split into four parts in the mid 1970s and completely revised by an ASSDA driven working group to its present form in 2001. It has been widely accepted especially since the 2006 publication by ASSDA of what is now the Food Code of Practice for the fabrication and installation of stainless steel process plant and equipment in the food and beverage industries.  The New Zealand dairy industry has effectively adopted the AS 1528 requirements for dairy tube and fittings. Multiple overseas suppliers provide tube to the AS 1528 specification.

Food and beverage manufacture is obviously worldwide and this has resulted in national, regional and international standards which are different and locally focused. The sizes of the ISO alternatives (ISO 2037, 2851 – 3) are quite different. The European standard (EN 10357- which supersedes BS4825.1 and DIN 11850) covers similar tube but does not cover the range of sizes commonly used in Australia. The British Standard products (BS 4825) are similar in sizes to the AS 1528, but with a restricted range. The American 3A products also cover a restricted range. 

“As a result, ASSDA is spearheading an industry effort to revise the 15-year-old suite of AS 1528 standards”.

What is in need of review?

There are a number of typographical errors and inconsistencies between the parts, there are only some pressure ratings and the listing of fittings requires some revisions. The tolerance on the tube wall thickness has been narrow and one sided since inception and while the standard allows modification by agreement, the current wall thickness requirement will be reviewed.  Other issues for discussion will be the addition of larger sizes and assessment of differences for internal finishes between parts of the suite. And finally, it is intended that AS 1528 will be converted to a joint Australian and New Zealand standard to formalise New Zealand’s use.

If users of the AS1528 suite of standards have any suggestions for changes or improvements to the standards, ASSDA would welcome your emailed comments to This email address is being protected from spambots. You need JavaScript enabled to view it..

Acknowledgements

This article has drawn heavily on documents produced by the ASSDA/NZSSDA working group dealing with the proposed revision of AS 1528 and in particular Peter Moore from Atlas Steels, Kim Burton from Prochem Pipeline Products and Russell Thorburn from Steel and Tube in New Zealand.

This article is featured in Australian Stainless Issue 56 (Winter 2016).

Stainless steel has helped deliver improved environmental performance and increased efficiency for a major food production company.

In 2014, Australian agribusiness GrainCorp announced a $125 million investment in a consolidation strategy to integrate its GrainCorp Foods’ manufacturing operations, including the relocation of its Brisbane plant to the existing West Footscray facility in Victoria. This move effectively terminates the use of its coal-fired equipment, giving GrainCorp Foods the opportunity to invest in efficient and environmentally sustainable technology and significantly reduce its carbon footprint.

As a result, GrainCorp Foods’ West Footscray operation commenced its expansion and upgrade in 2015 to deliver a state-of-the-art food processing plant.

GrainCorp awarded the design, engineering and installation to SPX Flow Technology Australia, and SPXFlow awarded ASSDA Member and Accredited Fabricator TFG Group the contract to install and fabricate specialised components for the facility’s new margarine production line.

TFG Group’s Foodline Projects division installed and assembled the stainless steel equipment under the direction of SPX Flow Technology Australia, including numerous pumps, valves, heat exchangers, vessels and specialised processing equipment.

The TFG Foodline Projects team also mechanically installed over 12km of stainless steel pipe, AS 1528 304L and 316L tube ranging from 25mm to 100mm in diameter, and over 6000 fittings supplied by ASSDA Sponsor Prochem Pipeline Products.

Hygiene and cleanability of equipment used in food production is paramount, and the correct specification and fabrication quality of stainless steel ensured this criterion was met.

The TFG Foodline Projects team consisted of 35 specialised welders, fitters and installation specialists to ensure the project’s tight lead-time of 24 weeks to completion was met with zero safety incidents. Orbital welding was applied to ensure speed, accuracy and prevention of bacterial contamination in the products.

As part of the factory upgrade, TFG Group’s Austline Fabrications division assisted with the fabrication and installation of the specialised scalloped stainless steel tank access platforms, break tanks, stainless steel chemical bunds and support racks. Jacketed pipework was fabricated to ensure the internal temperature of the process pipework was controlled to prevent the viscous product from solidifying.

These specialised items were all fabricated at TFG Group’s purpose-built factories in both Western Australia and Victoria, and transported to the West Footscray facility for installation by the Foodline Projects division.

GrainCorp’s investment in its West Footscray plant has delivered a fully integrated facility and a more efficient focal point for the sourcing, refining, and distribution of GrainCorp’s locally-produced edible oils and food ingredients.

This article is featured in Australian Stainless Issue 56 (Winter 2016).

Images courtesy of TFG Group.

Coca-Cola Amatil is reducing the carbon footprint of its 600ml PET bottles by 22% with the help of stainless steel.

Innovation in process technology and the successful application of stainless steel has led to efficiency gains and sustainable outcomes for one of the world's most recognised brands in the food and beverage industry.

In 2011, Coca-Cola Amatil (CCA) announced a $450 million investment in PET bottle self-manufacture, or ‘blowfill’ technology at its production facilities across Australia, New Zealand, Indonesia, Papua New Guinea and Fiji.

Blow-fill technology is a manufacturing technique that allows companies to produce their own PET (polyethylene terephthalate) bottles within their own facility. It allows manufacturers to form, fill and seal bottles in one continuous process at the one location without human intervention. Blow-fill has enabled CCA to make its PET bottles using significantly less PET resin, resulting in production of the lightest-weight bottles in the global Coca-Cola system.

Previously, CCA would buy blow-moulded bottles from a third party supplier, transporting them to its own facility to sterilise and fill with product. CCA’s integration of these three steps into one operation has automated its production lines, creating economies of scale and
optimising efficiencies of operation.

CCA’s Kewdale facility in Perth is one packaging line that recently completed its installation of blow-fill equipment, procured from Krones AG, a German-based process manufacturer.

CCA engaged ASSDA member and Accredited Fabricator TFG Pty Ltd for the installation and fabrication of the stainless steel interconnecting pipework for the facility’s new blow-fill equipment.

Sydney-based ME Engineering detailed the scope of works, and coordinated the process engineering and installation of the new equipment.

Over 6km of 304L and 316L AS1528 standard grade stainless steel tube was supplied by ASSDA sponsor Prochem Pipeline Products, ranging in size from 25mm-200mm diameter.

The TFG team purge TIG welded all stainless steel components on site and internally passivated the stainless steel using citric acid.

ME Engineering’s Project Manager Andrew Meagher said grade 316L was specified for CCA’s Kewdale facility because of the high chloride content of the water supply in Perth.

With spring water one of CCA’s main products, sanitation is key to avoiding microbiologically-influenced corrosion.

Tom Moultrie, General Manager of TFG, said that whilst there are other materials that can be specified for equipment using compressed air, stainless steel provides aesthetic appeal, trusted hygiene and longer life span.

The use of stainess steel has been successful in the output of this project, with CCA’s State Projects Engineer Simon Wall stating that ‘as a beverage manufacturer, food safety aspects of our processes and equipment are critical to ensuring the integrity and quality of our products – an area that stainless steel ensures.’

Kewdale’s new blow-fill line commenced operation in June 2012. It features 14 blowing stations, 108 filling nozzles and 18 capping stations, and has the capacity to produce 26,000 bottles per hour.

Mr Wall said the investment in PET bottle self-manufacture will continue to deliver savings in raw materials - bottles are made using less PET resin and less water is used in the bottling process - and meet future consumer growth and demand.

CCA’s ongoing commitment to innovation and sustainability has maximised production capabilities whilst minimising the use of resources.

By the end of 2012, 10 blow-fill lines will have been deployed across CCA’s production facilities in Australia, bringing self-sufficiency to over 70%. Once all 26 production lines are implemented, CCA estimates a saving of 7000 tonnes of PET resin per year, a 15% reduction in bottle weight and 50,000 truck movements eliminated per year. Overall, this is reducing the carbon footprint of every 600ml bottle by an average of 22%.

Images courtesy of TFG Pty Ltd.

This article is featured in Australian Stainless magazine, issue 52.

This is an abridged version of a story that first appeared under the same title in Stainless Steel Focus No. 07/2012.

The Nickel Institute's director of promotion, Peter Cutler, and consultant Gary Coates, reveal some of the reasons for the continuing popularity of nickel in stainless steels.

Stainless steel is everywhere in our world and contributes to all aspects of our lives. We find stainless steel in our homes, in our buildings and offices, in the vehicles we travel in and in every imaginable industrial sector. Yet the first patents for stainless steel were issued only 100 years ago.

How did this metal become so desirable over the past century that more than 32 million tonnes was produced in 2011? And how does nickel, a vital alloying element in most stainless steel alloys, contribute to the high demand for stainless steel?

THE 'CREATION' OF STAINLESS STEEL
By definition, a ‘stainless’ steel has a minimum level of about 10.5% chromium, so the discovery of chromium in 1799 by Nicolas Louis Vauquelin in France was the first key event in the creation of stainless steel. In 1821 another Frenchman, Pierre Berthier, published research that showed a correlation between increasing chromium content and increasing corrosion resistance, but the high carbon content of his alloys prevented them from showing a true ‘stainless’ behaviour.

Still in France, in 1904 Leon Guillet first published his metallographic work on alloys that today would be classified as ferritic and martensitic stainless steel. In 1906 Guillet published his work on the nickel-containing austenitic stainless steel family, but his studies did not include corrosion resistance. Albert Portevin then continued to build on Guillet’s work.

In 1911, a German scientist named Philip Monnartz reported that as the chromium content neared 12% in a steel with a relatively low carbon content, the alloy exhibited ‘stainless’ properties. Further developments then rapidly occurred in many other countries. In the United States, Elwood Haynes started working with martensitic alloys while Becket and Dantsizen were developing a ferritic stainless steel as lead-in wires for electric light bulbs. In 1912, Great Britain’s Harry Brearley worked on a 13% chromium martensitic alloy, initially for high temperature service in exhaust valves for aeroplane engines.

Meanwhile in Germany, Eduard Maurer and Benno Strauss were testing nickel-containingalloys and, in 1912, two patents were awarded. One of these grades, containing about 20% chromium and 7% nickel, was called V2A, and was found to have exceptional corrosion resistance in nitric acid. That grade had a relatively high carbon content compared to today’s stainless steel, and would be
similar to a Type 302 (EN 1.4317) stainless steel. 100 years later, the most commonly used alloy for nitric acid is 304L (EN 1.4307) with approximately 18.5% chromium and 8.5% nickel, quite similar to the V2A composition other than having a much lower carbon content.

Brearley’s martensitic stainless steel alloy would not rust when wet. He worked with Sheffield cutlery manufacturers to forge it into knife blades and then harden it, replacing the carbon steel blades they were then making. Stainless steel knives rapidly became a common household item. However, for forks and spoons, where high hardness was not so important, the 18-8 (302) composition became the most commonly used alloy.

300 SERIES
We normally think of the austenitic or 300 series family of stainless steels as the ‘nickel stainless steels’, but many other families contain nickel. One of the prime reasons for using nickel in the 300 series alloys is that nickel is an austenite former, but other reasons include:

• Nickel adds corrosion resistance, especially in certain aqueous environments, and in certain high temperature environments.
• Nickel can retard the formation of embrittling intermetallic phases at elevated temperatures, a major downfall of the non-austenitic families.
• The austenitic structure can mean high toughness at cryogenic temperatures.
• The advantages of the 300 series extend to welding and forming operations.

A fuller discussion of these topics can be found in 'The Nickel Advantage - Nickel in Stainless Steels', available on the Nickel Institute website.

200 SERIES
The 200 series stainless steels are also austenitic in structure. The standardised 200 series grades, which have chromium contents close to the level of a 304L alloy (about 18%), have an intermediate level of nickel. The ‘non-standardised’ 200 series not only have lower contents of nickel, but also lower contents of chromium, with the net effect of significantly reduced corrosion resistance, although still an improvement over the 11-13% chromium ferritic stainless steels.

DUPLEX
The duplex (austenitic-ferritic) family of alloys also need some nickel as well as nitrogen to ensure proper austenite formation. Most ‘matching’ duplex filler metals are actually over-alloyed with nickel to ensure that the welds have the required properties.

PRECIPITATION HARDENABLE
The precipitation hardenable (PH) stainless steel family contain nickel, which increases their corrosion resistance, ductility and weldability compared with hardenable non-nickel-containing stainless steel alloys. One of the other major advantages of the PH grades is that, unlike the martensitic grades, they do not need a quenching operation, which considerably reduces risk of distortion. Some of the martensitic grades also contain a small nickel addition. In the higher chromium types, the nickel is needed for the martensitic transition. In all nickel containing martensitic grades, nickel improves their corrosion resistance, ductility and weldability.

Some of the lower alloyed ferritic grades such as UNS S41003 (EN 1.4001) and S40975 contain a small intentional nickel alloying addition that allows for grain size control, which aids especially in welded constructions. A few of the higher alloyed ferritic grades also have a small nickel addition to increase toughness and ductility, which is beneficial during both hot rolling and in their end use.

Clearly, it is important for each specific application to select the appropriate alloy or alloys to give the desired properties.

GROWTH IN DEMAND FOR STAINLESS STEEL
According to the ISSF, 300 series stainless steel still dominates the worldwide production figures, as shown in Figure 1.

The properties of the various 300 series grades - created by the addition of nickel - are clearly valued by users, both in industry and the general public. Upwards of two thirds of all stainless steel produced in 2011 fell within the 300 series and close to three quarters of all stainless steel produced contains nickel.

The growth of worldwide production of stainless steel over the past 100 years has been steady, if not spectacular. This has meant that the demand for new nickel has steadily increased along with the demand for stainless steel, as shown in Figure 2. Recycled stainless steel is also a very important component in the alloy supply chain.

EFFICIENCY AND 'GREEN' CREDENTIALS
Resource efficiency is a recurring theme as the global economy faces economic challenges. Stainless steel not only contributes towards efficiency in many applications, it also shows continuous improvement in the resource efficiency related to stainless steel itself.

There are three important factors:

1. Stainless steel’s long service life, which might average 15 to 20 years, although much longer in prestigious buildings.
2. The extent of recycling: The percentage recovered and recycled at end-of-life - around 90% - is amongst the highest of all materials. Moreover, this recycling can be repeated many times without loss of quality. While the recycled content may appear to be relatively low, this is simply a result of stainless steel’s long service life (15 to 20 years) coupled with much lower global production 15 to 20 years ago.
3. Continual production improvements for stainless steel and its raw materials. For example, whilst the ores being processed today are of lower grade than before, the extraction and recovery processes are more efficient.

THE FUTURE
The history of stainless steel would be incomplete without celebrating the extent to which it has enabled innovation not just in the area of improved performance, but also in the more intangible, aesthetic aspects. From chemical plants to medical equipment to iconic stainless steel-clad buildings, stainless steel has made - and will continue to make - a major contribution to almost every aspect of our lives.

With durability, recyclability, versatility and aesthetic appeal at the core of its appeal, stainless steel - with nickel as one of its trusted alloys - is well placed to continue to innovate and expand its applications.

STAINLESS STEEL IN USE

FOOD AND BEVERAGE INDUSTRY
The popularity of stainless steels in kitchens did not go unnoticed in the food and beverage industry.

If we take milk, we know of an early stainless steel bulk milk tank truck from 1927 in the USA. A paper entitled ‘The Corrosion of Metals by Milk’ from the January 1932 Journal of Dairy Science by Fink and Rohrman states: ‘It has long been known that milk in contact with iron and copper will not only acquire a metallic taste, but corrode these metals readily’. At that time, tin-coated metals were commonly used. It went on to say that ‘High chromium nickel (18-8) iron alloys … are very resistant to corrosion by milk and are satisfactory for dairy equipment …’. The modern milk processing industry is filled with stainless steel equipment, mostly of Type 304 (EN 1.4301) or 304L.

The report also went on to state that some materials that are otherwise suitable for processing of milk ‘…do not stand up well to the action of cleaning compounds that are commonly used in dairies’, but that the 18-8 alloy was suitable for those cleaning compounds. Today, the typical cleaning acids and hypochlorite sanitising compounds that are used not only in the dairy industry but also in most food and beverage plants worldwide, require that same 18-8 alloy as a minimum. A correctly chosen stainless steel alloy will not change the taste or appearance
of the food product. However, it is the ability to withstand repeated use of the sanitising chemicals over the lifetime of the equipment that has led to the widespread use of stainless steel in all sectors of the food and beverage industry. Producers are then able to guarantee the
safety of their food products.

ARCHITECTURE
Another area of quick acceptance was in architecture. The first recorded use for that purpose was in 1929 in London at the Savoy Hotel where a sidewalk canopy and a sign were erected with the 18-8 alloy. These were soon followed by two iconic skyscrapers in New York that used stainless steel as a dominant element on their exteriors: the Chrysler Building in 1930 and the Empire State Building in 1931.

Since then, many prestigious buildings around the world have used stainless steel, including the Petronas Tower in Kuala Lumpur, the Trump Tower in Chicago, and the Jin Mao Tower in Shanghai. Related to architecture is sculpture, and Isamu Noguchi convinced the Associated Press in 1940 to approve stainless steel instead of bronze for his sculpture above the entrance to its building in New York. Since then, artists around the world have been using stainless steel, mostly either 304L or 316L (EN 1.4404), in their works. The St Louis Arch in the USA, Frank Gehry’s Peis (Fish) in Barcelona, Spain, and more recently Genghis Khan in Mongolia are examples of what can be done with stainless steel.

TRANSPORTATION
During the Great Depression in the USA, Edward Budd realised the untapped potential for stainless steels. Although their use in aeroplanes was his first application, his legacy remains the building of more than 10,000 passenger railcars, some of them still in use today.

Around the world, stainless steel is used extensively for passenger rail cars for subways, commuter trains and long distance trains, ensuring safety plus long life and low maintenance costs. In addition, stainless steels are used to transport cargoes such as food products, petroleum products and corrosive chemicals by rail, road, water and even air, both domestically and internationally.

ENERGY
In the broad field of energy, stainless steels have been used to extract oil and gas containing hazardous substances as well as for use in the refining stages. For power plants, stainless steel is used extensively at both low and high temperatures, whether the fuel is coal, oil, gas, uranium or waste products. Hydroelectric stations use stainless steel for dam gates as well as turbines. Many of the established sustainable
energy technologies such as solar and geothermal are using stainless steel, as well as the present biofuels industry with corn or sugar cane as feed stock.

WATER
Fresh water is an essential commodity for mankind, and stainless steel is used extensively in treatment plants for potable water as well as for wastewater. Cost effectively producing fresh water from seawater or brackish water by desalination also requires the use of stainless steel. In some countries, underground stainless steel pipe is used to deliver potable water to homes to prevent leakage, or in other special cases to protect either the environment outside the pipe or the water inside the pipe. Stainless steel plumbing is also common in certain countries and offers a long lasting, low maintenance option.

SURGERY
The first recorded example of an austenitic stainless steel surgical implant is from 1926. Medical instruments are also known from that time period. The ability to easily and repeatedly sterilise components that come in contact with the human body or are used in hospitals and clinics contributed to the early acceptance of stainless steel. Today, there are well-established international specifications for materials used in this industry. For example, stainless steel alloys for implants must meet stringent metallurgical cleanliness requirements and be completely non-magnetic so that the patient can safely undergo diagnosis by Magnetic Resonance Imaging.

FUTURE USES OF STAINLESS STEEL
Strong growth in the use of stainless steel has continued in the past decades despite the rapid and diverse developments in other materials and the more recent economic turmoil. The nickel-containing alloys in the 300 series still account for nearly two thirds of current stainless steel production worldwide, and there is nickel in the 200 series, duplex and precipitation hardening families, as well as in some of the martensitic and ferritic alloys. The reason for this is the great value that is placed on the properties which nickel provides.

Society is rapidly evolving and facing challenges on a global scale. Population is increasing, expectations are growing and resources are limited. Therefore we must use those resources more efficiently. This is particularly apparent for energy where stainless steel, and especially the nickel-containing alloys, already plays a major role in the more difficult to extract fossil fuels. Stainless steel’s corrosion and heat resisting properties are key to more cost-efficient operations. This also applies to the renewable sources that are now being developed, such as wave power and biofuels from new organic sources.

The worldwide need for higher quality, safe food and beverages and water will only increase, especially as food products can come from anywhere in the world. Stainless steel has evolved as the material of choice in this industry, both industrially and domestically, and it is likely to continue to meet the demands of a global population that is predicted to increase to nine billion by 2050.

This growing population, combined with a rapid movement to urbanisation, requires an expanded and more efficient transport infrastructure. The characteristics of stainless steel enable it to deliver lightweight and durable designs, leading to more efficient performance, safety, lower energy requirements and reduced emissions while giving lower life-cycle costs.

Image of Trump Tower (Chicago, USA) pictured above courtesy of C.Houska.

This article is featured in Australian Stainless magazine, issue 52.

As bottled water continues to gain popularity in Australia, maintaining the quality and purity of the water extracted from natural springs is paramount.

This is just one example within the food and beverage sector where hygiene is vitally important and, therefore, stainless steel continues to be the material of choice for processing and storage facilities.

In 2011, Coca-Cola Amatil (CCA) commissioned ‘Project Flint’ to upgrade three spring water storage tanks for their Moorabbin plant in Victoria plus an additional two tanks for their Thebarton plant in South Australia.

GEA Process Engineering Australia engaged Byford Equipment on behalf of CCA to fabricate and install the five storage tanks.

GEA Engineering’s General Manager Operations, Andrew Fillery, said stainless steel was an important specification as the tanks had to cope with the chemical and thermal rigours of cleaning processes.

“Stainless steel was chosen for process and hygienic reasons, and the vessels needed to withstand the process and cleaning conditions where mild caustic and acid CIP solutions were used,” said Fillery.

Strength and durability was key for the 200,000L capacity silos, which measured 4.7m in diameter by 14.5m high for the Moorabbin site and 5.5m in diameter by 10m high for the Thebarton plant.

ASSDA Sponsor Midway Metals supplied 27 tonnes of grade 304 stainless steel coil with a 2B finish in 2mm, 2.5mm, 3mm and 4mm thicknesses. The coil widths were 1219mm and 1500mm.

With a team of five fabricators on the project, the tanks were welded together using a semi-automatic MIG welding process. The welds were then pickled to restore the chromium oxide layer and abstain from rusting.

Byford Equipment’s Project Manager Geoff Smallwood said coordinating the delivery of the tanks was a challenge, given the logistics of travelling through three states by road.

The delivery of the vessels was critical added Fillery, as there were specific installation windows to work within.

The storage tanks were delivered from Byford’s workshop in New South Wales to Moorabbin in March 2011. The two remaining tanks were delivered to Thebarton a month later for installation. It took one day and one crane to install each tank on site.

The connecting pipework was positioned on site, which was grade 304 polished tube in diameters ranging from 38mm to 150mm and purge welded prior to installation.

Images courtesy of Byford Equipment.

This article is featured in Australian Stainless magazine, issue 51.

A worrying trend among Australia's major resource companies is the increasing amount of engineering, detailing and fabrication work being sent offshore - a move that has had significant impact on local fabrication. But there are some positive signs in the food and beverage sector that local fabricators are more than capable of meeting design and fabrication expectations.

When ASSDA member and Accredited Fabricator, A&G Engineering, put in a bid to build 10 x 100 hectolitre beer fermenters for Casella Estate - a company best known for their Yellowtail wine label - they had to compete against companies as far away as Europe for the coveted project.

But A&G had a few advantages over the offshore companies: they had worked with Casella before, fabricating 88 x 1.1 million litre wine tanks for the company’s tank farm in Yenda, NSW; they have supplied stainless steel tanks to Australia’s leading breweries, wineries and beverage companies; and they are one of the largest users of stainless steel in Australia.

A&G’s win is an important victory for the Australian industry as a whole and another milestone for A&G Engineering, which was founded in 1963.

The five-month Casella Brewery project, completed in August 2011, saw 25 of A&G’s 200 staff use 65 tonnes of 304 grade stainless steel (including 2-4mm coil and 8mm plate) to build the 10 vessels.

A&G’s Design Manager Heath Woodland said the tanks were designed to AS1210-2010 pressure vessel standards, in order to withstand a pressure rating of 115kPa.

The stainless was welded with A&G’s semi-automated welding process and the internal welds were polished to achieve a 0.6R_a surface finish, to meet beverage industry standards of a food grade finish.

A&G built the vessels at their Griffith and Irymple plants, before transporting them to Yenda. With the beer fermenters now in place, it is hoped the Casella Brewery will be operational by the end of 2011.

Images courtesy of A&G Engineering.

This article is featured in Australian Stainless magazine - Issue 50, Summer 2011/12.

Stainless steel forms a significant part of a beef abattoir, including the conveyors, fixed and elevated platforms, sterilisers, chutes, hand wash basins and, of late, water supply and wastewater piping. The stainless component may now expand even further in new abattoirs with the recent development of cast stainless steel skids and forged hooks for use on dressing conveyors.

Dressing conveyors in beef abattoirs traditionally use rollers rather than a skid system or, in some cases, extruded aluminium skids and hooks are used. Both of these systems have limited service lives due to the weight of the beasts. They also result in downtime when cleaning and, in the case of rollers, lubrication is required. Hygiene is critical throughout the trimming process, as the carcass' meat is exposed to the environment.

G & B Stainless (Crestmead, Old) and Meateng (Melbourne, Vic) recognised the need to develop a dressing conveyor system which would allow a rapid turnaround of hooks while assuring a high level of hygiene.

Using stainless steel would provide sufficient strength to hold heavy carcasses (weighing up to 1,000kg), while allowing the skids and hooks to simply pass through a washbox for sterilisation on their return to the starting point of the conveyor.

The project has evolved over six months from a prototype fabricated skid, which did not provide enough strength, to the existing cast skid and forged hook. The cast skid also incorporates a high density polyethylene insert, which is the only component to experience wear during service. This insert can be replaced at low cost when required.

The skids are cast by Austcast Stainless (Northgate, Old) using a vertical joint automoulding sand casting system. Grade AS2074 H5A (equivalent to AISI 304) stainless is used and full traceability exists for the castings, The stainless hooks are forged by John Ure (Wacol, Qld). Production costs are comparable with extruded aluminium skids, but the low rate of replacement makes the lifecycle costs very attractive.

Over 1,000 stainless steel skids and hooks have been in service at Stockyard (Grantham, Qld) for six months and, according to site engineer, Roger Tocknell, they have been performing excellently.

The new skids are not interchangeable with existing mild steel rollers, but G & B Stainless' Director, John Van Koeverden, said the company's next goal is to develop stainless rollers which can be used on existing conveyors.

This article featured in Australian Stainless Issue 11 - March 1998.

15 million dollars worth of stainless steel has been used to construct the largest rotary fermentation area in Australia.

The facility at Southcorp's Karadoc Winery in Victoria comprises 88 stainless steel red grade processing tanks, pipes and tubes, brine jackets and rotary fermenters.

Southcorp Wines Engineering Manager (Eastern Region) Geoff Leighton said stainless steel was preferred by the wine industry because it is "corrosion resistant, provides a stable environment for the wine, is easy to clean and maintain and has a long service life."

Grade 304 stainless steel was used for the tanks, with a thickness range of 2mm - 6mm, with the highest tank 1 5 metres tall. An extensive amount of 304 and 316 tube was also used.

ASSDA members Atlas Steel (SA), Alfa Laval, APV Valves and James Contract Supplies were all involved in the project.

The expansion brings the Karadoc site's total storage capacity to approximately 93 million litres.

The winery, which produces known brands Lindemans, Queen Adelaide, Kaiser Stuhl and Matthew Lang exports approximately 60% of its bottled wine production.

"The project has provided infrastructure to the district and significant employment opportunities in the areas of viticulture, transport and production facilities," Mr Leighton said.

Mr Leighton said while stainless steel met the needs of the wine industry, there was room for improvement.

"Stainless steel demand exceeds supply on occasions," he said. "It is not totally corrosion resistant and requires diligence in the specification and fabrication process."

The Karadoc project is one example of current growth in the Australian wine industry, which has brought with it exciting opportunities for the stainless steel industry.

Domestic wine production has increased five fold since 1966, from 156 million litres to over 800 million litres.

Vision 2025, a strategic plan by the Australian wine industry, aims to make the industry a global force by achieving $4.5 billion in annual sales of wine and 6.5% of the value of world production by 2025.

Results to date have been positive, with 1999 total sales estimated to be approximately $2.4 billion and 3.5% of the world export volume.

The number and size of fabrication firms in wine growing regions is expanding and as such, real opportunities to explore new applications and methods of design, fabrication and maintenance exist.

To assist the wine and stainless industries meet their objectives, ASSDA is conducting "Using Stainless Steels in the Food Industry" seminar in May and June which will cover fabrication, corrosion, welding, cleaning and sanitation issues for stainless steel use in the food industries as well as issues specific to the wine industry.

For more information on ASSDA's "Using Stainless Steels in the Food Industry" Seminars, please contact ASSDA on (07) 3220 0722.

REFERENCES
1. Australian Wine Foundation (1996) Strategy 2025 - The Australian Wine Industry.

This article featured in Australian Stainless magazine - Issue 15, February 2000.