Stainless steels are widely used in the food industries, including wine production, because of their corrosion resistance and ease of cleaning which result in negligible product contamination.

Long life can be expected from stainless steel equipment provided care is taken with:

> Vessel design
> Grade selection
> Fabrication procedures
> Maintenance practices.

The precautions to be taken are not complicated but are most important - neglecting to follow them can lead to rapid failure.

VESSEL DESIGN
Much can be done in the detailed design to improve corrosion resistance. The two cardinal rules are:

1. Design for complete and free drainage
2. Eliminate or seal weld crevices.

A series of drawings, with accompanying narrative, comparing good and bad design practices, are set out in Part Ill of Nickel Development Institute publication #11 007: Guidelines for the welded fabrication of nickel-containing stainless steels for corrosion resistant services.

GRADE SELECTION
Two stainless steel grades are particularly used in the wine industry, grades 304 and 316, and both 'standard' and 'low carbon (L)' versions are available. Their compositions are shown in Table One below.

The 'L grades are specified w here welding is to be carried out and there is concern that time-at-temperature may be sufficient to precipitate chromium carbides and hence cause sensitisation of the metal, resulting in susceptibility to intergranular corrosion.

The molybdenum content of grade 316 significantly improves its resistance to p1tting and crevice corrosion, particularly in the presence of chlorides. It also increases the material cost by about 20 to 25 percent.

For handling waters, grade 304 is satisfactory up to about 200 parts per million (ppm) chlorides, while grade 316 can be used up to 1 000 ppm chlorides.

Tartaric, acetic, tannic, malic and citric acids are not corrosive to stainless steel at the concentrations found in juices or wines. However, the level of su lphur dioxide is an issue. Grade 304 is generally regarded as resistant to corrosion when immersed in juice or wine at free SO2 levels up to 700 ppm. Above this, grade 316 is recommended. The problem is greater in the vapour space where sulphurcontaining acids can form. Grade 304 is not recommended for use in areas where there is more than 75 ppm SO2 in the liquid. This can lead to composite tanks using grade 316 in the ullage zone and grade 304 in the submerged zone.

FABRICATION PROCEDURES
Cracks and crevices in stainless steel welds can act as initiation points for pitting and crevice corrosion. They can also result in product contamination . The aim should be for smooth weld beads without porosity, slag inclusions or undercut.

During the welding of stainless steels, 'heat tint' is formed. This is a high temperature oxide, rich in chromium which has been drawn from the stainless steel. The result is a very thin low-chromium layer on the underlying stainless steel surtace. For best corrosion resistance, both the oxide film and underlying chromiumdeficient layer must be removed. This can be done by pickling using a nitric/hydrofluoric acid mix, either in a bath or as paste, or by mechanical removal.

Since stainless steel depends for its corrosion resistance on the presence of an extremely thin, continuous chromium oxide film, any contaminants which disrupt this film will reduce its corrosion performance and can initiate pitting. A common contaminant is embedded iron particles from nearby grinding of carbon steel fabrications or the use of iron-contaminated tools. Such contamination can be removed by passivating the stainless steel with nitric acid, followed by a thorough water rinse.

After hydrotesting and before being put into service, tanks should be drained and thoroughly dried. There are too many instances of new stainless steel systems failing due to pitting or crevice corrosion because either:

> Contaminated test water has been left stagnant in the system, or
> The system has been drained but not dried, leaving pools of water to evaporate, concentrating dissolved salts and resulting in corrosive attack.

MAINTENANCE
Stainless steel is inherently a low maintenance material - but it is not zero maintenance. The main requirements are:

> Deposits which build up on stainless steel surfaces should be regularly removed. This is because crevices exist under deposits and crevice corrosion can be initiated in such areas.
> Following cleaning, regular inspection is necessary to establish the condition of the equipment. This will ensure early detection of any developing problems so that steps can be taken to prevent further deterioration.

If guidelines such as these are followed, long and trouble free service can be expected from stainless steel equipment.

Words by David Jenkinson from the Nickel Development Institute.

This article featured in Australian Stainless magazine - Issue 18, May 2001.

A stainless steel stackable wine storage and fermentation system has been adapted to carry water for use in hospitals. 

STAKVATs feature internal temperature control tubes and a sloped design for complete drainage and radius corners for protection against crevice corrosion and bacteria collection.

Each vat has a storage capacity of 900 litres, can be stacked five high and easily transported on a tray truck. They are also fork-liftable four ways.

The vats are made from grade 316 stainless steel sheet and grade 304 tube. Standard BSM grade 316 fittings are used for the outlets, with door handles and locking pins made from grade 304.

The original STAKVAT design featured replaceable French and American Oak sides used for wine enhancement. The modified STAKVAT has a stainless steel side instead of oak, but maintains the cooling/heating tube system and sloped design.

Oxygenated water is created in the STAKVAT via the airspace in the top of the vat. The water will be circulated through a system of STAKVATs at approximately 30 litres per minute.

Managing Director of Ausvat, Peter Warren said the STAKVAT helped meet an industry need for efficiency in storage space.

"Stainless steel internal cooling systems and the space saved by using STAKVATS produces many cost-effective advantages," Mr Warren said.

Stainless steel for the STAKVATS were supplied by ASSDA member Stirling Stainless Steel, with fabrication by ASSDA members Simcraft Products and Unique Metal Works Pty Ltd.

This article featured in Australian Stainless magazine - Issue 18, May 2001.

Nearly four tonnes of stainless steel has been used to extend and upgrade facilities at Cape Clairault Winery in Western Australia's Margaret River region.

The project involved the installation of four 5 000 litre red wine hopper fermenters, four 12 000 litre and one 4 500 litre white wine storage tanks and the upgrade of 15 existing tanks of 1 000 -12 000 litre capacities.

Each hopper has a 20 degree sloping bottom to allow complete drainage after service. The design reduces the need for manual cleaning, a potentially dangerous practice due to the build-up of carbon dioxide in the enclosed tank space.

The white wine storage tanks have a conical bottom, also for drainage, and a two piece controllable heating/cooling system constructed from grade 316 stainless steel high pressure cavity plate. If the tank is only half full, refrigeration can be pumped through just the bottom cavity plate.

The cavity plate, constructed by ASSDA member Simcraft Products also features off-centre dimples for greater distribution of the cooling brine.

To convert the winery's existing tanks from storage to fermentation, high pressure cavity plate and temperature probes were added for cold stabilisation, while one of the 5 000 litre tanks was converted to a fermentation hopper.

The tanks were fabricated or upgraded with grade 316 stainless steel in coil, with all welds acid cleaned with post-fabrication polishing to ensure greater corrosion resistance.

The tanks were fabricated in sections then joined together, stacked one on top of the other. Plug welds were used to reduce the risk of cracking at contact points and for improved corrosion resistance.

Simcraft Products undertook all fabrication for the project. Stainless steel and stainless steel components for the tanks were supplied by ASSDA member Austral Wright Metals.

This article featured in Australian Stainless magazine - Issue 18, May 2001.

A combination of grades 304 and 316L stainless steel has been utilised for all contact surfaces in Murray Goulburn's milk processing plant in Rochester, Victoria, which was upgraded in 2000.

The plant comprises an evaporator to concentrate cow's milk and spray dryer to produce various milk powders. Approximately 100 000 litres of milk is processed per hour, with the majority of product for export to over 100 countries. The evaporator and dryer represent more than half of the total project, a capital investment of around A$50 million.

The stainless surfaces and components carry milk feed, evaporated vapour, milk concentrate, milk powder, hot drying gas and cleaning chemicals of alkali and acid.

All product contact surfaces are of austenitic stainless steel grade AISI 304, with the 12m long evaporator tubes being produced from strip then rolled with the seam welded and bead rolled; the tubes have a 2B internal finish.

Principal contractor Niro Australia received instructions to proceed in July 1999 and conducted the first powder trials 14 months later, with commercial production starting November 2000.

To carry out the project, Niro involved Victorian fabricators Stainless Technology and PLC Engineering, though some fabrication was also conducted in New Zealand.

ASSDA member Alfa Laval supplied food grade stainless steel pumps, process valves, tank equipment, fittings and tubing worth over $2.5 million. The total supply was in excess of 40 tonnes and included 40km of tubing in sizes 1" to 6".

Grade 316L stainless steel was used for wetted parts (parts in contact with process fluids) and 304 for non-wetted areas. Products were generally supplied with a no.4 external surface finish; AS 1528 was used as the guideline for component standards.

Many of the process pumps and valves were chosen for their product handling characteristics. Specialist mixproof valves, which allow two different products to travel through the same valve without fear of intermixing, and high efficiency pumps were selected. Spillage-free mixproof valves were specified to prevent accidental discharge onto process floors and ensure a clean process environment, and rotary lobe pumps were selected for their gentle handling of cream products.

Pre-fabrication of many of the valve and pipework assemblies was carried out off-site in controlled environments. Due to the critical nature of the process applications, importance was placed on welding techniques and subsequent cleaning of welds. Valve manifolds were pre-fabricated and transported to site on completion, minimising the number of critical welds performed on site.

TOMATO PROCESSING
Fifty thousand tonnes of tomatoes have passed through Ardmona's processing plant in Mooroopna, Victoria, since it began operation a year ago.

The $15 million plant, which produces whole peeled and crushed tomatoes, was constructed entirely in stainless steel using grade 304 for the structural components and 316 tube and fittings for the wetted parts. Stainless steel was specified for its corrosion resistance and low maintenance, and to meet the health and safety requirements of a food processing plant.

Designed with a life expectancy of 30 years, the plant is capable of processing 40 tonnes of tomatoes per hour.

Ardmona's Engineering and Production Department, in conjunction with Italian firm Sasib Foods, were responsible for the design, engineering and construction aspects of the nine-month installation.

This article featured in Australian Stainless magazine - Issue 20, February 2002.

A contaminant-free surface is a critical requirement of the food processing sector and electropolishing is a highly effective way to achieve the level of surface smoothness required for keeping stainless steel components scrupulously clean. 

Pillsbury Australia in Melbourne's outer east is one of a growing number of food processors who have opted for electropolishing for hygienic and durable stainless steel components. Pillsbury produces the fresh pasta brand Latina Fresh. The range consists of filled pasta types like ravioli and tortellini for which the fillings are cooked during manufacture, but the consumer completes the cooking process at home. For some years now, Pillsbury has specified an electropolished finish for all its stainless steel food preparation equipment and related components such as trolleys, cooling racks and other fittings. These are manufactured by GP's Fabrications and electropolished by ASSDA member MME Surface Finishing.

As well as promoting hygiene, electropolishing enhances stainless steel's corrosion resistance. Many fittings in Pillsbury's plant have been in constant operation for eight to ten years and show no sign of surface deterioration despite exposure to steam-laden, high temperature atmospheres.

Electropolishing works by selectively removing surface metal thereby smoothing and levelling the stainless steel. This is done by immersing the component in a chemical bath to which lowvoltage electric current is added. Stock removal is controlled to a high degree of accuracy by adjusting the time, temperature and current density.

The resulting finish is free of surface flaws and impurities, giving no opportunities for deposits to lodge and contaminate the food product. A further benefit is that it makes the components easier to keep clean, allowing for longer periods of processing activity.

This article featured in Australian Stainless magazine - Issue 22, September 2002.

A new technique for manufacturing high pressure cavity plate for heat exchange applications developed by the Australian stainless steel industry increases the options available to the food processing and manufacturing sectors. 

'Laser welded cavity plate' has been developed by ASSDA member J Furphy & Sons, a Shepparton fabricator of stainless steel tanks and processing equipment, as an alternative to resistance or plug welded dimple plate used for the heating or cooling jackets on stainless steel tanks, vessels and silos.

A wide range of industries stands to benefit from the new cavity plate, from dairy, brewing, food, wine, pulp and paper, chemical, pharmaceutical, refrigeration to textiles and manufacturing.

It is designed to be used in jacketed tanks, pressure vessels, shells and heads, troughing, chutes and hoppers, immersion plates, bank assemblies, baffles, ice-making plates, water chillers and food cookers.

The method of manufacture allows design flexibility enabling it to be tailored to specific performance requirements. It can be designed to suit both the flow characteristics of the refrigerant or heating medium and the required performance objective for the equipment by programming the cavity pattern and dimensions into a CNC controlled laser welding system.

The process involves laser welding two sheets of stainless steel in their flat form and inflating to form the cavity through which the cooling or heating medium is transferred.

The laser welds are exceptionally strong and have been burst tested in excess of 13 000 kPa, with most common demand being for operating pressures between 300 and 3 000kPa.

The product is available single embossed for uses where a flat inner wall is required or double embossed for immersion where both sides of the plate are utilised to heat or chill.

It is in use in chocolate crucibles in the confectionery industry as well as in Peerless Holdings’ edible oils processing tanks. Orbis Engineering has used the cavity plate in a cooling tunnel conveyor bed and Barry Brown & Sons has utlised it in on-farm milk silos. It has also been used in various major winery projects, including Peace Wines and Jindalee Estate, for fermentation and storage vessels.

Another ASSDA member, A&G Engineering of Griffith, has specialised in cavity plate for use as a cooling plate in wine vessels for a number of
years. This product also incorporates technology unique to Australia.

This article featured in Australian Stainless magazine - Issue 22, September 2002.

The Australian construction and food processing sectors can specify stainless steel tube in large sizes with confidence in its quality and timely delivery, now that local production has commenced at a Victorian plant.

Manufacturing by an Australian firm will also make it easier for specificiers to communicate their special requirements.

Stainless Tube Mills' special purpose factory in Melbourne’s outer east is producing longitudinally welded tube in diameters up to 300mm and wall thicknesses up to 8mm – the largest seamwelded stainless steel tube available in Australia. Tube in this size range has always been imported.

The recently commissioned draw mill, designed in house by ASSDA member STM in conjunction with CSIRO, joins twelve other mills on site which produce welded tube up to 101.6mm outside diameter.

While a conventional mill uses a drive mechanism to feed the strip through the mill and produce welded tube, in the draw mill strip (1) is drawn through the mill with the forming rolls idling (2 & 3). This has the effect of producing a tube with minimal roll forming marks, as well as precise tolerances. The internal weld bead (4) is rolled to merge with the parent metal producing a smooth bore. Externally, the polished finish renders the seam all but invisible.

The smooth interior finish means tube produced on the draw mill is ideal for transfer of processing fluids, particularly food products, where the clean internal bore is mandatory.

Large diameter tube is also finding application architecturally for balustrades, barriers and structural column formers. As formers they make an attractive alternative to brick or concrete,
delivering a superlative appearance and impressive structural strength, which can be further bolstered by filling with concrete. STM used 300mm columns in T304 alloy to dramatically enhance its own office façade (left).

The draw mill has only been in operation commercially for a short time, however STM reports there has already been considerable demand. The firm's future plans include production of heavy walled large diameter sectional tubes for architectural applications.

This article featured in Australian Stainless Issue 21 - June 2002.

 A major new development project at the Jindalee Winery at Moorabool near Geelong utilises over 100 tonnes of grade 304 2B finish stainless steel.

Shepparton’s J Furphy & Sons fabricated 95 wine storage and fermentation tanks, ranging in size from 75,000 to 1,200 litres.

The new tanks provide almost three million litres of temperature-controlled storage capacity for grapes processed from the adjoining vineyard and a much larger vineyard which Jindalee’s owners, Vince and David Littore, operate in the Murray Darling region near Mildura.

Three years ago the Littore Brothers acquired the former Idyll Vineyard and winery at Geelong which they are now using as the production centre for their wines produced under the Jindalee and Fettlers Rest labels for both local and export markets.

In addition to the tankage, most of which features the new Furphy Laser Welded Dimple Plate design which provides the cooling jackets to the tanks for circulation of refrigerants, Furphy’s have also completed more than 350 lineal metres of galvanised walkway and tank access systems.

Jindalee’s winemaker Scott Ireland describes the project as a state of the art winery facility designed to produce wines which will appeal to the most discerning palates as well as capitalising on and growing the export market success already achieved under the Jindalee label.

A $1 million bottling hall and packaging facility will be added providing a fully integrated facility.

This article featured in Australian Stainless Issue 21 - June 2002.

Posted 1 July 2003

John Hodgkinson is mad about hams! The managing director of ASSDA member Smo-King Ovens really loves his products and is passionate about helping butchers generate more business through their use.

You may not have noticed these stainless steel ovens that are an important element of nearly every quality butcher shop in Australia. Just as you can tell a good patisserie by their éclairs, you can tell a good butcher by their smoked hams!

Of 304 stainless steel construction, Smo-King ovens are used extensively for smoking and cooking hams, bacon, roast meats, poultry, fish and a wide range of smallgoods. Cakes and pastries can also be made in one oven which can operate at temperatures high enough to allow baking.

“The 304 stainless steel ensures that the ovens are corrosion and stain resistant”, says Hodgkinson. “It also means they are very durable, easy to clean and many health and food safety authorities insist that stainless steel is used in all food processing applications if the equipment comes into contact with the food as it does in a smoke oven – plus it fulfills our requirement for high quality while still providing acceptable cost.

“I’ve been longing to make my own smoked products”, says Wally Dafter. Dafter’s Quality Meats is located in Charmhaven on the NSW Central Coast. “We have one Smo-King oven which operates at least four days a week and currently we produce 10 different types of smoked goods”, he says.

“We reckon our smoked foods are really good”, enthuses Dafter who is planning to enter them in the 2004 Royal Easter Show.

John Hodgkinson believes Smo-King ovens are about 70%-80% of the price of European ovens with similar features. “These ovens definitely allow our customers to add value to their products and their business”, says Hodgkinson.

This article featured in Australian Stainless magazine - Issue 25, July 2003.

Posted 1 July 2003

Consumers expect processed foods to be tasty and nutritious, affordable and safe. To meet these expectations, food contact equipment has to be hygienic and productive.

A manufacturer’s wish list for its food processing components might read like this:

>    durable, with easy release and easy-to-clean surface
>    inert, non-toxic and non-contaminating
>    corrosion-resistant and non-degrading
>    suited to continuous, in-line sanitation and cleaning
>    impervious and non-absorbent to food products, odours, stains and colourings
>    economical, reliable and safe over its entire working life
>    temperature versatile and highly conductive, eg from cooking to cryogenic temperatures
>    smooth, seamless, one-piece construction
>    removable and replaceable
>    repairable/maintainable by existing technologies.

At first sight this seems too much to ask of any single product, but stainless steel conveyor belts fit the bill.

Unique Belting for the Food Industry
Continuous carbon steel belts were introduced into US and European bakeries in the 1920s and are today used primarily for processing baked goods. ASSDA member Sandvik launched a stainless steel belt in 1931 to withstand wet or corrosive conditions in the food and chemical industries.

The product found a foothold in the market and increasingly since the 1960s, the stainless steel belt has moved from being a simple food conveying medium to a processing platform. Now ranging in width from 200mm up to several metres and in solid or perforated forms, stainless belts are used in cooling (chilling, freezing, pastillating, freeze drying), heating (drying, roasting, blanching, steaming) and mass transfer (dehydrating, aeration, dewatering) for value added processing of foods. Stainless provides superb temperature versatility, from -200ºC (in cryo-freezing belt tunnels) up to +300ºC (high-temperature cooking tunnels). It can be continuously sanitised during operation using zoned washing boxes fitted to the lower strand of the belt.

The smooth, continuous stainless belt is also versatile in the types of food product it can convey and process – powdery, granular, fragile, bacterially-sensitive, sticky, viscous, sharp, pasty, slurry, runny, chunky, awkward, hot, oily … you name it, chances are it can be handled by the stainless belt. Accordingly, the stainless belt has found application over wide areas of wet food processing – for dairy, confectionary, meats, seafoods, pet foods, beverages, snack foods, frozen foods, fruit, vegetables and nuts.

Quality stainless belts for the food industry are solid, continuous, smooth and seamless and free of links, hinges, pins, weaves or anything that could trap food residues, dirt and bacteria.

Textured Stainless Brings Increased Efficiency

Case Study 1 - GP Graders
Melbourne-based GP Graders has captured the attention of fresh fruit packers around the world with its innovative grading and packing lines which utilize textured stainless by ASSDA member Rimex Metals.

Its machines, exported to the US, Chile, Switzerland, Norway, Turkey and Spain, are predominantly fabricated from stainless steel sheet and square tube, incorporating textured stainless steel sheet.

Rimex textured 6WL is used under flat conveyor belts and in ‘dead’ areas to reduce friction (wet belt adhesion) and eliminate product build up. The increased rigidity has enabled the company to reduce sheet thickness and fabrication time, which previously required labor-intensive friction reduction techniques. The end result is a lighter and more cost effective product.

GP Graders was established in 1963 to design and manufacture grading and packing equipment for the cherry, pome fruit, citrus, stone fruit and mango industries.

Case Study 2 - Tripax Engineering
Melbourne-based Tripax Engineering has been a major supplier of industrial food processing machinery in Australia for over 30 years, servicing the fresh vegetable, fruit, salad, potato, cheese, cereal/snack food, and frozen food industries and more.

Its diverse client profile ranges from large multinationals to small vegetable growers, and current export markets include the UK, New Zealand, South Africa, and Denmark.

The majority of equipment is purpose designed and manufactured. During the design process, special attention is paid to matching the type of stainless to the product type, whether sticky, wet, powdery, warm and so on. Rimex textured 6WL pattern is often selected for its low adhesion which reduces the chance of product build-up. It also provides extra strength and rigidity in vibratory conveyor equipment.

From washing equipment for the salad industry, to cheese shredders, abrasive peelers and cutting equipment, all Tripax equipment is made to food industry standards and incorporates high-grade stainless steel, food grade plastics and ancillary parts.

Serving the Australian Food Industry
The multiple benefits of stainless belt technology have assisted the development of new food products and will doubtless continue to do so.

As well as making the stainless belts, Sandvik Process Systems also designs, builds and services complete steel belt equipment. In parallel, within Australia, services in stainless steel belt technologies are available from Process Systems Services (PSS) in Sydney and Industrial Marketing Services in Melbourne, with the former having design, light fabrication and maintenance capabilities. Rimex Metals textured product is distributed by ASSDA member Fagersta Steels.

Words by Russell Jackson and Neil Lyons.

Image on left courtesy of Sandvik Steel.

This article featured in Australian Stainless magazine - Issue 25, July 2003.

Lightweight stainless steel construction has allowed the proprietor of a Tasmanian cafe to expand operations without building new brick and mortar premises.

Page’s of the Mall is a stainless steel satellite to an existing cafe located in the busy Launceston Mall. Custom built for the site, it has proved popular and profitable since opening shortly before Christmas 2002.

The client, Mark Page, approached Launceston fabricator FAME Foley Industries with a particular brief: to construct a portable cafe catering to both take-away and sit-down trade which met standard refrigeration, food preparation and hygiene requirements. The unit had to conform to local Council guidelines and match the awnings recently installed in the Mall.

PACK UP AND MOVE

The challenge was to produce a design measuring just 2m high by 1.9m wide and 5.5m long to be wheeled into Page’s main shop at night.

The design evolved over the course of a year with input from a Launceston Council architect and took two months to build. The unit unpacks to a height of 2.5m when the roof is unfolded forming wing-like canopies above the serving areas, and the sides open out to 2.8m in width.

Concealed wheels at one end allow the unit to be moved using an electric pallet lifter. It is positioned over a pit with access via a hatch to water, power and drainage.

A seating area is enclosed by stainless steel barriers clad with laminex signs arranged in a zig zag shape for strength. These are also completely portable and have lockable castors.

Inside the cafe, which has garnered the nickname ‘coffee tram’, stainless steel pie heaters, fridges and washing facilities are built in as integral parts of the unit. Fully enclosed stainless steel trolleys are used to transport supplies from the main cafe.

PRACTICAL AND ECONOMICAL

Stainless steel was chosen for the project both for its clean style and for its appropriateness to the design and usage. The construction is simultaneously lightweight and strong, allowing it to be wheeled around daily and to withstand the mall traffic. Hygiene is readily maintained with easy to clean food preparation surfaces.

Most of the unit, including framework, walls, benches and supports are made from grade 304 stainless while grade 316 is used for the roof as it is exposed to the weather. The fridges, part of Foley’s range of kitchen and bathroom ware, are made from grade 430. Stainless steel was supplied by ASSDA member Atlas Steels.

Costs compare favourably with erecting a permanent building, at around $100,000 to construct and fit out, and the concept can be adapted to suit other locations.

The article featured in Australian Stainless Issue 24 - March 2003

PDT Architects, Brisbane in association with HOK Sport, Venue and Event designed and documented the $280m Suncorp Stadium for the Queensland Government.

"It is the top grade material and that's what we wanted for the stadium...

When you take that the client is the people of Queensland, they expect the best to go into the stadium.

If they're paying $280 million for a stadium they want the thing to last and stainless will give you that longevity."

Director, John Brown of PDT Architects described the pros and cons of specifying stainless steel for the redevelopment of Lang Park (Suncorp Stadium).

Ticket Counters
When PDT Architects expressed concerns by Ticketek staff that stainless steel ticket counters would be too glary, ASSDA provided the necessary technical assistance required and prevented a switch to timber material.

JB: The client talked about changing from stainless to timber because Ticketek and others had commented that stainless steel would be too glary.

We found that we could use a brushed finish which wouldn’t throw up too much glare and we also did some sun shade diagrams and all sorts of diagrams to make sure the sun wasn’t hitting the ticket counters.

Full Stainless: Commercial Kitchens
JB: It was always going to be stainless steel, mainly because of the health reasons ... but also for cleaniness and ease of cleaning.

All the commercial kitchens at the stadium have them. All the finishing kitchens, all the food outlets, beverage and of course the main kitchen. All the food is prepared in that kitchen and taken up through the service lifts into the finishing kitchens, warming kitchens and then out into the public.

Stainless Wire Rope for Visibility
PDT Architects has recommended replacing the stadium’s flat bar rails with stainless steel wire rope to improve visibility.

JB: We've been able to convince the State Government code people that we can take a lot of the galvanising rails out and put in stainless steel wire rope which would give a better view.

We’ve put in a report to the Government whereby we can cut out a lot of these flat bars and put in stainless steel wire rope through them which will just open the whole place up.

Stadium Stainless Statistics
ASSDA member Fagersta supplied 60 tonnes of stainless steel coil of various widths and thicknesses to ASSDA member Tom Stoddart. A further 10 tonnes of stainless steel was supplied to Eziform for gutters and box gutters.

Tom Stoddart produced works at a cost of $11 million and approximately 50,000 man hours including full kitchen and bar fitouts, refrigeration units, cash register stations balustrading and some food service equipment.

Fagersta was also the main supplier of stainless steel for Colonial Stadium in Melbourne and Telstra Stadium in Sydney.

The Post Game Wrap-Up
JB: Firstly, it satisfied us as far as an architectural feature went, it satisfied us as far as life cycle went and most certainly it then satisfied us as far as safety issues went.

This article featured in Australian Stainless magazine - Issue 26, November 2003.

Brewed for Efficiency

When Carlton & United Breweries (CUB) announced plans last year to expand production capacity at the Yatala site in Queensland, the company considered both purchase of new stainless tankage as well as transfer of tanks from its Sydney brewery and re-use of second hand tanks in its inventory.

 Six such vessels had been stored by CUB on leased land in the City of Redcliffe, unsealed and exposed to the weather.

Constructed in 321 stainless, the 3 x 12 metre tanks were out of service for the last ten years and placed in the yard for future use.

The six beer storage tanks are part of a series of 16 tanks built in 1966, that have proven the test of time and reinforced the material's durability and returned back to service 'as good as new'.

ASSDA member, D & R Stainless was approached to upgrade the six 1,000 hectalitre (hl) vessels to the new fittings with design verification and tested to meet AS 1220 Standard.

The Brisbane-based fabricator modified, checked and tested the beer storage tanks so as to meet CUB's exacting standards for beer production which would include popular CUB brands such as VB, Fosters Lager, Carlton Midstrength and Crown Lager, allowing them to be used as part of the ongoing expansion.

Work on the six tanks involved cleaning down and refurbishing with new stainless steel tubes and fittings supplied by Matrix Process Solutions.

The six tanks were taken to D & R Stainless and pumped with 4,000 litres of water constantly through the system and back through the CIP spray balls so that all of the tank area was wet to see if there was any carbon steel pick up.

All tanks were checked thoroughly for any rust spots and repolished where required. New nozzles were also installed and internally polished.

D & R Stainless Manager, Ray Powell was initially concerned that the carbon steel supporting rings around the vessel would bleed through onto the stainless as there were no compensating plates.

"We only had one tank [the first tank] that had a problem and that was laminating in the heat effected zones. And that was only on one tank on the bottom of the seams, so we came back in and dye checked, found the problems, ground back and repaired," Mr Powell said.

"The quality of the tank is in good condition. The beauty of stainless is that if it's looked after it will last forever and proof's in the pudding, they're coming up nearly 40 years old - they've certainly proved the test of time," he said.

The expansion of CUB's Yatala facility follows an announcement in April last year of the closure of the Kent Brewery in NSW by February 2005.

This operational review will see the relocation of over 50 beer fermentation and storage tanks from Sydney, a brand new twin stream brewhouse and new filtration equipment to the Queensland facility, which is CUB's most efficient brewery. Total project cost is around $170 million.

As a result of the review, the Yatala facility will double its capacity from 230 million litres of beer a year to over 500 million litres.

Despite being out of service for more than a decade, the excellent condition of the tanks ensures that stainless steel has significantly contributed to product quality and cost efficiency for Carlton & United Breweries long into the future.

This article featured in Australian Stainless magazine - Issue 27, February 2004.

Built on Reputation

Alistair Patterson has a flair for the food and beverage industry that borders on obsession. As the sole proprietor for ASSDA Accredited Fabricator, Australian Stainless Products, Patterson's reputation within the industry means when projects are on, he is onto it!

Australian Stainless Products are custom manufacturers of quality stainless steel food, beverage and pharmaceutical process products and equipment.

Established more than 20 years ago, Australian Stainless Products started out building basic dairy machinery, primarily small repairs and maintenance of equipment for a few of the local food processing equipment plants.

“Back then the business was basically building milking machinery. We did small repairs and maintenance and equipment for a few of the local food processing plants in the area.”

Now, the Melbourne-based company manufactures original equipment from large tanks, vessels and hoppers including process equipment up to 50,000 litre capacity.

Working with a small but loyal client base, Patterson has worked with some engineering consultants such as dairy equipment supplier DeLeval for more than a decade.

“It's quite a small industry. We operate by word of mouth and references of jobs. It takes a long time to build, grow and develop a business within this industry,” said Patterson.

This article featured in Australian Stainless magazine - Issue 35, Autumn 2006.

As a general rule, the waste management method adopted for disposing of radioactive substances is critical. The main method of disposal is the dilution and dispersion of radioactive wastes using stainless steel equipment such as isotope flushing sinks

Last year, the University of Western Australia's School of Biomedical, Biomolecular and Chemical Sciences moved into the new $65M Molecular and Chemical Sciences building with state-of-the-art laboratories and equipment.

Generally, the materials used in biological sciences research work contain low radiotoxicity substances, however, full precautions are taken to ensure safe handling.

As part of the School of Biomedical, Biomolecular and Chemical Sciences upgrade, many of the laboratories were fitted with a number of isotope sinks and flushing isotope sinks fabricated by ASSDA Accredited Fabricator, Simcraft Products.

Isotope flushing sinks are designed to prevent splashing and to allow for the gradual flow of waste liquid into a stream of waters as it runs to waste.

Simcraft Products fabricates the sinks in 1.2mm grade 316 stainless steel with satin finish to the Australian Standard, AS2243.4.

Isotope flushing sinks feature an absolutely splash free flush action with a non-turbulent continuous curtain of water for a total surface wash and can also be custom built for hospitals, medical centres and laboratories.

This article featured in Australian Stainless magazine - Issue 35, Autumn 2006.

Australians really enjoy a good beer - at home barbeques, parties, music concerts, sporting events - in fact, everywhere!

World beer consumption is increasing by more than two per cent a year, a trend that is set to continue. There is an important relationship with beer consumption and demand for its main and critical ingredient - malt.

Malting is the partial germination and kilning of a grain, usually barley. Malt gives varying colour, flavour and body to beer depending on the style of malt being used.

Australia is a key player in the world market representing about 32 per cent of world trade in malting barley and 12% of the world malt trade.

Joe White Maltings, an ABB Grain Ltd company, is Australia's largest malt producer with eight malting plants Australia-wide with a capacity to produce 500,000 tonnes annually.

An expansion at the company's Perth plant in May 2006 saw production capacity more than double from 90,000 tonnes to 200,000 tonnes.

As the largest malting facility in the southern hemisphere, the Perth plant features stainless steel vessels throughout with cylindrico-conical steep vessels, circular germination vessels, a separate circular kiln, full automation and in-place cleaning.

ASSDA member, Stirlings Australia sourced more than 155 tonnes of grade 304 stainless steel with 2B finish from ASSDA Major Sponsor, Outokumpu Stainless for the expansion. Stirlings Australia also used its hi-definition plasma cutting service for processing of material ranging from 2mm to 20mm thick sheets by 1200,1500 and 2000mm wide plates.

The Perth-based global metals distributor also supplied more than $150,000 worth of stainless steel to Built Environs subcontractors for the fabrication of the project.

Press Construction Services were supplied with various grade 304 stainless steel pipe, plate, angle and flats including processing of all plate material for the fabrication of six steep vessels.

ASSDA member, Austline Fabrication of the Foodline Group of Companies was supplied various grade 304 stainless steel sheet, plate and angle for the fabrication of fan ducts and kiln hoods.

From this expansion, Joe White Maltings are able to meet increased demand from producers of most Australian beers and for the major brewers throughout Asia.

This article featured in Australian Stainless Issue 36, Winter 2006.

Hygiene and the 'cleanability' of equipment used in the production of food are paramount. The widespread use of stainless steel equipment in the food industry goes some way towards ensuring these criteria are met - but the assurances provided by stainless steel are only as good as the fabrication quality of the equipment.

Following a presentation at ASSDA’s annual conference in 2003 on the quality of food fabrications, particularly in the dairy industry, it became apparent that fabrication specifications, if they existed, were often inadequate and inconsistent.

As a result, ASSDA launched a co-operative venture, working closely with many fabricators involved in the food industry, to create the recently released "ASSDA Food Specification: Fabrication and Installation of Stainless Steel Process Plant and Equipment in the Food and Beverage Industries".

The title may be complex, but the intention is simple: used in conjunction with ASSDA's Accredited Fabricator Scheme, it will standardise fabrication practices in Australia and improve efficiency and reliability by raising the standard of quality delivered.

ASSDA's Food Spec is not intended to replace accepted national and international standards. Instead, it reflects their requirements in the design and fabrication process specifically for food and beverage plant. The specification is intended as a step forward from the more generic advice offered by the well-known "Blue Book", published ASSDA's sister organisation NZSSDA.

The Food Spec supplements the purchaser's specification and contract, with the purchaser's performance criteria and the supplier's design being the default conditions. There are prescriptive sections, such as those relating to spacing for access or acceptable levels of heat tint. However, best practice is flagged with the expectation that a contrary decision must be well supported. The consistent theme throughout is the delivery of cleanable surfaces in a hygienic environment.

The specification can be broken into four sections:

1. Scope, definitions, interpretation, document hierarchy and suppliers systems required.
2. Design requirements with both general rules and specific items for process equipment, process piping and other piping;
3. Fabrication requirements for:
   
   • overall necessities of grade, materials care, welding and finishing procedures;
   • process vessel fabrication, whether by the supplier or others;
   • the handling, welding and finishing of process tubing at ambient or elevated pressure; and
   • the fabrication of non-product contact pipework at low or high pressures.
4. Practicalities such as transport, installation, commissioning and insurance.

The specification includes two appendices that list relevant standards and a discussion on the pros and cons of autogenous and filler metal sue in welding of tubing.

There is no doubt that ASSDA's Food Specification fills a void in the food industry. It is now up to operators in the industry to use it to improve practices in both their own businesses and the industry as a whole.

Copies of the specification are available from the ASSDA office on (07) 3220 0722. Details of the complementary Accredited Fabricator Scheme are available from www.assda.asn.au

This articles was written bu ASSDA's technical advisor, Graham Sussex.

The ASSDA Food Specification has drawn on the work of many operators in the industry and their assistance in time and documents is gratefully acknowledged.

This article featured in Australian Stainless magazine - Issue 37, Spring 2006.

Loss in production due to installation of new equipment is always undesirable, which is why an upgrade on the scale of Australia Meat Holdings’ recent boning room expansion at Aubigny (west of Toowoomba, Qld) was even more remarkable.

The project, managed by Wiley & Co, more than doubled the size of AMH’s existing boning room, improved work place ergonomics and provided for future growth – all without interruption to production.

The expansion incorporated more than $4 million worth or 100 tonnes of stainless steel, around half of which was fabricated by ASSDA Accredited Fabricator G & B Stainless from Crestmead, Qld.

G & B Stainless director John van Koeverden said their company’s work on the project involved 20 to 30 people in their workshop and eight people on site for around 5 months.

The company fabricated and installed the majority of conveyor equipment, including the product conveyors, empty carton conveyors and packed carton conveyors.

Mr van Koeverden said mainly 304 and some 316 stainless was used for the double and triple tier conveyors.

“One of the unique features of the job was the two 60 metre long boning conveyors and integral slicing tables, which we designed specifically for this application,” he said.

“The tables incorporate over 100 stations and feature pneumatic lifts to raise the tables up to 90 degrees for ease of cleaning.”

G & B Stainless used a glass bead blast finish over most of the stainless steel, primarily to remove weld stain and further enhance the hygiene features of stainless steel.

Wiley & Co project engineer Scott Hebbard said the fact that G & B Stainless was ASSDA Accredited played a role in their selection to fabricate the majority of the stainless steel equipment in the new boning room.

Four other fabricators shared the remainder of the work, including the fully enclosed walkways and the conveyors up to and taking away from the vacuum packing equipment.

This article featured in Australian Stainless magazine - Issue 37, Spring 2006.

Twelve months after the design and installation of a unique cabbage processing system in Melbourne, the importance of quality stainless steel fabrication has never been clearer.

ASSDA Accredited fabricator Bridgeman Stainless Solutions (Brendale, Queensland) was commissioned to design the unique facility at Mrs Crocket's Kitchens, which was completed in October 2005.

The $500,000 project incorporated various plate, sheet, pipe and RHS stainless in grades 304 and 316, and was specified to reduce the risk of contamination in the handling processes for all coleslaws, pastas and food products.

Bridgeman's Managing Director Len Webb said there was previously no system available to perform the process that Crocket's required.

"We engineered and designed the equipment with input from the Crocket's engineer. Always at the forefront of our minds was that the prevention of food contamination is paramount in commercial food preparation areas."

The design of the cabbage line was significant and a huge improvement to the current system set up at the head office site in Queensland. The new design incorporated all processes: tipping, coring, washing, dicing, hopper and outfeed, all in a compact line that now has significantly less labour attributed to it.

The stainless itself was rolled, formed, bent, welded, sanded and polished to meet food grade requirements. Mrs Crocket's Kitchens Maintenance Manager Mark McGauley says stainless was specified because it is easy to clean and maintain.

"We know that the contact area and machinery is clean so this ensures any piece of food that comes into contact with these areas is safe."

This article featured in Australian Stainless magazine - Issue 38, Summer 2006.

This article is the second in a series showcasing the uses of 445M2 stainless steel. Read Part 1. Read Part 3.

The use of stainless steel plant and equipment in the food industry continues to prove its worth as an increasing number of processors adopt its use in line with the dedication and obligation to food quality and safety.

Whilst stainless steel grades 316 and 304 offer an environment of easy maintenance and cleaning, 445M2 stainless steel goes one step further.

445M2 panels have been supplied to Bertocchi Smallgoods by ASSDA Major Sponsor Austral Wright Metals, following a four-month trial of all three grades of stainless steel.

Bertocchi, a Melbourne-based company producing hams, bacon, salamis and other specialised continental smallgoods, sought an alternative to their existing painted steel linings after they discovered the life of the linings was too short for their high cleaning standards.

The walls and ceiling of the factory are regularly cleaned in line with a guarantee of the highest quality health and safety standards, together with absolute traceability of every unit of product.

This is where stainless steel stepped in.  The hardness and smoothness of stainless steel enables it to resist the adhesion of soils and bio-films, and the excellent corrosion resistance allows it to be easily cleaned and sanitised. Indeed, laboratory tests prove stainless steel is significantly more hygienic than other materials, even when used for food contact surfaces. Moreover, the taste and colour of food products are not affected by stainless steels.

After four months of trialing panels of stainless steel grades 304, 316 and 445M2, Bertocchi Smallgoods chose the new generation ferritic grade 445M2 to line the factory – ceilings and walls. With superior corrosion resistance to grade 316, 445M2 resists the powerful cleaning agents used to keep the factory clean, as well as the hot, humid and salty atmosphere around the brine lines.

So far, Bertocchi has installed 10 tonnes of 445M2 0.7 x 1219 mm sheet with a 2B finish.  The result?  A clean, bright factory that’s easy to keep that way.  And Bertocchi intends to keep going until the entire factory is lined with 445M2.

This article featured in Australian Stainless magazine - Issue 38, Summer 2006.