Australian Bulk Handling Review July/August 2022

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VOLUME 28, ISSUE 3 | JULY/AUGUST 2022

In this issue: BULK2022 showguide Highlighting Australian manufacturers Navigating chute design

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CONTENTS JULY/AUGUST 2022

18

26

38

54

6 Industry news

36 Keeping Aussie producers buzzing

AUSTRALIAN MANUFACTURING

10 Fenner invests in the factory of the future

38 Nestlé Singapore improves metal

44 LGPM delivers bespoke stockfeed plant

12 Could conveyors replace

detection with flexible screw conveyor

46 Supplying silos for on-farm demand

40 New generation Dugless 903: does the work

earthmoving equipment?

48 Tecweigh expands its conveying

14 Fighting the marine surveyor skill shortage

of a 20 strong team in places they can’t reach

16 The silver lining for equipment longevity

42 TAKRAF’s engineering stacks up

50 Unusual solutions for unusual problems

18 Industry feedback fuels safety guard

60 Simulation helps guide bulk

52 Kinder Australia skirts with air

development – GuardlitePro

handling’s leap forward

20 The quest for absolute zero

62 BULK2022’s mega connections

22 Page Macrae expands range of port equipment

64 Best of both worlds

24 Dana drives excellence in bulk handling

66 Lincom and Thor recognised

26 Agriculture allies share their success

and weighing range

54 Rolling out Australian innovation 56 Bulk handling in Australia: an overview

BULK SHOWGUIDE 82 Shining the spotlight on bulk handling

for stacker success

28 Managing conveyor belt carryback

68 Sensing a better future

84 BULK2022 Floorplan

30 Gearing up to drop in

70 Crane rail mountings

85 Quick reference guide

32 Plastic: the strongest link

74 Navigating competing design criteria

86 Conference program

34 What is pallet hooding?

89 BULK2022 Showguide

in transfer chute design

COVER STORY: FENNER INVESTS IN THE FACTORY OF THE FUTURE Iron mines are a relentless environment for conveying equipment. The ore can cut, gouge and rip through heavy-duty belts, while the fines can lead to serious abrasion issues.

Miners know these conditions require some of the strongest belts on the market, but durability is only one aspect. Due to the remoteness, mines need to know that their equipment has local support to keep conveyors moving.

Australian manufacturer Fenner has invested $23.5 million into its Kwinana facility in WA. ABHR learns more about the project, including how it will boost local manufacturing of steel cord and ply conveyor belts.

For the full story, see page 10.

Australian Bulk Handling Review: July/August 2022 І 3

XXX

Published by:

11-15 Buckhurst St South Melbourne VIC 3205 T: 03 9690 8766 www.primecreativemedia.com.au Publisher Christine Clancy E: christine.clancy@primecreative.com.au Editor William Arnott E: william.arnott@primecreative.com.au Business Development Manager Rob O’Bryan E: rob.obryan@primecreative.com.au Client Success Manager Janine Clements E: janine.clements@primecreative.com.au Design Production Manager Michelle Weston E: michelle.weston@primecreative.com.au Art Director Blake Storey Design Kerry Pert, Aisling McComiskey Subscriptions T: 03 9690 8766 E: subscriptions@primecreative.com.au

www.bulkhandlingreview.com The Publisher reserves the right to alter or omit any article or advertisement submitted and requires indemnity from the advertisers and contributors against damages or liabilities that may arise from material published. © Copyright – No part of this publication may be reproduced, stored in a retrieval system or transmitted in any means electronic, mechanical, photocopying, recording or otherwise without the permission of the publisher.

EDITORIAL

Dodging supply chain disruption If there was one word to sum up the past two years of business, it would be disruption.

Events such as the COVID-19 pandemic and the various resulting lockdowns, the blocking of the Suez Canal, and the outbreak of war in Ukraine have all affected the global economy and its fragile supply chains.

Disruptions send ripples throughout the chain and have created an increasingly difficult situation for businesses around the world. A key component could be stuck on a container vessel in Singapore for weeks, or the price of steel could fluctuate wildly.

In industries where lead time is everything, local manufacturing has become even more important. Not only does it provide Australian jobs, but it ensures equipment can be fabricated and delivered in a timely manner. Local support also faces fewer language, cultural or time-zone barriers.

In this edition of Australian Bulk Handling Review (ABHR), we shine the spotlight on the Australian manufacturers that are growing local industries, organisations and people.

ABHR is also proud to include the showguide for the 2022 Australian Bulk Handling Expo (BULK2022). The long-awaited event will take place at the Melbourne Convention and Exhibition Centre from 24–26 August.

Attendees and exhibitors will come together to connect, network and share knowledge. Key decision-makers from a broad range of industries will have the opportunity to get an close-up look at the latest in technology and innovation, whether they specialise in agricultural silos, shiploaders or mining conveyors.

Additionally, the event will host the 2022 Australian Bulk Handling Awards, the only awards program that highlights the quiet achievers of the Australian economy. ABHR wishes a hearty congratulations to all the finalists.

Looking ahead, our next edition will see the return of ABHR’s conveyor showcase, which highlights companies involved in all things related to conveyors, including belts, scrapers, rollers and more.

Coverage will also be included online through Prime Creative Media’s digital platforms and magazines. It will then be housed on the respective websites as a PDF, with an extensive marketing campaign planned to increase awareness.

If you’d like to hear more about advertising in the September–October edition of ABHR and increase your business’ exposure in the conveyor showcase, please contact Rob O’Bryan at rob.obryan@primecreative.com.au.

William Arnott Editor - ABHR

4 І Australian Bulk Handling Review: July/August 2022

F P • • • •

Filling, Closing, Conveying, Palletizing, Service & Consumables •

Increase production performance & reliability

•

Reduce manual labour issues

•

Increase accuracy

•

Reduce health & safety risk

NEWS

Kerman Contracting wins $60M ore storage facility contract KERMAN CONTRACTING HAS WON a $60 million contract to design and build Mineral Resources Limited (MRL)’s Port of Ashburton Ore Storage facility in Onslow, WA. The scope of the contract includes the design, fabrication, supply and erection of an enclosed 284-metrelong ore storage facility and associated materials handling.

Design works are already underway,

with construction works expected to begin in January 2023.

Kerman Contracting’s Managing Director Chris Kerman said the project fits perfectly into its core business and will provide employment for about 60 site personnel and opportunities for local businesses.

“To deliver a world class facility for MRL we will call upon our previous experience in the design and

construction of port bulk storage and materials handling facilities in locations such as Bunbury, Esperance, Geraldton, Port Kembla and Whyalla,” Kerman said.

“We are very pleased with the opportunity to design and construct a storage facility with these dimensions in the Pilbara region. Once constructed this facility will be one of the largest enclosed bulk storage buildings in Australia’s cyclone region.”

Tianqi Lithium produces Australia’s first battery-grade lithium hydroxide TIANQI LITHIUM ENERGY Australia, a joint venture between IGO and Tianqi Lithium, has produced Australia’s first battery-grade lithium hydroxide at its Kwinana plant.

Lithium hydroxide produced at the WA-plant will be exported overseas and used in the production of high energy density batteries for electric vehicles and energy storage systems.

Tianqi’s plant is one of the few battery-grade lithium hydroxide facilities outside of China.

It employs 200 staff at the Kwinana plant, and is expected to reach commercial production in the coming months once product qualification is achieved, with a nameplate capacity of 24,000 tonnes.

More than 900 jobs were created during the construction of Train 1, with further local employment expected when construction of Train 2 recommences.

WA State Development, Jobs and Trade Minister Roger Cook said the state has been exporting the minerals needed to make batteries for decades and

the milestone demonstrates its ability to manufacture battery-grade materials locally.

“It’s great to see this burgeoning industry making Kwinana its home, further reinforcing the importance of the Industrial Area and the Western Trade Coast in positioning WA as a Global Advanced Industries Hub,” he said.

The next step in the plant’s ramp-up process is customer qualification, which will be completed over the next four to eight months. During this time, the plant will continue to focus on stable, consistent, and reliable production of battery-grade lithium.

TLK Chief Operating Officer Raj Surendran said the organisation is immensely proud to demonstrate that Australia can value add to its minerals onshore.

“This is an exciting time for our shareholders, suppliers and service providers who have contributed to the construction and ramp-up of the Kwinana Plant, and our employees who have worked so hard to turn the

Lithium hydroxide produced at the plant will be exported overseas and used in the production of high energy density batteries.

W i a n p n

dream of producing battery-grade lithium hydroxide in Australia into a reality,” Surendran said.

“However, we also remain acutely aware that there is more work to do to establish the Kwinana plant as a reliable, significant producer of battery-grade lithium, starting with customer acceptance.”

6 І Australian Bulk Handling Review: July/August 2022

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NEWS

The next evolution in sprag-type backstop tech ALTRA INDUSTRIAL MOTION HAS developed a new backstop designed to provide high quality performance at a competitive price point.

The Marland ABC Sprag backstop is the result of a collaboration between Altra’s brands.

The new design features indexed sprags to evenly distribute force and have less internal friction between the inner and outer races.

It also features lower operating temperatures when compared with similar units.

The ABC series backstops are designed for installation on lowspeed shafts with typical dimensional tolerances and clearances.

They are symmetrical and can be mounted according to the desired free rotation direction of the shaft.

The torque arm is a single-section I-beam connected to the backstop by two precision pins. This dramatically simplifies field installation, and the component can be installed vertically, horizontally or at any

The ABC Sprag Backstop is the result of collaboration.

desired angle while maintaining a uniform load on the flanges.

The components and bearings are continuously self-lubricated in a shielded oil chamber. A doublelip seal is positioned adjacent to the bearings to keep oil and environmental contaminants out of the backstop chamber.

Grease nipples in each outer labyrinth are provided for any reapplication of the sealing grease and, when fed, force dirt and old grease out of the labyrinth through the trap.

In addition, a periodic check of the

oil level and purity can be performed utilising the oil level indicator during operation or at rest. If the inspection reveals impurities in the oil, draining, flushing, and refilling can be easily accomplished using piping, T-connections and traps.

Altra’s Marland brand has been producing roller ramp-type backstops since 1931. The new ABC backstops utilise the engineering operating principles proven by decades of development and thousands of installations worldwide by sister divisions Formsprag and Stieber.

4B releases next generation of industrial buckets THE 4B GROUP, A MAJOR manufacturer of bucket elevator components, has developed a new range of its Nylathane elevator buckets.

The buckets have a high impact resistance and are some of the toughest polymer industrial buckets on the market.

Constructed out of Nylathane, a highly-durable nylon, the buckets have excellent wear resistance, anti-static

8 І Australian Bulk Handling Review: July/August 2022

Nylathane is highly durable.

and non-corroding properties, and can operate in temperatures ranging from -40°C to 110°C.

The 4B AA and AC Nylathane buckets features a reinforced front lip, high impact strength, and self-cleaning surfaces. The buckets are around 75 per cent lighter than fabricated steel and are suitable for light to heavy abrasive industrial products, such as sand, aggregate, cement, wood chips and fertiliser.

The 4B MF Nylathane buckets have no occlusions within the structure for use in continuous discharge elevators.

R I

W h

Fenner to acquire Conveyor Products & Solutions FENNER AUSTRALIA WILL ACQUIRE full ownership of WA-based Conveyor Products & Solutions Pty Ltd (CPS).

CPS designs, engineers and locally manufacturers high-quality conveyor rollers, idlers, and pulleys for the mining and bulk handling markets.

Fenner Australia is an Australianbased manufacturer of conveyor belting for mining and industrial applications, as well as supporting engineering and conveyor services.

Fenner executive director David Landgren said he is excited about the company joining Fenner, and the One Michelin Group Australia, as it will provide great opportunities for its collective customers and its combined team of talented people.

CPS managing director and CEO Michael Einhorn said joining with Fenner represents an exciting time for the companies, which has established itself as the industry leader in composite conveyor rollers, idlers, and pulleys.

“Integration with Fenner allows CPS’ successful growth strategy to continue on the next phase of ensuring we deliver maximum, sustainable value to our customers and provide opportunity to our people,” Einhorn said.

CPS is equipped with modern industrial means, automation, digital and robotic production tools, which will add significant value when combined with Fenner’s existing Australia–wide conveyor footprint.

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After closing, CPS will become a whollyowned subsidiary of Fenner Australia.

of both companies provide further synergy and strength to a national and international capability.

The acquisition may be subject to regulatory approval and is subject to the satisfaction of customary closing conditions. After closing, CPS will become a wholly-owned subsidiary of Fenner Australia.

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COVER STORY

Fenner invests in the factory of the future Siempelkamp is industry-leading in belt manufacturing equipment.

Australian manufacturer Fenner has invested $23.5 million into its Kwinana facility in WA. ABHR learns more about the project, including how it will boost local manufacturing of steel cord and ply conveyor belts.

IRON MINES ARE A RELENTLESS environment for conveying equipment.

The ore can cut, gouge and rip through heavy-duty belts, while the fines can lead to serious abrasion issues.

Miners know these conditions require some of the strongest belts on the market, but durability is only one aspect.

Due to the remoteness, mines need to know that their equipment has local support to keep conveyors moving.

Hong Koh, Fenner Conveyors general manager – manufacturing, said this is why the company has invested heavily into manufacturing its belts in Kwinana, Perth.

“Fenner opened a strategic location around 40km south of Perth to help

10 І Australian Bulk Handling Review: July/August 2022

support the nearby iron ore and boarder mining industry,” he said.

“Being local means we have lower freight costs and drastically lower lead times, as we’re only shipping the belts

“Siempelkamp is industry-leading in belt manufacturing equipment.

Their technology provides us with enhanced visibility over the manufacturing process.” from the plant to the site.”

The $70 million facility opened in 2009 and primarily produces the steel cord belting. At the time, the move was one of the largest investments into

conveyor belt manufacturing made in Australia by a single company.

In 2020, the company partnered with German-based Siempelkamp as part of a $23.5 million expansion to the Kwinana facility. A third press line was to be installed to increase Fenner’s steel cord capacity by a further 50 per cent.

The facility already housed two of the world’s largest steel cord press lines, measuring 18.5m in length and having the capability to produce steel cord and rubber ply belts up to 3200mm wide and 50mm thick.

Koh said an increasing demand for steel cord belts meant Fenner needed to significantly expand its production facility.

“Installing state-of-the-art equipment lets us continue investing into the latest technologies and improve the service we can offer.”

“Our customers have seen the belts in action and keep coming back for more,” he said.

“Siempelkamp is industry-leading in belt manufacturing equipment. Their technology provides us with enhanced visibility over the manufacturing process.

“It allows us to increase the level of automation and provides more control over our ability to produce custom-made belts.”

Koh said a critical factor for the plant’s success was its inventory management.

“Manufacturing operations across the world have been affected by COVID-19 lockdowns, but while others were running out of raw material, we ensured our factories could continue manufacturing belts in a timely manner,” he said.

The Kwinana plant incorporates a testing and research and development (R&D) laboratory on-site, which is primarily used for Australian Standards testing.

Nithin Chandran, plant manager at the Kwinana site, said the company

Fenner Conveyors invests heavily into developing the skills of its manufacturing staff.

is always considering ways to make its existing range better.

“Our team is constantly developing new and improved compounds and ways to make every aspect of the business better,” he said.

Fenner Conveyors also invests heavily into its manufacturing staff. Chandran began his career as an engineer at the company’s Footscray site.

“Investing into people is one of Fenner’s strong points,” he said.

“Since I started, I have been encouraged to develop my skills, which has been a huge positive for me.

“When staff are supported in this way, there’s a sense of

Fenner’s Kwinana facility houses two of the world’s largest steel cord press lines.

Fast Fact Fenner’s staff understand the local conditions and regulations and can provide on-site assistance much faster.

With the third press line now fully operational, the company is planning an open day at the factory to allow customers to see how Fenner steel cord belts are made. fulfillment that comes with the role.

It’s more than just doing a job; its contributing to the success of the team and overall business.”

Another benefit of being a local manufacturer is the support Fenner offers. The company’s staff understand the local conditions and regulations and can provide on-site assistance much faster.

With the third press line now fully operational, the company is planning an open day at the factory to allow customers to see how Fenner steel cord belts are made.

“We are committed to supporting local manufacturing, and the Kwinana expansion is proof of that,” Chandran said.

“Installing state-of-the-art equipment lets us continue investing into the latest technologies and improve the service we can offer.

“This investment enables our operations, and that of our customers, to be more efficient, sustainable and safe for the future.”

Australian Bulk Handling Review: July/August 2022 І 11

CONVEYORS

Could conveyors replace earthmoving equipment?

Telestack equipment has been used across Australia to free up labour and reduce costs by replacing wheel loaders and dump trucks.

WHEEL LOADERS AND DUMP trucks are typically used to move material from the extraction point to the stockpile.

This method has some downside, including increased labour costs and associated costs for the operation and maintenance of loaders and trucks.

This is why some companies have installed conveyor systems at their sites, feeding the material directly into the crushing and screening circuit.

Some of the additional benefits include higher production capacities, greater flexibility of mobile link conveyors and greater fuel efficiency.

In the right circumstances, installing linking conveyors can complement, if not replace, a load and haul fleet, allowing workers to perform other tasks.

The Telestack mobile conveyor products have been used across Australia for this purpose, distributed in its entirety by the OPS Group Australia wide.

Stockpiling in the Pilbara OPS recently provided a Telestack TS-842 Radial Telescopic Conveyor as part of a multi-plant operation for a contractor on an FMG Iron Ore site in the Pilbara, Western Australia.

Stockpiling -10mm Iron Ore at rates up to 800tph, the TS-842 Radial

Telescopic Conveyor runs as part of a stockpile heights of up to 20m. multi equipment plant which includes Shane Czerkasow, OPS Group a Terex Finlay J-1480 Jaw Crusher, managing director, said the Telestack C-1550S Cone Crusher, 984 Triple Deck TS range can be easily packed into Horizontal, 893 Heavy Duty Reclaimer as containers for worldwide shipment. a closed circuit.

“The range is renowned for its noAll material from this nonsense approach and is operational circuit discharges within days of onto the Telestack arrival with limited “Telestack has always been into one stockpile civils required due to renowned throughout the from a series of link their bolt-together aggregates industry for conveyors. design,” he said. the quality of its machines The TS 842 Fitted with an and the company has UKAS Radial Telescopic Allen Bradley Auto accreditation covering key conveyor is a 42m PLC stockpiling global standards, ISO radial conveyor programme, the 14001 (Environmental designed to work operator can use the Management), OHSAS independently or select stockpiling 18001 (Health & Safety as part of a multi program to Management) and ISO 9001 plant operation. manage (Quality Management).”

The radial conveyor stockpile also aims to reduce segregation, requirements based on the application, degradation, contamination, site and customer specification. This unit and compaction of material. is fully self-powered with a CAT 150kVA Telestack TS conveyors can handle genset and is fully mobile with track bogie. ‘in-specification’ material at rates of up to The TS842 was also supplied to 3000tph, with capacities of up to 200,000 AS4324.1 structural standards which tonnes at 270°. They can also stockpile are regarded as the most stringent in at an increased rate of 30 per cent the world. The unit also complies with when compared with AS3000 electrical standards, both of which a typical conical stockpile. With are required for stackers to operate in lengths available from 25m to 58m, the rugged environment of the Western the Telestack TS range can reach Australian iron ore mining industry.

T I Q C

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3

A

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In the right circumstances, installing linking conveyors can complement, if not replace, a load and haul fleet.

12 І Australian Bulk Handling Review: July/August 2022

A A

Telestack have two specialist departments, Telestack Mining and Aggregates and Telestack Ports and Terminals. The Mining and Aggregates business has developed throughout the years working with crushing and screening equipment in the field.

“The Telestack range is the very best in the industry with many of our engineers coming from the screening and crushing business, so their design reflects a complete understanding of the aggregate business,” Czerkasow said.

“Telestack has always been renowned throughout the aggregates industry for the quality of its machines and the company has UKAS accreditation covering key global standards, ISO 14001 (Environmental Management), OHSAS 18001 (Health & Safety Management) and ISO 9001 (Quality Management).

“They have a global proven record, and their products can handle all free flowing bulk materials including ores,

Telestack specialises in bulk material handling systems for the aggregats and mining sectors.

coal, aggregates, fertilizers, grains, woodchips, pellets and many more bulk materials that need moved.”

Telestack specialises in the complete design, manufacture, installation, and commissioning of mobile bulk material handling systems for the aggregates and mining sectors. Its products are used for stockpiling and linking in quarries around the world, handling materials from road base to iron ore.

Czerkasow said these quarries and mines recognise the many benefits of Telestack products, including eliminating the need

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for front end loaders on the site.

“The double handling of the material is reduced and productivity increased.

With Telestack products there is the ability to move and stockpile different grades of material,” he said.”

“Telestack are renowned throughout the globe for their personalised service.

The team of engineering and sales specialists work very closely with you throughout each stage of the process from pre-sales and pre-engineering to ensure that the equipment is specific to your project. Our product portfolio is vast as is our application knowledge.”

SURVEYORS

Fighting the marine surveyor skill shortage Marine surveyors are a vital part of Australia’s export process, but there are limited pathways into the profession.

ABHR investigates the skills shortage and what the industry is doing to solve it.

AUSTRALIA DEPENDS ON ITS exports for its economic wellbeing, with exports responsible for around 20 per cent of the country’s gross domestic product.

While ores and minerals make up a large majority of the country’s exports, the United Nations Comtrade database named Australia as the 10th largest exporter of cereals (by value) in 2018.

Marine surveyors play a vital role in the export process, inspecting bulk shipments to ensure the vessel is safe and the cargo will arrive unharmed.

Traditionally, bulk vessel marine surveyors have seafaring backgrounds such as master mariners, a broad role that involves the coordination and supervision of a vessel and its crew Stacey Taylor, general manager of the Australian Institute of Marine Surveyors (AIMS), said the industry was facing a major skills shortage.

“Most marine surveyors don’t start in the role until they’re halfway through their careers,” she told ABHR. “We have a large percentage of highly skilled marine surveyors that will be looking to retire in the next 10-15 years.”

“Australia is reliant on exports, most

of which is via shipping. This poses a serious risk, because if we have a shortage of skilled surveyors to protect those shipments, it may lead to serious safety concerns.”

The Australian seafarer population is relatively small, and when looking for a career change many in the industry either seek out an offshore job or become a ship pilot – positions that traditionally come with a higher salary On the other side, younger people tend to not be attracted by a job with no set shifts, 2.00am starts, and the need to be on call 24 hours a day.

John Holden, chairman of the AIMS board, adds that, due to the declining number of Australian seafarers, there are limited pathways for Australians to enter the industry.

“There are companies that take on marine surveyor trainees, but it is entirely up to them to fund that,” he said.

“When you look at other trades, there’s lots of different government assistance provided. There’s nothing like that to becoming a marine surveyor.

“Training is expensive, and it is a long-term investment. If the trainee decides that the early shifts and crazy hours

aren’t for them, you could have wasted 12 months of time and money.”

Holden began his career as a marine surveyor around 20 years ago. Originally a boilermaker, he decided to make the change to follow his passions as a boat builder. He believes that while a seafaring background is certainly helpful for the position, it’s not the be all and end all.

At the time Holden made the move to marine surveying, there were no courses available to be qualified for the role. Instead, he worked alongside an ex-master mariner who taught him the skills he would need.

“A lot of what we do is interacting with people,” Holden said. “It’s one of the more interesting aspects of the job – meeting people from all parts of the world with different cultural backgrounds.

“You also need an enquiring mind, need to be reasonably capable in the areas of maths and science, and have a reasonably good general knowledge. Everyone brings their own skillset to the role.

“People are surprised to hear me say you don’t need any qualifications to become a marine surveyor.

AIMS has been advocating for federal and state governments to

There are limited pathways for Australians to enter the marine surveying industry.

14 І Australian Bulk Handling Review: July/August 2022

“When you look at other trades, there’s lots of different government assistance provided. There’s nothing like that to becoming a marine surveyor.” make bringing people into the industry easier. It is believed that recognition of a Diploma of Marine Surveying as an acceptable qualification for those applying for Skilled Employer Sponsored Visa’s as well as recognised government supported traineeships for new Australian entrants will provide additional entry pathways and avoid future surveyor shortages.

AIMS is also supporting the training side of things, offering a range of Marine Surveying courses which, when coupled with supporting mentorship, provides a framework model that can be presented to government as part of its lobbying efforts.

Training includes a mixture of skillbased theoretical modules and practical components covering the fundamental

Marine surveyors inspect bulk shipments to ensure the vessel is safe and the cargo will arrive unharmed.

aspects of the role. These include report writing, workplace health and safety, stability requirements, and more.

Taylor said from there, surveyors can specialise into the different areas within the industry.

“Whether its surveying dry bulk vessels, liquid cargo vessels, or insurance or warranty surveys, we want trainees to have the skills to specialise in the sectors of the industry they are most interested in,” she said.

“They should come out with skills learned on paper and the practical capabilities to apply them.”

Despite the challenges faced, Holden remains optimistic about the industry and appreciates the businesses

that have encouraged new surveyors from non-traditional backgrounds.

“You look at the industry and you can see that our exports aren’t going to be stopping any time soon – in fact, they’re likely to increase,” he said.

“There will still be safety requirements and the value of new minerals means surveying will remain an essential part of the process.

“We need experienced people to do the job really well, and it’s great to see support from businesses investing into training and mentoring.

“There needs to be more government recognition and assistance to develop this. AIMS is pushing hard to see the industry get the support it needs.”

Innovation is our

Motivation...

find out more @ kinder.com.au

PLASTICS

The silver lining for equipment longevity E-Plas can extend the life of bulk handling equipment by up to 10 years through its advanced engineered plastic lining materials.

A chute lined with TIVAR 88 for a mining application.

REPLACING EQUIPMENT IS AN expensive endeavour, one that often involves lengthy shutdowns and production interruptions.

As a result, bulk handlers will often install specialised liners into chutes, hoppers, and other major CapEx investments to prolong their lifespans.

Not all liners are made equal, though. Lisa Marshall, managing director of plastic specialist E-Plas, said long-term performance is crucial.

“Whether it’s in mining, agriculture or heavy industry, everyone wants to get the most out of their equipment,” she said.

“Replacing machinery is something most people are looking to avoid, especially now while costs are rising.

You want to get the most out of your trucks, chutes and hoppers.

“Our high-quality liners can add up to five to 10 years of longevity to bulk handling equipment. They’re long lasting and have been proven to work

by Australian users.”

E-Plas has serviced a diverse range of industries for more than 40 years,

16 І Australian Bulk Handling Review: July/August 2022

from orthotics and nuclear medicine to food production, mining, ship building, and the transport industry with the specialised QuickSilver truck liner coils.

Each of these different industries has its own unique demands, which has led to the development of products such as the TIVAR ultra high molecular weight polyethylene UHMW-PE product range.

“Infrastructure needs to keep moving, and so did we.

Our plans are to continue cultivating a positive work culture, developing our onesite manufacturing capacity and support for local jobs.”

TIVAR polymers are produced using an advanced compression moulding technology and ram extrusion. They are designed to provide specific solutions to tough problems in some of the most demanding applications, such as the mining industry.

TIVAR 88 has a distinctive blue colour, and was developed specifically

for the bulk handling industry, undergoing rigorous laboratory and field testing to ensure it reduces arching, ratholing and erratic material flow.

The plastic has a high-abrasion, corrosion, and impact resistance, with no moisture absorption. It retains its properties at temperatures of -269–80 °C and is resistant to aggressive chemicals.

Several bulk handling applications can use TIVAR 88 liners, including chutes, silos, bins, screw conveyors, truck beds, slider beds, vibratory feeders and more. It can also be used for wear strips, belt scrapers, conveyor skirting and chain conveyor flights.

Marshall said E-Plas provides products for specific applications to ensure the client can get the most out of their equipment.

“When we sell someone a product, we are offering a way to add value to their investment, whether it’s a truck, hopper, silo or conveyor,” she said.

“Our liners have improved chemical resistance and help to improve flow,

• • •

AS en

Fast Fact TIVAR polymers are produced using an advanced compression moulding technology and ram extrusion. They are designed to provide specific solutions to tough problems in some of the most demanding applications, such as the mining industry. but they can also include additional elements where needed.

“TIVAR liners with burn-guard ensures increased protection against static build up and related fires. We can also include TIVAR with rubber backing to absorb major shocks if heavy objects are being conveyed.”

The company also offers TIVAR 88-2, a weldable UHMW-PE lining that can be used as a drop-in liner, which saves on installation time. It uses rapid release technology to eliminate

arching, ratholing and flow problems, working best in situations where sticky bulk materials are being conveyed.

These materials – which include cement, coal, bauxite, synthetic gypsum, sand, iron, fly ash and clay – are notorious for sticking and feeder plugging. They can also cause extreme surface wear to the equipment. TIVAR 88-2’s low co-efficient of friction and slippery non-stick surface mean bulk materials flow smoothly and discharge without hang-up.

Marshall said the company is looking to continue its growth following its success during the COVID-19 pandemic.

“Infrastructure needs to keep moving, and so did we,” she said. “Our plans are to continue cultivating a positive work culture, developing our one-site manufacturing capacity and support for local jobs.”

TIVAR polymers are designed to provide specific solutions in some of the most demanding applications, such as the mining industry.

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COVER STORY GUARDS

GuardlitePro is made from higher grade HDPE and is fully recyclable.

Industry feedback fuels safety guard development – GuardlitePro Transmin-ConveyorPro has designed a range of safety guards that provide the industry a lighter, zero maintenance, sustainable alternative to steel.

THE CONVEYORPRO TEAM IS constantly looking for feedback to achieve its goal of becoming a onestop-shop for its customers.

Key account managers meet with site and operations teams across Australia to learn more about the issues they’re facing on the ground, and there was an especially common problem identified by the team.

According to Arun Sutrave, a mechanical engineer on the ConveyorPro team, clients were constantly asking to see the latest designs in safety guarding.

“The frequent requests and inquiries made us want to design a unique product that could meet the requirements of the mining industry,” he told ABHR. Conventional guards are made from steel mesh and mounted on machinery to restrict access to hazardous areas. These guards are often heavy, requiring multiple people to remove them and regular maintenance to avoid issues with rust.

Mounting the steel guards can also be complicated, necessitating specific tools to properly remove or replace them.

To solve these issues, ConveyorPro has designed a range of safety guards made from higher grade high-density polyethylene (HDPE) – GuardlitePro.

18 І Australian Bulk Handling Review: July/August 2022

Sutrave said the design went through several alterations to find the most optimised version in terms of its weight and easy mounting.

“We wanted to design lightweight guards that were strong enough to meet the requirements for the Australian Standards,” he said.

“We used a high-quality grade of HDPE for the GuardlitePro. It is suitable for outdoor duty – UV rays won’t weaken

“Innovation is key to ConveyorPro’s success, so we are investing heavily into our research and development.” it or make the colour fade, it has a better tensile strength, and it is rust-free.

“Most importantly, it is 100 per cent recyclable.”

Safety guards are often deployed along the length of a conveyor to protect the idlers, belt, pulleys, drive system and take-up tower. They can also be installed on machines like stackers-reclaimers, spreaders, shiploaders-unloaders and in underground operations.

It can also be implemented in the oil and gas, and food industries to safeguard

people from hazardous equipment or zones. GuardlitePro comes with a UL94HB rating for fire resistance and has chemical resistance properties.

Each of these new guards is around 40 per cent lighter than an equivalent steel mesh guard, which makes handling and manufacturing significantly easier.

Sutrave said they weigh in the range of 7kg to maximum 20kg, so that a single person can lift them while performing maintenance. Guards are available in various sizes and can be used in a variety of combinations to fit almost any application.

“The guards were also designed with a unique mounting mechanism, which allows them to be placed on a new and existing applications easily,” he said.

“The posts they are mounted on are optimised to take up less space, and it only requires four screws to remove a single panel.”

Transmin also manufactures feeders and knows the costs and effort involved when it comes to manufacturing steel guards. This is why it is working to implement GuardlitePro into its range of Low Profile Feeders (LPFs).

Amerander ‘Reddy’ Emmadi, business

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Au

development manager at ConveyorPro, said the company is in a good position to get firsthand information about what the industry is looking for.

“We go on-site and identify the problems our clients have,” he said.

“We can then try to design a better product that is simple, workable and easy to manufacture.”

“The team is constantly working to improve our existing designs. At the moment we are looking to release our new range of GuardlitePro to the market and work with greenfield projects to help them adapt it into their models.

“By getting involved with the engineering, procurement and construction management businesses early, we can find ways to incorporate the new guards, or come up with custom solutions with them.”

ConveyorPro also offers a range of other equipment as part of its goal to be a one-stop conveyor shop. It specialises in providing everything an operator needs,

The guards went through several alterations to find the most optimised version for easy mounting.

including belts, idlers, rollers, pulleys, impact tables and scrapers.

The company has a presence in South Africa, India, and Canada, and can supply products around the world.

Emmadi said the brand is always looking to expand its offering, inspired by the success of its GuardlitePro. “ConveyorPro is expanding new

range of composite rollers to its current offerings, as market willing to adopt lighter products,” he said.

“In the long term, we are looking at how we can provide full turnkey solutions for small-to-medium-sized conveyors.

“Innovation is key to ConveyorPro’s success, so we are investing heavily into our research and development.”

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SCALES

The quest for absolute zero US-based Thayer Scale has started expanding into the Australian market. ABHR speaks with the company’s North American sales manager Peter Sirrico to find out how it builds scales for accuracy.

WHEN IT COMES TO WEIGHING bulk materials, it’s all about getting the zero right.

Accurate measurements are critical to understanding most mining, quarry and processing operations for inventory, material balance and measuring plant efficiency.

For truck, rail car, barge or shiploading operations, accuracy is key to determining freight costs, custody transfer, and commercial trade.

To achieve the highest possible level of accuracy in belt weighing, Thayer Scale has developed a set of scales with an approach/retreat weighbridge.

The scale provides for complete mass counterbalancing of the conveyor’s dead load – the idlers and belt – allowing the load sensor to react only to the net material load.

This means the measurements are not affected by dirt, shocks or vibration, and can withstand overloads without causing damage or affecting calibration.

Importantly, the leverage system over time,” he said. sums all load forces to one load cell “A proven ability to hold a stable and uses the test weight for both and steady zero is the foundation for counterbalancing and as a span weight. reliable and accurate weighing on Normally these test weights are light any continuous weighing device, and and easy to manipulate compared to especially a high-accuracy belt scale.” other systems which require multiple Thayer Scale initially developed additive test weights to perform a the pivoting belt scale in the early span calibration. ’70s, with the first The weights are six idler put into “A proven ability to hold a raised and lowered service in 1977. The stable and steady zero is the as needed from unit was certified foundation for reliable and outside of the by the Southern accurate weighing on any conveyor stringer.

Weights and continuous weighing device, The highly Inspection and especially a highadvanced and Bureau in the accuracy belt scale.” extremely robust US after intense sensing technology is based on the testing of the design and Thayer’s marriage of the weight transducer, test weight methodology versus the embedded temperature sensing and accepted test chain routine temperature compensating algorithms. that was prevalent at the time.

Peter Sirrico, Thayer Scale’s North The six-idler belt scale design American sales manager, said the became the standard Thayer approach/retreat level type suspension Certified Type with no changes weighbridge eliminates zero shifts and except instrumentation for bias using an opposing lever design and National Type Evaluation Program low-sensitivity idlers mounted near (NTEP) certification. the fulcrum points.

Sirrico said the strength of the belt “This is perhaps the scale was in the design of the leverage most important point and system, proved through repeated reason why Thayer’s certification over 45 years utilising design holds scale-zero instrumentation ranging from CMOS

Accuracy is key to determining freight costs, custody transfer, and commercial trade in truck, rail car or ship-loading operations.

20 І Australian Bulk Handling Review: July/August 2022

digital Integrators in the 70’s, to microprocessors in the 80’s and 90’s to the current PC based instrument.

“The system is the combination of a high-quality mechanical design and effective electronics,” he said.

Its genesis utilised the best design characteristics of older multiple idler mechanical belt scales and mated that to modern methodologies.

“Typically, when someone buys one for a site, they buy another.

It’s practically unheard of for nonrepeat business.

“One of the biggest wood pellet manufacturers in the world has one in every terminal after it solved their weighing problems.”

The belt scales are easy to maintain through periodic cleaning and ‘zero’ calibrations. But a belt scale is only as good as its installation, which is why Thayer Scale has a dedicated service department that can assist end users.

To ensure Australian customers can

The approach/retreat weighbridge only reacts to the net material load.

benefit from the same level of support, the Massachusetts-based company has begun expanding heavily into the south-east Asian market.

Sirrico said the company has started to see some traction and is in talks with several local companies.

“We want to become a supplier to the region,” he said. “We know it will take time to establish ourselves, but we have a solid design that people want.”

“It has proved itself time and time again, and we want to make it available to projects across the world.”

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COVER STORY

Page Macrae expands range of port equipment The New Zealand-based manufacturer has developed a new range of bulk grabs and buckets for port cranes.

A NEW ZEALAND PORT RECENTLY approached Page Macrae Engineering with a challenge. Unlike other ports, this one used mobile harbour cranes instead of standard (ships) cranes but wanted to load logs into vessels at the site.

Page Macrae has been in the log loading sector for more than 30 years, but the company does not usually develop products for harbour cranes.

Bruce Ennis, business development manager of product solutions at Page Macrae, said while the company tends to make equipment for shipbased cranes, its interest was piqued by this opportunity.

“Ship-based cranes are electric; they’ve got a power supply we can use for grabs and buckets. This also lets us use an electrical hydraulic system in the grapple,” Ennis told ABHR. “Harbour cranes have a much higher load rating than a ship-based crane. It goes from a 22-tonne working load to 35 tonnes or more.

Page Macrae is investigating what issues are affecting the port sector.

22 І Australian Bulk Handling Review: July/August 2022

“They also have higher duty requirements. Harbour cranes work quick, and where you might have three of four cranes on a ship, there’s probably only one or two shore-based cranes.”

Page Macrae’s engineers began designing its log loading and bucket equipment for the cranes, using the same kinds of mechanical parts upgraded to handle the higher frequency of use.

One of the design constraints that Page Macrae needed to work with was the ability to operate across different cranes, with different power supplies.

The new product the company developed includes a dedicated electric motor that runs faster than

“Being able to move more tonnes of cargo faster also improves productivity, which ports around the world are looking to improve.” most cranes to which it is attached to ensure it has the (rating) required for a worst-case scenario.

Another feature in development is cross compatibility between different grabs and buckets, which would allow ports to change the log loader to a bucket easily and quickly.

Peter Swan, Page Macrae’s GM of sales and marketing, said versatility is vital for smaller ports.

“Big ports often have a massive mixture of cargos coming and going, but smaller ports might not be able to justify capital expenditure for dedicated cranes,” he said.

“Being able to move more tonnes of cargo faster also improves productivity, which ports around the world are looking to improve.”

Page Macrae is investigating the widespread issues in the port sector to better understand the future

Page Macrae has been in the log loading sector for more than 30 years.

direction of its product development.

It’s found the global supply chain disruption has created congestion, with potentially dozens of ships waiting to offload their cargo.

Swan said that if the business could find a way to ease the chokepoints and constraints for its clients, it would represent is a massive opportunity for new business.

Page Macrae has manufactured and delivered the equipment to the New Zealand site, and it is now in the process of commissioning the equipment. An electrical engineer has been on-site to help the port and crane manufacturer map out the new wiring.

The new product is Page Macrae’s first bite at the new market, Ennis said, and the company will be pushing hard to establish itself.

“We really want to get develop more products for shore-based cranes,” he said. “They are more reliable, have higher capacity and require less manpower.

“It’s still early days, but we’re excited to be branching out and supporting the industry in new ways.”

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Crusher & Screen can offer in stock IMS PM1050-16TB Track pugmills and mobile 40 tonne silos. The Pugmills are available in manual adding water only or fully PLC automated control and recording system for adding powders and liquids to main road specs, including controlling the 40 tonne silo. The pugmill is loaded with features, high production, fully hydraulic from operation to transport mode, pughead lowers to the ground in a vertical position for ease of cleaning. The manual pugmill can be upgraded to the automated vision at a later date, the pugmill PLC control system can also operate with extra IMS feed hoppers from single to double track mounted and electric modular mobile pugmill blenders offering four different feed hoppers and two powders all remotely controlled.

Crusher & Screen can also offer in stock for sale or hire the IMS – BP1200-9TB high production track blender with two large feed hoppers with gear drive hydraulic motors with variable speed conveyors feeding a stockpile conveyor remotely controlled. There is a mixer between the feed hoppers which is ideal for improved product mix with top soil and compost that hydraulicly moves to one side when blending road base and aggregates.

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BULK HANDLING

Dana SAC Australia serves as a single source for high-quality, precision-made gears and drives.

Dana drives excellence in bulk handling Dana SAC Australia’s gearboxes ensure the flow of ore and aggregate remains constant in bulk material handling.

DANA HAS SUPPORTED Australian bulk handling operations for nearly half a century, providing hightorque drive components that optimise machine performance and maximise yields in bulk material handling.

The company offers Brevini planetary, helical and bevel helical gearboxes, gearmotors, slewing drives, winches and winch drives, GWB industrial driveshafts, and other motion systems for a wide range of mining applications.

As part of a long-term commitment to Australian customers, Dana SAC Australia has steadily increased the local production of shafts, housings and the use of local suppliers in bearings and fabrications. Dana has a head office, engineering centre and production facility in Sydney as well as branch offices in Melbourne, Brisbane and Perth, to attend to any customer requests or concerns.

The company specialises in gearboxes with hydraulic and alternating current Brevini K series gearboxes feature a monoblock housing, ideal for applications such as conveyors, mixers and small winches.

24 І Australian Bulk Handling Review: July/August 2022

(AC) drive technology for low-speed, have been refined to offer performance high-torque equipment and the company improvements that enhance productivity produces reducers that are particularly and further benefit the bottom line.” suited to slewing drives.

Offering nominal output torques All of Dana’s gear units are rated up to 1100kNm, Brevini helical and in accordance with ISO (International bevel helical gearboxes provide the Organisation for Standardisation)/DIN modularity and flexibility needed (German Institute for Standardisation) to optimise the performance of standards for continuous duty, and the stationary mining applications. company’s Australian engineers are able They have been redesigned with bestto calculate application specific gear and in-class torque density to deliver bearings lives for all more power “Long known for their standard and special from a smaller unmatched reliability and composition units. package, which durability, Brevini helical Later this improves efficiency, and bevel helical gearboxes year, Dana will reduces weight have been refined to offer begin offering and minimises performance improvements upgrades that more lubrication that enhance productivity precisely address requirements. and further benefit torque demands of Brevini helical the bottom line.” mining applications and bevel helical with two new gearboxes can monoblock models and three split-case be supplied with low-temperature models in its line of Brevini helical and housings and special seals that support bevel helical gearboxes. operations in extreme environments.

Dana has also made series-wide Additionally, they are available with a design enhancements to its helical wide range of shaft configurations, ratios, and bevel helical gearboxes that seals and painting systems suitable improve power density. for any application.

“Mining and bulk materialDana also recently introduced three handling customers rely on heavy-duty new planetary drives with wide ratio gearboxes to keep the flow of ore and ranges, better power density and modular aggregate moving and support sustained designs that enhance the performance of profitability,” Dana SAC Australia Brevini winch applications. Available now, managing director Greg Bunn said. the new drives offer output torque ratings “Long known for their unmatched from 80kNm to 130kNm and extend reliability and durability, Brevini Dana’s leadership in supplying flexible, helical and bevel helical gearboxes high-performing solutions

F l

T n i m p a u

for mining customers worldwide.

“As mining applications grow in size to meet more demanding market requirements, planetary drives face increased torque requirements within existing design envelopes,” Bunn said.

“We have expanded and revamped our line of planetary drives to deliver enhanced performance, efficiency and flexibility within an industry-leading, power-dense package.”

Dana offers Brevini BWE winches that feature a compact, high-speed piston motor for efficient operation in mining, with 13 different sizes that support lift capacities between 990 kilograms to 30 tonnes. Designed and engineered with best-in-class safety, efficiency and control, these high-performance winches have a modular design and are suitable for electric motor input.

Furthermore, Dana SAC Australia offers an updated range of gear motors and gearboxes based on three product types: parallel shaft helical, inline helical, and right-angle helical bevel.

The housing material is GG20-GG22 cast iron, with the gears made of quality case-carburised steel. Input options include electric motor with and without brakes, Brevini integrated motor, or IEC (International Electrotechnical Commission) or NEMA (National Electrical Manufacturers Association) mounts to suit users’ preferred brand of electric motor.

Dana also provides options for pneumatic and hydraulic motor inputs as well as a solid input shaft. The range is European-designed and manufactured and is interchangeable with other European manufacturers.

Ideal for applications such as conveyors, mixers and small winches, Brevini K series gearboxes feature a monoblock housing designed for higher efficiency and greater strength.

They offer flexible connections as well as integral backstops.

Dana SAC Australia serves as a single source for high-quality, precision-made gears and drives that

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The company specialises in gearboxes with hydraulic and alternating current drive technology.

deliver reliability year after year. The company has extensive expertise in the cost-effective design and manufacturing of custom-made gears as well as complete drives that address industry-specific accreditations, certifications and plant approvals.

Whether a customer requires a standard product or a solution specifically engineered for their needs, Dana can deliver the right solution that checks all the boxes for performance, durability, reliability, serviceability, turnaround times and long-term value.

AGRICULTURE

Agriculture allies share their success AGI and Allied Grain Systems discuss how a partnership between the two businesses has led to benefits for Australian agriculture.

AG GROWTH INTERNATIONAL (AGI) is a massive company, with thousands of staff and dozens of respected brands. It understands the importance of trusted partnerships, including local dealers and agents that help to communicate its mission and solve customers’ problems around the world.

While AGI has operations on six continents, in big and geographically diverse countries like Australia, it relies heavily on local partnerships to provide specialised support.

Peter Forster, AGI’s Australia and New Zealand business manager, said these relationships help meet the immediate needs of Australian bulk handlers and processors.

“We develop these partnerships all around the world,” he told ABHR. “We want to help feed the world and having local support that can deliver a facility that doesn’t stop is vital for that goal.”

Allied Grain Systems is one of these key partners in Australia. The companies began working closely following AGI’s acquisition of Global Industries, which owned the MFS, Yorke, and Hutchinson brands.

Forster said Allied Grain Systems brings real value to the industry.

“They’ve got the building crews and the experience to know exactly how to design and deliver an efficient facility,” he said.

“Their team handles the crane lifts, schedules the electrical infrastructure, builds the silos and ensures they meet Australian standards for silo sealing and safety.”

John White, Allied Grain System managing director, said one of the major benefits of partnering with a multinational company like AGI is the efficiency of scale.

“AGI are good manufacturers with good engineers. A lot of the equipment we buy off them is pretty much the best

26 І Australian Bulk Handling Review: July/August 2022

Allied ensures AGI’s products are ready to use in the Australian market.

you can buy, which is good for Australian enclosed, self-cleaning and selfconsumers,” he said. reloading. All of the bearings are isolated “Big companies sell a lot of and there are no ledges for build-up equipment, so they invest a lot of to gather. Instead, any spilled product time, energy and resources into their or dust falls onto the return belt and is production. They have the scale to mass brought back to the tail section, where produce high-quality components, which it is then diverted to the outer edges of we greatly benefit from. the pulleys, which have flippers to pass it “All of their tooling and workshops back onto the belt. are state of the art – and highly Allied is including Hi Roller conveyors automated. We as part of a major would never have project to deliver “AGI has installed more enough work to transhipment than 10,000 Hi Roller justify spending infrastructure for conveyors around the world. T-Ports at Wallaroo that much on our We know it can handle own manufacturing on South Australia’s these conditions and can processes, but Yorke Peninsula. help with the design and we still benefit The project will scoping process to ensure the see two new silos from their mass final version will meet the production.” built, providing client’s needs.”

Allied ensures 20,500 tonnes of AGI’s products are storage at the port ready to use in the Australian market, itself. Each will be fully sealed to allow using local gearboxes and electrical for fumigation and will be connected to components. Its team knows what works two hoppers each with an intake of 500 well in the local region, which means it tonnes per hour. will pick the right equipment for the job Hi Roller conveyors, with dust from AGI’s global catalogue. filters equipped at each transfer point The Hi Roller enclosed belt conveyor to minimise dust emissions, will travel is one such example. across the top of the silos.

AGI Hi Roller conveyors are totally Forster said the client wanted a

Fast Fact Allied ensures AGI’s products are ready to use in the Australian market, using local gearboxes and electrical components. Its team knows what works well in the local region, which means it will pick the right equipment for the job from AGI’s global catalogue. design life that could last for 20 to 30 years and needed equipment that had been tried and tested.

“Wallaroo is near the sea, so you’re dealing with a high-wind, high-corrosion environment,” he said.

“AGI has installed more than 10,000 Hi Roller conveyors around the world.

We know it can handle these conditions and can help with the design and scoping process to ensure the final version will meet the client’s needs.”

“Allied have a lot of experience and pride in what they do. They’ll only recommend the equipment that is best for the job and have developed their own

Hi Roller conveyors are being installed in T-Ports’ Wallaroo project.

batch conveyor for the project.”

AGI also invests heavily into research for new and existing products. Feedback from around the world helps guide the development of equipment as it encounters a vast range of conditions.

White said the continual improvements in AGI’s technology was a big advantage for Australian businesses.

“AGI puts a lot of effort into the design and development of new technologies, which we can make available to the general public,” he said.

“Because they sell to a lot of big commercial projects, we can supply the local market with leading

technology and equipment that wouldn’t otherwise be available here.”

AGI and Allied Grain Systems will be sharing a booth at the Australian Bulk Handling Expo 2022 (BULK2022).

Forster said he was eager to show Australian businesses how they can benefit from the joint offering between a multinational manufacturer and local expert.

“I’m excited to meet our customers and see what they’re doing and where they are going,” he said.

“It’s always great to meet customers face to face and see how we can help them.”

CUSTOM ENGINEERED WEIGHTOMETERS & WEIGHING SOLUTIONS Manufacturer of conveyer belt scales (weightometers), weigh belt feeders and volumetric and gravimetric auger feeders all manufactured in australia WEIGH BELT FEEDERS Mild Steel Powder Coated for Quarry and Mine installations or Stainless Steel construction for the Food Industry or the Harshest Environments.

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BELT CLEANERS

Managing conveyor belt carryback R. Todd Swinderman from Martin Engineering explains how proper belt cleaning can improve production, minimise carryback and prolonging the life of equipment.

CARRYBACK IS THE MATERIAL that fails to unload from a conveyor belt, adhering to the belt and typically falling off at some point other than the intended discharge.

Accumulation on moving components from dirty belts can cause premature wear and require frequent cleanup, which exposes workers to potential workplace injuries and respiratory diseases.

A conveyor belt cannot be cleaned 100 per cent, because the surface of the belt and the blades are not without imperfections. However, this doesn’t mean operators shouldn’t take a proactive approach to keeping the belt clean. Most industries have gravitated to basic mechanical scraping with a metal or elastomeric blade for flat rubber or PVC belting as the best combination of effectiveness, ease of maintenance and low belt wear to yield the lowest cost of ownership.

Belt cleaners Belt cleaning effectiveness varies day to day with changing conditions and the number and type of cleaners applied, as well as the maintenance they receive.

Keeping the material in the process is always better than letting it accumulate on components and build up under the conveyor. Without effective belt cleaning, experience has shown that as much as 3 per cent of the total cargo can be lost due to spillage, dust and carryback.

Exposure to hazards and injuries are also reduced when less cleanup is

Metal secondary blade pressure at zero rake angle.

Typical installation of primary, secondary and tertiary cleaners

required, saving significant – but seldom considered – indirect costs. The key to consistent cleaning effectiveness is to control the process through proper selection, installation, inspection, and maintenance of the belt cleaning system and establish a safe cleanup routine and schedule.

The use of multiple mechanical scrapers on a belt has been accepted for quite some time as an effective cleaning approach. In most operations, multiple cleaners are required to reduce the carryback to a safe, acceptable level while limiting manual cleanup to weekly or even monthly tasks.

Effectiveness vs. efficiency The undulating action of the loaded belt passing over idlers tends to cause fines and moisture to migrate and compact on the surface of the belt. The amount of carryback that clings to the belt can range from a few grams to a few kilograms per square meter. The level of belt cleaning required is a function of the operational schedule and method of collecting / disposing of the carryback that is cleaned from the belt or dislodged by return idlers and collects outside of the conveyor discharge chute.

When discussing the efficiency

of a belt cleaner, it’s meaningless to talk about efficiency without stating the initial level of carryback. When considering the beginning and ending levels of carryback as a measure of improvement, effectiveness is a better term. Some guidelines do exist. The U.S. Bureau of Mines states that an average of 100 g/m2 of carryback is a reasonable level of performance for belt cleaning. At this level, a 1200 mm wide belt traveling 2 m/s and operating 24-7 would create a cleanup workload of about 7 tonnes per day, a significant labor investment that also increases worker exposure to a moving conveyor and the associated risks.

Carryback level determines the cleanup schedule, but a typical belt cleaner loses effectiveness over time due to wear, lack of inspection and

TrampMe

S

T

E i m a e

Elastomeric primary blade pressure at a positive rake angle.

As 28 І Australian Bulk Handling Review: July/August 2022

ZO

Belt cleaning positions

maintenance. On systems with average or poor maintenance, effectiveness values are generally in the range of 40-60 per cent, thus the need for multiple cleaners.

Cleaning location Unfortunately, designers often focus on the lowest installed cost of the structure around the head and snub pulleys, without allowing enough space for optimum cleaner installation. The figure below shows the clear areas needed on a discharge chute for installation of belt cleaners in the optimum positions. The installations should be at an ergonomic height above the work platform to encourage proper inspection and service.

Consideration in the design stage for locating cleaners in the optimum locations will lead to more effective inspections, maintenance, and belt cleaner performance.

Belt cleaners can be placed anywhere along the return run of the belt, as long as the belt is supported in some fashion.

Since it’s desirable for the carryback TrampMetalAd_1/3Pg_ABHR7/8_22.qxp_Layout 1 6/27/22 cleaned from the belt to be returned

to the main material flow, most belt cleaners are installed inside the discharge chute. Cleaning on the head pulley – labeled the ‘primary cleaning position’– is preferred. Cleaning the dirty side of the belt before it reaches a snub, bend pulley or return idlers is considered less desirable, requiring a dribble chute for cleaners in the secondary position.

The secondary position is complicated by another fact: the nature of carryback is such that it can adhere to vertical surfaces and not flow down a sloped dribble chute. A tertiary position is sometimes required for difficult materials or critical applications such as conveying over wetlands. In such cases, the tertiary cleaners are often enclosed in a spraybox and the effluent directed to a settling basin.

Belt cleaning pressure and blade wear Without enough cleaning pressure, the blade cannot stay in contact with the belt, resulting in poor carryback removal effectiveness and increased blade and belt wear. With too much cleaning pressure, the cleaning performance declines due to deflection of the elastomeric blade or metal blade indentation into the rubber belt. Power consumption also increases dramatically with excessive cleaning pressure.

Keeping a belt cleaner properly 11:22 PM Page 1 tensioned is critical for maximum

Fast Fact Belt cleaning effectiveness varies day to day with changing conditions and the number and type of cleaners applied, as well as the maintenance they receive. Keeping the material in the process is always better than letting it accumulate on components and build up under the conveyor. effectiveness and lowest cost of ownership. The cleaning pressure usually varies over time, based on the maintenance department’s attention or lack thereof. Some manufacturers have begun to offer automatic tensioners and wear indicators which maintain the optimum cleaning pressure and alert operators when blades are worn.

Many belt cleaner systems are installed and forgotten. Lack of inspection and maintenance results in a gradually lower level of effectiveness, higher operating cost and an increased exposure to the hazards associated with cleaning up carryback.

Effective belt cleaning starts in the design stage, with adequate space for cleaners and well-positioned work platforms for ergonomic inspection and maintenance access.

Service-friendly designs improve production, minimising carryback and prolonging the life of equipment.

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GEARBOXES

Gearing up to drop in Sumitomo Hansen has established a dedicated team that designs drop-in gearboxes to replace ageing equipment with minimal disruptions.

TECHNOLOGY ACROSS THE BOARD has become smaller over the past 30 years, and gear boxes are no exception.

Advancements in gearbox design has allowed manufacturers to get an equivalent amount of power from a much smaller product.

However, according to Sumitomo Hansen Australia product manager Wayne Dunstan, upgrading gearboxes with the smaller modern versions requires additional design work to minimise the on-site interruptions.

“Typically, from a power perspective, when we’re replacing a gear box that is 20 to 30 years old, it can be twice the size of a modern equivalent,” he said.

“Over recent years the opportunities to help replace gearboxes with custom drop-ins that will fit in the existing envelope has continued to grow.

Sumitomo offers custom gearboxes that fit into existing applications.

This can be achieved by using a current series gearbox with an adapter plate or a custom fabricated housing.

“This provides a solution for obsolete and unsupported models, with no modifications needed to the rest of the drive system.”

Dunstan said the practice of creating drop-in gearboxes has become more common. Companies will approach Sumitomo after identifying a risk of failure with their current gearboxes and will collaborate to

Sumitomo offers custom gearboxes that fit into existing applications.

30 І Australian Bulk Handling Review: July/August 2022

Sumitomo includes the instrumentation and sensors to ensure the gearboxes can be connected to the cloud.

find the best replacement option.

The new gearbox can be designed and manufactured while the existing unit is still operating, which has proved popular in industries that cannot afford lengthy production stoppages.

“We offer both partial and full

“Over recent years the opportunities to help replace gearboxes with custom drop-ins that will fit in the existing envelope has continued to grow.” drop-in by fabricated steel housings, custom baseplates, custom gearing and shafting and lubrication and cooling solutions,” he said.

“This product will literally drop into place; same footprint, same shaft positions.”

The method has become so popular that Sumitomo formed a dedicated team that designs custom gearboxes. They use the existing gearbox data and engineering expertise to fabricate new designs based on current technology.

Dunstan said the new offering added serious growth for the business, and

customer feedback has been excellent.

“A lot of these sites are getting to the age where there are two or three different generations of gearboxes in use,” he said. “They’ve been in service for a long time, and there have been a lot of advancements in gearbox design since they were installed.

“The drop-in units use the latest materials, manufacturing processes, gear geometry, and are future-proofed for future retrofits.”

Sumitomo includes the instrumentation and sensors to ensure the gearboxes can be connected to a programmable logic controller or to the cloud. This allows the client to take advantage of future technological developments and the internet if required.

Dunstan adds that Sumitomo also offers installation assistance and field services if required.

“We have offices in Melbourne, Perth, Sydney, Brisbane and Mackay that can provide support, assembly and repairs, if necessary,” he said.

“The drop-in replacement is a proven method growing in popularity, especially as supply chain disruptions continue.”

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CABLES

Plastic: the strongest link Treotham Automation’s energy chains are helping bulk handlers protect critical cables from salt, dust and downtime.

Cable chains use high-durability plastic.

MOST MAJOR MOBILE MATERIAL handling machinery depend on cables, often using a festoon system to operate.

If these cables are damaged, or the festoon system requires maintenance, it can cost an operation serious money in lost productivity.

John Sharp, Bulk Materials Handing Specialist at Treotham Automation, said mobile machinery could create violent motions between the trolleys on a festoon system, leading to damage over time.

“Cables are also exposed to the elements, which can degrade them,” he said. “Cable reelers can be helpful, but if you need to add an additional cable, for water or data, you will need another reeler, which can get expensive quickly.”

German manufacturer igus has developed a solution to these issues, which Treotham imports for Australian businesses. Its energy chain – also known as a power chain, drag chain or cable chain – supplies, guides and protects moving cables and hoses.

The cable chains use high-durability plastic and, as a result, suffer from significantly less wear when compared with metal components. They can also be

32 І Australian Bulk Handling Review: July/August 2022

run in environments with sand or near corrosive salt water.

Sharp said the plastic used in energy chains has a low coefficient of friction and low-wear, providing additional longevity.

“Most people can’t see the difference between different types of plastics.

We make sure to pick the right one for the job,” he said.

“In most bulk handling situations, dust is an issue, which can cause issues for festoons. This can cause the premature demise of a system.

“Energy chains can last 10 to 15 years, virtually maintenance-free, with extremely high duty cycles because of its construction. It’s also significantly cheaper than stainless steel or steel versions.”

Energy chains are moulded on the inside so any cables within don’t experience any wear and can handle high use in harsh environments like ports and wharves.

If a component begins to wear, the design of the energy chains makes it easy to inspect and replace. They are also customisable and made from a catalogue of standard parts that

can be tailored to a specific application.

Energy chain can also be used in areas where a significant travel is required.

Treotham offers specific solutions for longer travel lengths, as potential challenges can arise when the length of chain goes over 400m at cable loads of 50kg per metre.

Sharp said igus also developed ways to incorporate the chains into the Internet of Things (IoT), using sensors to detect the push and pull forces while the chain is travelling.

“Globally, the technology has been used in more than 1000 facilities across a range of industries, from the mining and ports sector to manufacturing and warehousing,” he said.

“Australia is more conservative when it comes to upgrading certain parts of its infrastructure. There’s often a tendency to stick with what you know, even if it is potentially outdated.

“Engineers who are looking to embrace innovation have seen the benefits of energy chains.

A lot of the time once they realise the benefits, they’re rolled out across the whole site.”

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PALLETS

What is pallet hooding?

Pallet hooding has traditionally been deployed on high-volume manufacturing lines.

Put simply, it keeps bags and cartons of product secure on their transport pallets, protecting them from the elements as they make their way to the end user. ABHR learns more about the technology and its increasing availability.

THE CONVENTIONAL METHOD OF securing loads onto a pallet is a fairly basic one: wrapping a roll of plastic film around the pallet, typically with a turntable. This ensures the load is stable in transport and mitigates the risk of pallets collapsing on people.

However, this wrapping process often doesn’t fully protect the bags on the pallet from the environment or extended logistics chains.

Braden Goddin, sales and marketing manager at Aurora Process Solutions, said there is a far better way to secure pallets.

“Pallet hooding technology forms a one-piece plastic hood that rapidly stretches over a pallet and its load he told ABHR. “There are several benefits to this. It provides a high level of load containment.

It’s waterproof, dustproof and UV-proof, which lends itself to industrial products that might be stored outside or have a portion of their ‘to-market’ logistics chain exposed to weather “It’s particularly important for products that use paper bags, as moisture ingress can cause a product to deteriorate before it’s even reached the customer.”

Pallet hooding has traditionally been deployed on high-volume manufacturing lines. The technology has

undergone further developments that have made them more accessible for smaller businesses that aren’t operating on a 24–7 schedule.

Aurora Process Solutions specialises in scaling technologies and processes to meet the needs of small-to-medium businesses. The company provides products that semi- and fully automate the packaging, conveying, conditioning, palletising and hooding processes.

Its equipment systems can handle commodities including grain, seed, flour, cement, landscape products and stockfeed.

Goddin said the hooding technology is growing in popularity among lower volume users, leading to better protected products.

“Pallet hoods provide a higher degree of load containment than wrapping, especially if the product is stacked high, is irregular or is not as stable,” he said.

“It also provides far better protection for the product throughout an extended domestic or export supply chain. Traditionally, wrapping tends to come loose or to start unravelling, which wastes plastic and can lead to the product load collapsing.

“There’s also the aesthetics to consider. If you’re selling to a merchant or retailer, plastic hoods tend to look

far neater and more appealing.”

According to Goddin, the building product and landscaping industries have been rapid adopters of the technology, given cements and mortars are typically stored outdoors and need to be protected from moisture to ensure they work properly.

The pet and animal supply sector is another industry that has adopted pallet hooding machinery, mainly for products like animal bedding, wood shavings and bales of fodder.

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Goddin said products that have a plastic hood do not require re-wrapping, which means less plastic is used across the supply chain.

“Pallets can be dispatched across the world through an extensive distribution network,” he said. “If wrapping fails, it needs to be re-wrapped to ensure it is safe, which adds time and cost to the process.

“The plastic hoods can also be made from polymer recipes using a high percentage of recycled plastic, similar to other polyethylene wrap products.”

Aurora works with potential clients to learn about their process and materials.

It can provide a flexible solution to cater for companies with mixed pallets.

Adjustments can also be made to increase the hood’s size and shape on a pallet-by-pallet basis.

Aurora’s staff will work closely with the client’s finance and accounting staff to model a return on investment from

the proposed solution. If it stacks up, so to speak, then all parties have the confidence to move forward.

Curious clients can also visit installations to talk with the operators and learn the ins and outs of the equipment in similar industries.

Goddin said the company had plenty of satisfied clients around Australasia who are happy to share their successful experiences.

“We also have a lot of video resources we can provide to give them an idea of how it all works,” he said.

“It’s a lot easier than people think. It might seem like a major change to move from wrapping to hooding, but changing can be done simply and rapidly.”

The company will also be presenting the technology at BULK2022. The trade show, which will be held at the Melbourne Convention and Exhibition Centre from August 24–26, gives attendees an opportunity to see the latest

Pallet hoods tend to provide a higher degree of load containment than wrapping.

emerging technologies in the industry.

“We will have a stand at BULK2022 and are excited to discuss the latest innovations in the world of industrial packaging and hooding,” Goddin said.

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VIBRATORS

Keeping Aussie producers buzzing Mark Thompson, director at Oli Vibrators, explains how the company helps manufacturers – whether they’re concrete producers or a biscuit factory.

WHEN IT COMES TO HELPING manufacturers, every day brings Oli Vibrators a different product and challenge to overcome.

Mark Thompson, the company’s director, said he could be working with a flour mill in the morning, a major metropolitan construction project by lunchtime, and a quarry in the afternoon.

“Vibrators can be used pretty much anywhere where bulk materials are involved in a process,” he told ABHR. “For example, if you’re producing bread with a range of different ingredients, they could be used to promote flow from bins, silos and hoppers.

“Or if you’re producing concrete and loading it onto a truck, vibrators can batch out sand, cement and aggregate accurately into the weigh bin.”

With so many different products and industries, Oli Vibrators works closely with its customers to learn as much as they can about their processes. The customer will often provide a checklist of important information, along with some technical drawings to get started.

Oli Vibrators’ team will work with customers to determine the characteristics of the product, such as bulk density, explosive risk, hygiene requirements, whether it is hydroscopic, the vessel it is being stored in, and more.

Vibrators are used much across the bulk materials handling industry.

36 І Australian Bulk Handling Review: July/August 2022

With that information, the company’s engineers will usually find a solution that will work for the customer within 24 to 48 hours.

“We were working recently with a manufacturer of artificial reefs. They need the cement concrete they’re using to fill in all the aspects of the formwork to ensure the process is efficient and avoids creating rejects,” he said.

“We came up with a solution that helped the concrete flow to where it was needed.”

Another reason customers call Oli Vibrators is to solve problems with dust collectors. Dust could be coming from the hoppers and bins underneath a

Each product comes with a two-year warranty, which includes full replacement or repair.

Fast Fact Cleaning is another way manufacturers use vibrators.

Oli has previously installed its equipment to clear out residual sulphur to allow other products to be added without the risk of cross contamination. Other vibrators are used to help compact the same sulphur product into bags. woodworking manufacturing process, or it could be coal or gypsum dust.

Cleaning is another way manufacturers use vibrators. Oli has previously installed its equipment to clear out residual sulphur to allow other products to be added without the risk of cross contamination. Other vibrators are used to help compact the same sulphur product into bags.

Oli can also work with customers to reduce noise emissions from vibrators if needed.

Thompson said his team has been in the industry for more than 20 years, gathering a broad range of collective experience in the process.

“We also have many engineers that we work with on a daily basis,” he said. “If we need specialist help, we can also reach out

to the European-based experts.”

The company is based in Modella Italy, where it engineers and develops its products. Its mission statement, ‘When you need it, where you need it’, has helped form its strategy to keep all 24 of its global trading subsidiaries well-stocked.

In Australia, the business has a service centre in Scoresby, Melbourne, along with a network of support agents across the country.

“The vibrator market is competitive, so we rely on our high-quality products, technical expertise and the ability to provide all the specifications an engineer could possibly want.”

“Our sales team members in Australia are highly trained, and we even run education programs for our customers,”Thompson said.

“A concrete company asked for this kind of support, so we came in, showed the staff there how to properly mount the vibrators, explained how they should be used and on what applications.”

This education helps users gain a deeper understanding of their manufacturing process and helps them

get a longer life out of the vibrators, while protecting their assets.

When used correctly, Thompson said the vibrators are virtually maintenancefree and easily replaced at the end of their life. Once fitted, they go about their business based on the operation and can be programmed to work in conjunction with the process.

“The vibrators are made from high-quality components and undergo a rigorous testing regime before being released onto the market,” Thompson said.

“Each product also comes with a two-year warranty, which includes full replacement or repair.

“The vibrator market is competitive, so we rely on our high-quality products, technical expertise and the ability to provide all the specifications an engineer could possibly want.”

The company is currently targeting the concrete and mining sectors, following several high-profile tunnel project works across Australia.

“We have good partnerships with large mining businesses and original equipment manufacturers,” Thompson said.

“We are looking forward to growing in this area and looking forward to meeting key stakeholders at BULK2022.”

Australian Bulk Handling Review: July/August 2022 І 37

SCREW CONVEYORS

Nestlé Singapore improves metal detection with flexible screw conveyor

Detecting contaminants in Nestlé’s Singapore plant was a cumbersome process, until it installed a new flexible screw conveyor.

MILO, THE MALT BARLEY AND cocoa drink, is a household name in Australia. Owned by Nestlé, the chocolatey beverage is also widely popular in Southeast Asia.

The company has operated a manufacturing plant in Singapore since 1912, producing and packaging the Milo powder in its iconic tins, as well as sachets that are formed and filled on a high-speed rotary filler.

Upstream of the sachet filler is a metal detector that scans the powder to identify contaminants. Detection of a contaminant, called a “strike,” triggers the metal detector to divert a portion of the powder stream into a collection bag. Workers then inspect the rejected powder to verify that the contaminant was removed and log the incident into a quality-assurance report. This had been a cumbersome process until a flexible screw conveyor smoothed the flow to the metal detector.

Agglomerated powder complicated detection The metal detector originally sat directly below the surge hopper that discharged the Milo powder through a butterfly valve.

Sean Phua, technical engineer at the site said when the valve opened, often one large chunk of powder would flow through the metal detector which wasn’t fast enough to reject the As a result, some portion of the powder—and possibly the contaminant— passed through the metal detector and into a flexible screw conveyor that transferred it to the sachet filler. That would force operators to halt production.

With production halted, the operators would run the flexible screw conveyor in reverse to empty all the powder in flight. That powder, along with the

38 І Australian Bulk Handling Review: July/August 2022

Contaminant-free powder gravity feeds from the raised metal detector (top right) and is transported by the flexible screw conveyor to the sachet filler.

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“All strikes are rejected before the powder enters the original flexible screw conveyor to the sachet filler, eliminating false rejections and manual clearing of powder from the conveyor.” rejected material, was then hand-sieved and dissolved with water to find the contaminant and “determine whether we had a real or a false strike. It was messy and the interruptions reduced packaging productivity,” Phua said.

He learned that the operation would improve if the powder could free fall into the metal detector in a steady

stream. One possible solution would be to add a rotary valve under the surge hopper, but lack of headspace made that impossible, Phua said.

Instead, Flexicon recommended offsetting and raising the metal detector, allowing room to add a new flexible screw conveyor to feed powder to the metal detector in a steady, controlled flow. Flexicon Singapore provided the new conveyor to accommodate spatial constraints and throughput requirements.

The conveyor is 1.5m long and includes a spiral enclosed in a 90mm diameter outer tube made of ultrahigh-molecular-weight polyethylene.

The screw—the only moving part that

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contacts the product—ensures that the powder does not pack, cake or separate.

The conveyor includes a 150mm diameter inlet flange and charging adapter that connects under the surge hopper’s butterfly valve. From there, the powder is transported at a 41-degree angle and discharges into the metal detector through a 150mm diameter downspout. The conveyor’s 2.2 kW drive

Fast Fact The conveyor is 1.5m long and includes a spiral enclosed in a 90mm diameter outer tube made of ultra-high-molecular-weight polyethylene. The screw—the only moving part that contacts the product—ensures that the powder does not pack, cake or separate.

The conveyor includes a 150mm diameter inlet flange and charging adapter.

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Nestlé Singapore packages 720 kg/hour of Milo powder.

turns at a constant speed to transport about 720kg of powder per hour for 20 hours a day. Level sensors at the conveyor’s inlet and discharge are linked to the sachet filler’s controls, enabling both units to operate in sync.

Regulated flow improves detection, cuts downtime According to Phua, the new flexible screw conveyor has streamlined the operation.

“All strikes are rejected before the powder enters the original flexible screw conveyor to the sachet filler, eliminating false rejections and manual clearing of

powder from the conveyor,” he said.

His colleagues in the qualityassurance department welcome the improvement.

“Because we have more positive rejection from the metal detector, quality assurance people have less worry about contaminants not being rejected.”

More reliable rejection boosts productivity by increasing sachet filler uptime and reducing incident reporting, while conserving product.

“Previously, large chunks were being rejected. Now as a freefall, less powder is flowing, which reduces product loss by a good amount,” he said.

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LOADERS

The Dugless 903 includes a multi-cyclone block that reduces the need for filter changes.

New generation Dugless 903: does the work of a 20-strong team in places they can’t reach The Minprovise Dugless 903 mini loader cleans up underneath conveyor systems, without the need for shutting them down.

MINPROVISE DESIGNED AND manufactured the first Dugless 900 mini loader in Australia more than 10 years ago, winning awards for design and innovation.

Safely remote controlled from up to 50m away, the machine eliminates manual handling and can clean up large volumes of spilt material in a fraction of the time. The Dugless 900 has evolved into the Dugless 903, a new generation that features a 3D printed airbox with an enhanced air intake system that delivers more uptime between air filter changes.

Dust is a major concern for any mining operation, especially in dry and

The machine can be safely remote controlled from up to 50m away.

40 І Australian Bulk Handling Review: July/August 2022

windy areas, so it plays a significant That translates into a significant factor in the life of any mining machine. amount of time and money savings.”

The Dugless 903 includes a multiThe Dugless 903 also features an cyclone block that Minprovise managed air blowback system that expels the to fit into a 56-centimetre-tall footprint. ingress of water from the machine The cyclone-style air intake system after it’s washed. Whether cleaning reduces the need for filter changes underneath conveyor systems on dry and improves and dusty mine maintenance access sites or sludgy “We’ve been able to get a to filter cartridges spillage on project multi-cyclone block into “We’ve been sites and even a very, very small space. able to get a the odd chicken Everything has to be multi-cyclone compact. There’s nothing off coup, Sutton said block into a very, the Dugless 903 the shelf you can buy that’s very small space,” has a significant able to achieve what the Minprovise general advantage of Dugless 903 does.” manager Tony reaching places Sutton said. “Everything has to be that conventional front-end compact. There’s nothing off the shelf loaders simply can’t get to, you can buy that’s able to achieve and neither can people. what the Dugless 903 does.”

“The major advantage of the Dugless, The upgraded Dugless 903 uses of course, is that you can clean or retrieve vortex cyclones that provide an enhanced spillage while the conveyor is still level of particle extraction. running, so no shutdown needed for any “We could clearly see that the cyclone clean up. And then it’s a spray with the system pulled dust particles out much hose, a quick and easy check of filters and more effectively,” Sutton said. it’s ready for action again,” he said.

“You can expect to be around The Dugless 903 is on display at the 14 per cent more efficient every day BULK2022 Minprovise stand 4314. because of less filter change outs.

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BALANCED MACHINES

TAKRAF’s engineering stacks up TAKRAF’s team of engineers are highly specialised in balanced machines.

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ABHR talks to Pedro Beleigoli about how TAKRAF’s team of specialist engineers are helping bulk handlers get the most out of their balanced machines.

TAKRAF HAS BEEN SUCCESSFULLY providing balanced machines for the Australian market and has been expanding its after sales and service segment in an effort to provide services covering the entire lifecycle care of its clients’ machines.

TAKRAF offers after sales support and warehousing to its customers around Australia, with a dedicated aftermarket team.

From an initial assessment TAKRAF are able to provide a complete range of solutions including the actual implementation. One of the services portfolio focus is equipment upgrades and life extensions. Purchasing a new stacker, reclaimer or shiploader is a big investment and a lengthy process, which is why many mines and ports try to upgrade or extend

Fast Fact TAKRAF’s team of engineers are highly specialised in balanced machines, working closely with clients looking to improve, refurbish, upgrade, or maintain their stackers, reclaimers and shiploaders.

42 І Australian Bulk Handling Review: July/August 2022

the life of their existing equipment.

“Many times, we are faced with a challenge to increase production with the existing equipment or extend its lifetime – the clients want to get more out of what they already have.

“Recently we were tasked to increase the capacity of a machine by more than 50 per cent of its original design, without sacrificing reliability. This process also

“We put a lot of effort on designing engineered solutions to make the deconstruction process remarkably safe.” involves functional safety assessment and identification of gaps between the existing equipment and latest Australian Standards recommendations to decrease operational risks.”

TAKRAF’s team of engineers are highly specialised in balanced machines, working closely with clients looking to improve, refurbish, upgrade, or maintain their stackers, reclaimers and shiploaders.

Each team member has a career focus on designing bulk handling balanced machines, so they are well equipped to

find solutions. “Summing up our team experience, we have more than 150 year’s know-how in balanced machines”.

When the life of the equipment has really come to an end, TAKRAF is also helping client`s in the decommissioning process. It has recently successfully deconstructed three mobile machines in Australia.

“We put a lot of effort on designing engineered solutions to make the deconstruction process remarkably safe.”

Industry feedback has been positive, with customers reporting additional value added to their processes.

Beleigoli said this is because TAKRAF, as a designer and supplier of balanced machines, understands the equipment to the last bolt while keeping a holistic overview.

Their experience in balance machines design helps them find novel solutions to complex problems.

Additionally, TAKRAF can provide clients with complete solutions, from design, procurement, installation to commissioning and supervision, adding value and confidence to its clients entire lifecycle care and maintenance process.

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The Next Generation Dugless is here

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Continued Dugless 900 reputation of Quality and Innovation in the upgraded Dugless 903

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Remote controlled by one trained operator from up to 50m away. No teams. No injuries

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Same dependable and proven track record now with upgraded key features

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No expensive conveyor shutdown during maintenance

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New Design Air Intake System combats dust increasing engine and filter lifespan significantly

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Consistently removes large volumes of spilt material, including hazardous spills

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Improved productivity with speed and efficiency

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Decreased maintenance cost with new easy-access filters

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Maximum vortex effect through upgraded 8-chamber, single layer, multi cyclone

Easily accesses low ground clearance conveyor frames at only 560mm tall

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Utmost safety - lowest accident risk

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Maintenance managed by LV mechanics on-site

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Award winning WA designed, engineered and manufactured

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AUSTRALIAN MADE

LGPM delivers bespoke stockfeed plant LGPM won a major contract to deliver a new stockfeed processing plant in WA. ABHR speaks to the company’s general manager to learn about how its local manufacturing supported the project.

The company has full control over the design and manufacturing process allowing it to be flexible.

BULK MATERIALS HANDLING process business LGPM can trace its history back to 1968 with the creation of the Sydney-based company Grain Processing Machinery (GPM).

The company has since grown and flourished, expanding across the country and overseas. In 2004, a generational change in GPM’s management led to the merging of the company’s Melbourne division with Lynchborough Corporation to form Lynchborough–GPM Corporation (LGPM).

Bruce Stewart, LGPM’s general manager, said the company aims to be a one-stop shop for bulk materials handling and processing solutions.

“We do all our design work, engineering, drafting and fabrication in-house,” he told ABHR. “We have our own on site equipment like cranes, telehandlers and installation teams, which allows us handle a project from concept to manufacturing to installation.”

“This means we can be very flexible and tailor solutions for what the

44 І Australian Bulk Handling Review: July/August 2022

customer needs. Other suppliers in a similar industry might only be able to sell standard off the shelf products – we can hand pick the right tools for the job.

“We have full control over the process and aren’t completely reliant on external suppliers. We can be flexible and plan out our design and manufacturing to ensure it fits our scheduling needs.”

“We’re fully solar-powered and we ensure our materials are being ethically sourced.

We recycled or repurposed as much waste materials on site as possible” This flexibility was vital for the company’s most recent project, delivering a 30-tonne-per-hour, highfibre feed mill in Western Australia.

The plant required grinding equipment, bulk storage for grain and meals products, micro-ingredient batching and pelletising machinery.

The client needed to shred high-fibre hay bales, which are difficult to handle

and can be highly abrasive for process equipment. This hay, along with other ingredients, would then be ground, mixed, pelletised, stored and loaded onto road train trucks.

Stewart said the process needed to be highly efficient, require minimal operating labour and have fully automated process control to be able to operate at maximum throughput.

“We initially started working with the client on the design and submitted it to the local council for development approval,” he said. “We then won the contract to handle the whole project – bulk earthworks, building works, process, landscaping, signage and everything in between.

“We sent our installation crew from Victoria to the site and used local contractors for works like concrete.

We also sent all our equipment needed for the job, including cranes, telehandlers, and boomlifts.

“A Perth-based construction manager was employed to assist, and local consultants

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Fast Fact Handling the straw safely was key to the design. Straw is flammable and prone to explosion, so explosionventing devices were fitted on bins and filters. Spark-detection and suppression systems were also installed in transfer lines, and sensors check the conveyor belts for slippage and alignment to avoid any friction fires.

The plant required grinding equipment, bulk storage for grain and meals products, microingredient batching and pelletising machinery.

helped with the council submission.”

Handling the straw safely was key to the design. Straw is flammable and prone to explosion, so explosionventing devices were fitted on bins and filters. Spark-detection and suppression systems were also installed in transfer lines, and sensors check the conveyor belts for slippage and alignment to avoid any friction fires.

LGPM will also provide full after-sales support for the project and has a spare parts department

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Stewart said sustainability was also a key issue for the local manufacturer and project implementation.

“We’re fully solar-powered and we ensure our materials are being ethically sourced. We recycled or repurposed as much waste materials on site as possible” he said.

“We’re planning to expand our workshop and increase our manufacturing facility, which will let us further support the industry.”

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AUSTRALIAN MADE

Supplying silos for on-farm demand HE Silos tells ABHR about why demand for on-farm silos is increasing and how the company helps farmers grow their storage infrastructure.

THE INTRODUCTION OF WEBbased trading has opened a world of possibilities for Australian farmers.

Now, at the touch of a button, local growers can find the current market price of grain, browse the market fluctuations and forecasts, and sell their product through grain trading company portals.

Historically, farmers would have needed to trade through grain pooling organisations instead of directly on the market.

Larry Storm, business operations manager at HE Silos, said this often meant farmers would sell their grain at the harvest, when the price was usually at its lowest.

“Web-based trading lets

HE Silos manufactures high-quality silos at its NSW-based factories.

46 І Australian Bulk Handling Review: July/August 2022

farmers store and sell their commodities when and where they will get the best price,” he said.

“This maximises their returns, assists with cash flow and leads to growers adding further storage on-farm.”

HE Silos manufactures high-quality

“We look forward to talking to local growers about their on-farm demands and about how HE silos can provide solutions for their growing enterprise needs.” silos at its NSW-based factories, two in Forbes and one in Gunnedah. More than 70 staff work to deliver range of silos, from 1000-tonne flat bottom silos to four-tonne silos with a cone base.

Recently, the business has seen a marked

uptick in demand for on-site storage capacity.

Storm said on-farm storage can also greatly improve traceability and grain management.

“End users are driving demand for more traceability, which causes processors to enforce tighter quality specifications on the grower and through the supply chain,” he said.

“High quality and consistent grain allow processors to be more efficient in their conversion rates and equipment throughputs – all of which effect the cost of production.

“Being able to segregate grain by variety and quality on-farm means lower quality grain doesn’t degrade a large percentage of the overall harvest.”

There is more to on-farm storage than simply installing a few silos on site. HE Silos collaborates with its customers to ensure they have the right tools and knowledge to effectively store commodities for extended periods.

If stored incorrectly, insects can infest the grain or moisture can quickly

turn to mould. If stored in a bunker, rodents also become an issue for farmers.

To help farmers safely protect against insect infestations, HE silos has developed the Thermal Insect Control System (TICS), a thermal syphon used to activate and distribute phosphine gas throughout a silo, operated at ground level.

HE Silos developed TICS to remove the need to climb on top of a silo to fumigate it, which carries a high risk of injury or death.

“We are now providing the TICS System on most of our silos, with the famers adding the system as part of their order, knowing and understanding the TICS system solves a safety issue and provides a simple, fast, effective and consistent way to fumigate their silos, helping to manage and maintain their grain quality without insect damage, which increases their return on investment,” Storm said.

The company plans to expand its manufacturing capacity with a new

HE Silos collaborates with its customers to ensure they can store commodities for extended periods.

Australian Bulk Handling Expo (BULK2022) from 24 to 26 August.

“We look forward to talking to local growers about their on-farm demands and about how HE silos can provide solutions for their growing enterprise needs,” he said.

“We’re also hoping to review and expand our technology range with the latest innovations in the agriculture market.”

facility. It will feature dedicated space to conduct and test design changes and improvements, in-house.

HE Silos will also invest more into Computer Numerical Control (CNC) equipment that can be programmed directly from computer aided design (CAD) files, improving accuracy and throughput while decreasing waste.

Storm said HE Silos will also be attending the

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AUSTRALIAN MADE

Tecweigh expands its conveying and weighing range The Australian manufacturer’s latest feeders are designed for weighing and dosing in the food, quarry and mining industries.

DYNAMIC MEASURING IS A CRITICAL part of the process for many mines, quarries and food manufacturers.

Without accurate information about how much material is being conveyed, monitoring, storage management and feed metering become incredibly difficult.

This is why Tecweigh, an Australian manufacturer, produces a range of belt scales, weigh belt feeders and volumetric feeders.

Barry Gamble, Business Development Manager at Tecweigh, said being a local manufacturer for these products has allowed the company to keep costs down and ensure continued supply during periods of COVID lockdowns.

“We do all our manufacturing in Carrum Downs, Melbourne, which gives us a fast response time,” he said. “We can normally deliver what the client needs within seven to 10 days.”

“Custom designs are our standard.

Whether its chemicals, crushed stone, sand, coal, or materials that are

A fully populated board used in Tecweigh equipment.

48 І Australian Bulk Handling Review: July/August 2022

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Tecweigh manufactures its equipment in Carrum Downs, Melbourne.

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low density, sticky, or abrasive, we specialise in building the equipment needed to accurately weigh it.

“Our products are also designed for heavy-duty work and have been proven over time to be accurate in some of the world’s harshest environments.”

To ensure its products are reliable in Australia’s often-harsh conditions, Tecweigh uses stainless steel, hermetically sealed IP68 load cells designed to provide accuracies of ± 0.5 or ± 0.25 per cent for its weigh belt feeders and conveyer belt scales.

The weigh idler system has been designed to be easy to calibrate to provide consistent accuracy. Its volumetric feeders have a range from of up to 32,000 litres per hour with single or dual drives for loss in weight.

Its weigh belt feeders can also be manufactured to specific lengths and widths, using powder-coated mild steel or stainless steel, depending on the application.

Gamble said that in addition to its main range of products, the company is increasing its range with a new loss in weight controller “It uses an Australian-designed

and built signal conditioner circuit board, deployed at the heart of Tecweigh’s measuring and meteringproducts,” he said.

“The loss in weight controller gives users greater accuracy for dispensing products and provides an extra layer of control over an ordinary volumetric feeder.

The fact it is based in Australia means Tecweigh can also offer local after sales support. The company maintains a significant stock inventory for its conveyor belt scales, volumetric feeders, and weigh belt feeders. It also offers field service support and spare parts supply.

Gamble said the company has built a long-lasting relationship with its own local suppliers and aims to further grow in the industry.

“Tecweigh’s experts have more than 100 years of experience providing bespoke bulk weighing solutions,” he said.

“We’re excited by our new products and continue working with our customers to find innovative weighing solutions.”

Tecweigh is recognised as an Australian manufacturer.

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AUSTRALIAN MADE

Unusual solutions for unusual problems DYNA Engineering has undergone International Standards Office accreditation to prove users can rely on its mechanical engineering and locally manufactured products.

This shedder/chute (shown in green) was designed, built and installed by DYNA to prevent rockfall from twin conveyors.

UNLIKE REPLACING A ROLLER or installing a new belt, solving mechanical engineering problems can require a lot of thinking outside the box.

Because no two bulk handling sites are the same, what works in one application often just won’t fit in another.

For example, a mine site might need to include a pipe as part of a vital upgrade but doesn’t have the space for the required pipe stand.

That’s where DYNA Engineering comes in. General manager Thomas Greaves told ABHR that when clients have a mechanical engineering problem,

50 І Australian Bulk Handling Review: July/August 2022

it usually requires an unusual solution.

“We have provided this service for about 10 years. In most cases, an existing customer approaches us to see how we can help with a specific issue they have on-site,” he said.

“After we get the enquiry, we have a meeting internally to brainstorm a few ideas to present to the customer. It’s important to provide several options, as often factors that aren’t always apparent at the initial scope can affect the decision-making process.

“We then work closely with all the stakeholders – the project managers, teams on-site – and run the concept by them again.

“Once chosen, we proceed to conceptual design, and run about two to three design reviews to make sure they end up getting something that solves the problem in the way they want.”

DYNA Engineering is a fully Australian owned and operated business that manufactures most of its products in its Bayswater facility in Western Australia. These local components can be made in as little as a couple of days, as opposed to weeks or months for overseas suppliers.

The company manufactures rollers, pulleys, scrapers, and mechanical componentry for conveyors, along with the more complex engineered fabrications like pipe stands and chutes.

Greaves said the industry needs have been changing when it comes to accreditation.

“ISO (International Standards Office) accreditation is almost becoming an industry standard when bulk handlers look for vendors to conduct ongoing business with,” he said. “Manufacturers need these accreditations to operate in the industry.

“Manufacturing and mining are industries with higher risks. Workers are handling dangerous equipment like drill presses and grinders, so safety is paramount.”

DYNA Engineering has recently undergone the third-party accreditation processes. It has proven it meets the

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quality assurance, environmental, and work health and safety standards.

Greaves said the accreditation gives stakeholders and customers even greater confidence that they can rely on DYNA. “DYNA has always been near the ISO standards, and having the formalised audit proves that we have a level of commitment to the industry,” he said.

The accreditation has also improved the company’s risk management processes, as it used the opportunity to create a defined, methodical, and consistent documentation process.

“Over the last three years we have tripled in size. When you have a growing business, having a written procedure helps people get up to speed quicker and keeps things consistent,” Greaves said.

The accreditation decision also came at an opportune time for the business, as the WA Government has begun to implement harmonisation laws for health and safety.

The ISO process gave the company an

opportunity to look at the new legislation and ensure its processes met the new standards. It has also incorporated a cloud-based software for documenting and controlling its systems. Each employee has access to the software, allowing them to bring all stakeholders through the manufacturing process.

If a safety event occurs, workers can also log it on a mobile app, which notifies the relevant people and keeps note of what needs to be actioned and investigated.

Greaves said a paper-based system for record keeping and management was a nightmare to work with.

“The cloud-based system is a lot more accessible for small-to-mediumsize business,” he said.

“Nothing can get lost, which makes it a major benefit for us,” he said.

DYNA Engineering plans to continue growing and is looking to capitalise on the accreditations. It wants to leverage steady growth to help

DYNA Engineering’s general manager, Thomas Greaves.

create more local manufacturing jobs.

“We’re big on creating local jobs that provide local skills, which is why we have three apprentices and four trainees,” Greaves said.

“By upskilling our workforces and holding on to our valuable employees, we can continue to provide technical assistance and reliable components.”

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BULK2022

Kinder Australia skirts with air AirScrape uses a unique design to contain dust and bulk material while avoiding contact with the conveyor belt.

MOST SKIRTING SYSTEMS CREATE a passive barrier to stop material from escaping a belt near a transfer point.

While this prevents spillage, it can also lead to increased wear on the belt.

Kinder Australia’s AirScrape takes a different approach. The skirting system is suspended above the conveyor belt itself and uses air to prevent fine dust particles from escaping.

A diagonal arrangement of hardened lamellae leads air from the outside into the middle of the belt, creating powerful suction. The material movement, together with the moving belt support, increases the suction effect, trapping fine dust particles in the conveyor section.

Coarse materials pushing outward are led back to the middle of the belt by the lamellae, which can significantly minimise spillage.

Charles Pratt, Operations Manager at Kinder Australia, said the innovative system can save bulk handlers a significant amount of time and money.

“The reason most belts need to be changed is because a groove forms where the skirts are – you’re not getting the full life out of the width of the belt,” he said.

“Because the AirScrape doesn’t touch

AirScrape was designed to solve the issues found in underground coal mining operations.

Kinder Australia can design customised skirting systems.

the belt. It extends the life of the skirting the need for dust collectors at a few system and the conveyor belt itself, often of our clients’ sites. Some have even one of the most expensive components. been able to turn the dust collector off, “By reducing changeouts, less replacing it with a filter bag,” he said. downtime is needed, increasing the “It’s been successful in the cement profitability of most operations.” industry as well. Turning clinker into The system is installed using spacers, cement is a dusty process, so it’s been floating the blades 0–1mm freely above really suited to the task.” the belt, and is attached to the outside Kinder Australia can design of the chute by lifting tensioners via a customised skirting systems, help screw system. It is longitudinally and clients upgrade their existing designs to laterally adjustable to follow the contours facilitate the AirScrape, and organise its of conveyor belt rollers and the belt installation through its distributors and trough angle. service teams.

The system’s The technology “Because the Airscrape invention was will be on display at draws air from outside, it designed to solve BULK2022, which has significantly reduced the issues found in will take place on the need for dust collectors underground coal August 24–26 at at a few of our clients’ sites. mining operations, the Melbourne Some have even been able where dust can Convention and to turn the dust collector off, pose a significant Exhibition Centre. replacing it with a filter bag” health risk to Pratt said Kinder nearby workers. will also be showcasing its Magnaseal Kinder Australia has seen significant and Magnaplug products, used for interest since the patented technology containing leaks, liquids, and dust. was launched in July 2021.

“We’re looking forward to Pratt said the introduction of meeting customers at the trade show the AirScrape, particularly its radical and to see what else is happening in the design, came as a bit of a shock to industry,” he said. the Australian market.

“BULK2022 also gives us a great “Because the Airscrape draws air opportunity to hear directly from from outside, it has significantly reduced customers themselves.”

52 І Australian Bulk Handling Review: July/August 2022

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AUSTRALIAN MADE

PROK’s HDPE rollers use a non-metallic housing and three-tiered sealing system with multi labyrinth and contact seals.

Rolling out Australian innovation PROK’s HDPE rollers have provided the Australian mining industry with a lighter-weight alternative to steel. ABHR learns more about how the rollers are designed for long-lasting use in intense conditions.

MOST MINING CONVEYORS ARE high-capacity and high-tonnage systems that put considerable load onto rollers.

In the iron ore sector, especially, rollers are often made from steel to ensure they are strong enough to handle the load.

However, the fact steel is a heavy material adds considerable strain to the manual handling process. The heavier a roller, the harder it is to manipulate by hand.

Ray Anderson, engineering manager at PROK, told ABHR that this can lead to increased chance of injuries on-site.

“Changing a roller means someone needs to physically lift it into and out of position. The heavier it is, the harder it is,” he said.

A green inner layer is incorporated into the yellow rollers to act as a visual indicator for maintenance teams.

54 І Australian Bulk Handling Review: July/August 2022

“It can cause lower-back injuries associated with movement and rotation, as often the person will need to lean with the roller to get it into place.

“If the roller gets dropped, it can cause serious damage to anyone in its way, especially if it’s someone’s hand in a pinch point.”

PROK began working on a lighter roller that would still be strong enough to handle the intensive environment. The company undertook an extensive process, working with research institutions and the mining industry to find the right material and design that would work.

After years of development, PROK had developed a specially designed line of high-density polyethylene (HDPE) rollers that could support the changing mining industry.

Anderson said the plastic had proven itself in the market after having been in used for mining applications for years.

“HDPE can be UV-stabilised and can contain different additives to change its structural or mechanical properties,” he said.

“It’s stable, rigid and strong, a perfect mix for the mining industry.”

The rollers were released to the market around 2020, and have been installed all over Australia, particularly in the WA iron ore industry.

On average, the PROK HDPE rollers are around 40 per cent lighter than steel alternatives, allowing maintenance personnel to quickly and safely perform roller changeouts. The non-metallic tube also significantly reduces the likelihood

of damage occurring to the belt in the event of a failure.

The rollers have now been operating in mines for two years, with miners praising the longevity of the rollers. One leading iron ore miner recently sought out PROK to help solve reliability issues with its existing composite rollers.

PROK replaced the rollers with its HDPE rollers, and after 12 months of continuous operation in a highly loaded conveyor, PROK HDPE has experienced zero failures.

Anderson said the rollers’ longevity was partially due to their high-quality sealing system.

“Roller failure often occurs when there is a failure due to contamination in the bearing housing,” he said.

“Once solid contaminants such dust enters the bearing, they can get caught between the raceway and the balls, creating micro indentations and small fragments. Over time, this promotes spalling and causes a chain event that cannot be reversed.

“Fluids entering the bearing will not only dilute the grease (reducing the effectiveness of the grease) but promote corrosion, again a chain event that cannot be reversed. Both solid and liquid forms of contaminant will result in a seized bearing days-months after entering.”

The bearing will become noisy, have increased vibration eventually seize and stop rotating, where it will either flogout the bearing housing (ie the housing spins without the bearing rotating) or the shell will become fixed. These issues

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can cause unscheduled shutdowns to protect the belt from damage.

PROK’s HDPE rollers use a nonmetallic housing and three-tiered sealing system with multi labyrinth and contact seals to protect the bearings from contaminants.

It also makes use of an internal seal moulded with a low-friction stainless steel running face that is positioned against a contact seal. This prevents the ingress of dirt into the bearing and optimises seal efficiency, resulting in a longer service life.

The rollers also include a unique method of monitoring wear.

“Mining companies can change out dozens of rollers on any given day, and sometimes this is done without knowing whether the roller has reached the point of potential failure,” Anderson said.

“Traditionally, it is hard to know how much and the type of wear a roller has experienced, especially when it comes to return rollers that are exposed to high levels of carry-back.

“That’s why PROK’s rollers include visual wear indicator technology to help mining companies plan their maintenance.”

A green inner layer is incorporated into the yellow rollers to act as a visual indicator for maintenance teams.

This helps mining companies identify which idlers need to be replaced

“HDPE can be UV-stabilised and can contain different additives to change its structural or mechanical properties. It’s stable, rigid and strong, a perfect mix for the mining industry.” and can assist with implementing maintenance scheduling strategies or highlighting problematic areas.

Australian made PROK is a proud Australian manufacturer, seeing it as a distinct advantage that complements its brand. The

company manufactures its rollers at facilities around the country for use in local mines.

Wade Guelfi, the company’s general manager for WA and Southeast Asia, said PROK being on the doorstep of its major customer base creates greater opportunities for flexibility.

“Our local engineering and production capabilities are readily accessible to our customers,” he said.

“With new products coming online and continual changes in developing products, PROK’s excited to further invest in automated roller manufacturing to really complement the long-term contracts that our major mining companies have entrusted to our business.

“We’ve always been focused on Australian manufacturing because we believe it provides us with a distinct advantage. Having flexibility and local knowhow is a massive advantage.”

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AUSTRALIAN MADE

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talk

Bulk handling in Australia: an overview I HAVE BEEN BASED IN

STEVE DAVIS Steve Davis discusses Australia’s bulk handling sector, highlighting the advancements the industry has made and the organisations that are providing local innovations and expertise.

Steve has worked in bulk handling for 30 years, for both resource companies and professional engineering firms, in Australia, South Africa, the Middle East and Canada.

His experience encompasses such commodities as iron ore, coal, potash, phosphates, petcoke, sulphur, sands and grain.

Australia for more than 25 years and involved in materials handling for many projects in many countries in this time. I am a supporter of local buying and pleased to see that Australia has some of the best bulk handling products and systems available in the global marketplace.

We have the best safety standards and protocols available in mining and bulk handling.

These standards are seen in most Australian operations, and around the world where Australian developed and managed operations exist.

We have many products and processes that have been developed to improve operations and maintenance and to protect the environment.

Australian Standard 1755 first developed in 1975, upgraded in 1986 and 2000 and now

56 І Australian Bulk Handling Review: July/August 2022

part of the 4024.3600 Safety of Machinery series gives excellent guidance on the safe conveyor design. Current Worksafe and OHS Regulations ensure the application of the Standard by ensuring ownership of liability rests with everyone involved.

If you are involved in conveyor design, you must understand and apply this Standard. Many Australian developments offer a safety benefit from the manual handling aspect, and others provide more general operation and maintenance safety benefits.

These might be the solution to the mandate to reduce risk to the lowest reasonably practical level as required in the OH&S regulations.

Australian Standard 4324.1 provides the best structural design guidance for the larger toys in the bulk handling arsenal; rail mounted stackers, reclaimers,

shiploaders and unloaders.

The Standard requires sensible input to design parameters, and critically, demands an independent structural audit of the design before construction.

We have excellent engineers to complete the audits, including Aspec, SIE and Logan Engineering. Notably, we do not have machines in Australia that fail structurally if the Standard is applied correctly.

Many of our other Standards, some of which are also mandatory, cover specifics in design of most bulk handling systems, and if used well will lead to safer and easier to maintain equipment.

Australia has been at the forefront of the bulk handling world for over fifty years. We have many suppliers that provide solutions and innovations to improve bulk handling

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systems. We have suppliers that improve performance, that provide an expectation of much longer life, better manual handling, and access for maintainers.

Why install painted steel fabricated guard systems, many of which are heavy, don’t retain shape and are difficult to remove and install when we have Australian manufacturers of selfcoloured and purpose designed HDPE guard systems that meet Standards.

H&B mining, Dyna and Diacon are showing the way. These guards are lightweight and have design features to assist removal and replacement.

Why use basic fabricated access doors when purpose designed doors are available from suppliers such as Bendtech? These doors have good hinges and latches that don’t bend, seize or fail and include secondary safety mesh to protect personnel from fly-rock.

Are you still using old school heavy

steel idlers with basic bearing and seal arrangement, poor balance and high noise? These can fail in many ways and most are too heavy for one man to lift.

Talk to PROK, CPS or RMK to see the

“Australia has been at the forefront of the bulk handling world for over fifty years. We have many suppliers that provide solutions and innovations to improve bulk handling systems. We have suppliers that improve performance, that provide an expectation of much longer life, better manual handling, and access for maintainers. ” range of plastic, composite and hybrid rolls that are available. These are much lighter, better balanced and have much better seal arrangement and fabrication methods than the older styles.

When it comes to conveyor design provision for idler change look to Techmine for their lightweight load rated systems that are adapted to the conveyor design.

There are several types of retractable idler frame available, but H&B mining have developed this into a fully integrated system including guards, skirts and skirt boxes with ability to adjust skirt liners externally.

In addition, they have a range of single side slide out frames for general application for any conveyor. Using Mobile Elevating Work Platforms or scaffolding for conveyors with single walkway access could become unnecessary with a significant safety benefit.

High quality conveyor belting is manufactured locally to Australian Standards by Conti-Tech and Fenner Dunlop. Both manufacturers have in depth support nationwide, with global access to their other facilities

AUSTRALIAN BULK HANDLING EXPO

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AUSTRALIAN MADE

Gulf Conveyor Systems StallFlow chutes are designed for ease of access and maintenance.

for a wider range of belting for unusual or special duty.

We have some interesting condition monitoring technologies developed in Australia. Vayeron provide full wireless monitoring of individual idler roll condition. DXTA wirelessly monitors individual idler frames and hence idler roll condition. Mining3 has developed a system that uses a fibre optic cable to monitor the idlers and pulleys on a conveyor. Beltscan has systems that continuously monitor the conditions of the belt on a conveyor.

Australia has expertise in wear liners and three local manufacturers, Alloy Steel arcoplate, Bisalloy and Bradken, provide a wide range of well proven wear liners. Bradken provides a full service of wear liner design, fabrication and installation.

58 І Australian Bulk Handling Review: July/August 2022

Bradken also have wear liner remote monitoring. Both Davies Wear Plate Systems and Bradken have single sided wear liner fixing systems which allow installation from outside of chutes and other lined equipment.

I must give kudos to our bulk material testing gurus at TUNRA and BMEA. The services provided in assessing bulk flow and other properties should be mandatory for any bulk storage or bulk flow system.

There are many examples where lack of this information has led to chutes, bins and hoppers that don’t work as well as expected or at all from guesswork.

Both TUNRA and BMEA offer guidance and assessment of designs. TUNRA provides regular courses and workshops to further knowledge in our industry.

TUNRA has developed a novel troughed conveyor system, the Rail Running System, that is worth considering as an option for new installations. The belt is supported on frames that run along rails, and energy consumption is lower than idler supported belts. ThyssenKrupp will build the first of these in 2023.

Transmin developed the LowProfile Feeder, which provides a robust and flexible low height minimum spillage option compared to apron and belt feeders and does this in a smaller space with the benefit of being able to change from horizontal to incline in profile. Transmin also manufacture large horizontal isolation gates for bin and hopper outlets. These devices mean that spile bars, rod gates and similar cumbersome and often ineffective

Fast Fact High quality conveyor belting is manufactured locally to Australian Standards by Conti-Tech and Fenner Dunlop. Both manufacturers have in depth support nationwide, with global access to their other facilities for a wider range of belting for unusual or special duty. manual isolation can be avoided.

Gulf Conveyor Systems are at the forefront of transfer chute design, amongst other things. Having developed the concept for hood and spoon style chutes almost 40 years ago they have moved on to a more effective StallFlow methodology and provide fully integrated chutes designed for ease of access and maintenance Control Systems Technology are synonymous with the biggest and best in belt weighing. If accurate weighing

is a requirement, from a system that is robust, there is no better guidance for this poorly understood aspect of bulk handling than CST. If ultimate accuracy is not required, the new Intelliroll selfpowered wireless weigher in an idler roll offers a new approach in a simple installation that can be read on a mobile device.

Two Australian companies, Rotainer and Doric, have developed different systems for containerised bulk handling. These machines allow mine or plant to ship transport in covered containers, which is ideal for rail or road transport of dusty or hazardous bulk materials and where the container can be unloaded in the depth of the ship’s hold.

A-Ward, based in New Zealand provides a range of container tilting machines that allow stuffing and emptying of end loading containers with bulk materials.

Kinder Australia has been supplying

various conveyor components for over 30 years and offers a wide range of wear, chute sealing and belt cleaning products and a wide range of accessories for conveyors.

Mideco, with its Burnley baffle devices provide excellent dust control over rail and road discharge hoppers.

DSH manufacture dust reducing free fall hoppers for dry bulk materials. These can replace telescopic chutes and have lighter weight and no moving parts.

I have focused on Australian organisations, and doubtless missed many who are worthy of mention.

There are other suppliers of innovative and beneficial methods and systems many of which are available in Australia. I encourage Australian designers and operators to look to the innovators in Australia for better and safer systems rather than continuing with dated concepts and poor safety considerations.

Bulk Materials Handling Machinery Engineering and Design Finite Element Analysis and Advanced Structural Analysis Asset Life Extension

Asset Management Complex Structural Repairs, Upgrades and Maintenance Total Life Cycle Engineering Support Services Spare Parts, Wear Parts and Special Tools

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BULK2022

Simulation helps guide bulk handling’s leap forward Peter Rizkalla, Rocky DEM product manager at LEAP Australia, explains how discrete element method modelling software gives engineers all the information they need to design bulk handling systems.

IF AN ENGINEER DOESN’T HAVE A good understanding of how material flows through a bulk handling system, it can be difficult to achieve the throughput targets required.

Acquiring this information can be tricky. In some cases, the is due to how the system is built or operates. In other cases, building a prototype is prohibitively expensive and not worth it in the long run.

This is where simulation software can add value, and according to Peter Rizkalla, the industrial use of discrete element method (DEM) software such as Rocky DEM is becoming more and more popular.

“A lot of engineers are confronted with problems which involve the design and troubleshooting of machinery but can’t always access the data they need, no matter how many sensors or cameras are onboard,” he said.

“This can be particularly important for equipment operating close to capacity or in extreme conditions, such as transferring wet, sticky ore.

In addition, there can be a safety aspect to this, as not all equipment is safe to access while it is operational.

“Such problems are addressed by

LEAP Australia is a sponsor of the BULK2022 industry conference.

DEM software provides engineers with the data they need to tackle complex problems.

simulation software which provides demonstrate the capability to couple DEM all the data you need to make simulations with ANSYS for structural and an informed decision.” fluid flow applications.

LEAP Australia is supporting the “Our main objective at the show is to BULK2022 industry conference and will educate Australian engineers on how DEM be showcasing several software offerings, simulation can be integrated into their such as ANSYS and Rocky DEM. workflow including the many benefits of Rocky DEM is a high-fidelity particle using Rocky for DEM,” Rizkalla said. simulation tool which models the “The uptake of Rocky over the past movement of granular material and the decade has been quite staggering. We’ve way it interacts with a bulk handling had lots of interest especially throughout system. It allows engineers to visualise the mining hubs, Western Australia and the general flow Queensland and trajectory to Rocky DEM has “Our main objective at the understand forces, proved very popular show is to educate Australian with bulk materials velocities and how engineers on how DEM they affect critical handling product simulation can be integrated points in a system. designers and into their workflow including This can help engineers.” the many benefits of diagnose problems BULK2022 Show using Rocky for DEM” such as spillage, Director, Lauren breakage or wear Winterbottom, said early in the design phase or to improve LEAP’s support means that BULK2022 can and optimise processes so that costly offer delegates an up-to-date knowledge shutdowns or frequent maintenance for software applications that could assist intervals can be avoided. their business.

LEAP Australia’s booth will be “We’re committed to providing staffed with DEM simulation experts to conference attendees with the best answer questions regarding the virtual spread of content to ensure they prototyping process and the ability to run have the information they need to simulations on a desktop or workstation. enhance their bulk solid handling It will also be a chance for the company to operations,” she said.

60 І Australian Bulk Handling Review: July/August 2022

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BULK2022’s mega connections Following the success of MEGATRANS2018, Premier Tech Managing Director Francois Steyn explains the value the company sees in BULK2022.

PREMIER TECH, FORMERLY

Expo 2022 (BULK2022) is Australia’s known as Kockums Bulk Systems, only exhibition dedicated solely to takes pride in being a leader in the the bulk solids handling industry. field of handling and packaging The event is designed for businesses difficult to convey bulk powders. that are bulk commodities producers, Traditionally, the company targeted which require the use of equipment the manufacturing industry, as many for the movement of bulk goods, processes involve some sort of powder. domestically or internationally.

However, as the market developed, Held in conjunction with the business began to diversify its MEGATRANS2022 at the Melbourne offering to cover the needs of the Convention and Exhibition growing logistics industry.

Centre, BULK2022 will showcase The company’s first major foray into some of the latest technology, logistics was at MEGATRANS2018, one of equipment, and services the bulk Australia’s biggest intermodal logistics handling industry has to offer for trade events, where it was able to display manufacturers and producers. its manual handling solutions.

Some examples of the equipment “MEGATRANS that will be on was such a valuable “It has been many years display include event, as we since we had an exhibition conveyors and connected with a dedicated to bulk handling their components, new demographic in Australia, and this will motors and drives, of customers and be an excellent opportunity belt scrapers, listened to some of to connect bulk handling container tipplers, the issues they were engineers with suppliers weighing and level facing in their dayacross multiple industries.” measurement to-day operations,” devices.

Francois Steyn, the company’s Steyn said he is keen to see how the managing director said. connection between the two shows will “So, when we heard that provide additional value.

BULK2022 would be connected to “MEGATRANS2018 was big, MEGATRANS2022, we knew we had to so with the addition of the bulk jump on board to showcase our materials handling side of things, we expect handling capabilities as well as our there will be even more networking manual handling solutions. We will truly opportunities available,” he said. have a foot in both camps of the show.”

“It also helps get all the suppliers The Australian Bulk Handling together in the one room, letting people see what’s going on in the industry, who is doing what, and plans Fast Fact for moving forward.”

As part of this industry Held in conjunction with collaboration, the Australian MEGATRANS2022 at the Melbourne Society for Bulk Solids Handling Convention and Exhibition (ASBSH) will host an industry Centre, BULK2022 will showcase conference at the inaugural event. some of the latest technology, “It has been many years since we equipment, and services the bulk had an exhibition dedicated to bulk handling industry has to offer for handling in Australia, and this will be manufacturers and producers. an excellent opportunity to connect

62 І Australian Bulk Handling Review: July/August 2022

Premier Tech, formerly known as Kockums Bulk Systems, manufactures technology to handle and package bulk powders.

bulk handling engineers with suppliers across multiple industries,” Mark Jones, President of the ASBSH, said.

“We will be advising organisers Prime Creative Media on the conference program and look forward to seeing you all there.”

Lauren Winterbottom, the BULK2022 Show Director, said there has been local and international interest from exhibitors and visitors.

“It’s exciting to have all these exhibitors together, in not only a great place for business opportunities, but also a fantastic occasion to network within this fast-paced and essential industry,” she said.

BULK2022

Best of both worlds ABHR speaks with Bonfiglioli to learn more about its combined planetary/helical bevel drives and why the company will be showcasing them at BULK2022.

MORE THAN 20 YEARS AGO, Bonfiglioli began working on a new type of gearbox that would meet the Australian industry’s demand for hightorque density with the robustness low-speed transmissions in a very compact space.

The company, a family-owned Italian manufacturer of power transmission solutions, had two highly popular products in the region – its planetary gear drives and its bevel helical heavy-duty gearboxes.

Martin Broglia, managing director for Bonfiglioli, explained that the company’s Australian engineers decided to create a combination of the two gearboxes.

“We thought, why not put two of our best products together?” he told ABHR. “We can give customers a more robust and larger range.

“Australia’s mining industry is very demanding and wanted a heavy-duty product that could handle high-torque, low-speed applications like underground or overland conveyor drives, apron feeders, low profile feeders, or crushers.”

First tested in Australia, the gearboxes combined the performance and efficiency of planetary gearboxes and the robustness, quality and reliability of bevel helical gearboxes by extending the ratio range to achieve multiple output arrangements in modular design.

The industry was quick to adopt them. Bonfiglioli quickly went from selling a few units a year to

Martin Broglia, managing director for Bonfiglioli.

64 І Australian Bulk Handling Review: July/August 2022

The combined gearbox brings the best qualities from both designs.

around 30-50 units per year.

Broglia said the robust nature of the gearboxes and flexibility in the design to adapt customer’s machines, made it a favourite of the mining industry.

“The combination gearbox design means there is more area for heat to dissipate and provides more torque. This means there is less maintenance required and higher-output results,” he said.

“This arrangement also offers many other options for our customers such as backstop devices, torque arm arrangements, baseplates, fluid couplings for soft start operation, drum brakes for safety and/or provision for sensors to monitor condition of the drive during operation which reduces the maintenance cost/time during planned shutdowns.

“The combination gearboxes have been used in applications across Australia for more than 20 years now and they really are those set and forget type solutions. There are very little incidences of a failed drive.”

Bonfiglioli has also won contracts to supply the gearmotors to Australian mine sites, including a deal to provide 22 drives for a major iron ore operation in WA under a single project.

Broglia said one of the main factors to winning these project contracts was competitive lead time, flexibility in design and overall cost reduction in capital expenditure with this new design.

The project was completed and delivered to its customer ahead of the deadline provided by the mine site. Bonfiglioli has

branches in New South Wales, Victoria, Queensland, Perth, and New Zealand, where staff assemble equipment and hold onto stock.

In early 2020, the company predicted major supply-chain disruptions due to Covid-19 pandemic. Its management team decided to increase the local stock holding by around 15–20 per cent. The move paid off, with sales going up across the board.

“Price used to be the major factor, but with uncertainty surrounding supply chains, the first question we get asked about our lead time,” Broglia said.

“Customer service is key for us.

Australian industry wants gearboxes that have minimal maintenance and long lifespans, which is what we are focusing on for 2022 and beyond.”

Bonfiglioli will be exhibiting at the Australian Bulk Handling Expo 2022 (BULK2022) and plans to show off its wide range of gearboxes, drives, inverters, and motors.

The company aims to be a one-stopshop for power transmission needs and will have its Australian sales team at the event to show attendees how Bonfiglioli can improve their operations.

Broglia said it’s vital to meet clients and customers in-person.

“You can’t achieve the same results with meetings over the phone or online,” he said.

“Our team is excited to share technical advice and showcase how we can support our customers.”

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BULK2022

The Thor Towerstacker Telescopic Cable Mast Conveyor is versatile and adaptable.

Lincom and Thor recognised for stacker success A collaboration between Lincom Group and Thor Global has been named a finalist in the Australian Bulk Handling Awards. ABHR learns more about the project and the innovative technology being deployed.

WHEN DESIGNING THE MATERIALS handling component of a plant layout, engineers will often use database designs that are tried and tested.

These designs have proven to work over the years, which is why many product stockpile conveyors create a conical stockpile with a fixed boom length and fixed boom height.

To make life easier for mining companies, Lincom Group and Thor Global have collaborated to design a stacker that can be quickly and easily set up for this task.

The Thor Towerstacker Telescopic Cable Mast Conveyor is versatile and adaptable, allowing companies to easily integrate it into their operations.

Lincom chief executive officer Stephen Watterson said time is of the essence in the mining industry.

“It’s that ease of getting it built quickly, getting it erected quickly and getting mines up and running quickly,” he said.

Timing was a major factor for a Central Queensland thermal coal open pit mine, which purchased two Thor Towerstackers.

66 І Australian Bulk Handling Review: July/August 2022

Fitted with luffing capability, the stacker can be raised or lowered to ensure that the material discharged is as close as operationally possible to mitigate material degradation or dust generation.

The stacker combines a radial and telescopic functionality to maximise the available real estate and substantial

“The RPEQ is a very stringent set of engineering checks from an independent party that has to do a sign-off on the design.

It’s not about just giving them a brochure, they get full structural drawings and more. So, for these machines to pass that – it’s a huge feather in our cap.” additional stockpile capacity. By slewing to a set point, it can also be used to transfer to another conveyor or create an emergency stockpile.

The successful project is recognised as a finalist for the Australian Bulk Handling Awards 2021,

with winners to be announced on 25 August 2022 at BULK2022.

The Thor Towerstackers used an existing modular design and standard mechanical products to reduce the overall capital project cost, while reducing operational costs through nonproprietary components.

Watterson said the price point of the machine is what sets the towerstacker apart from the competition.

“The price point of that machine, bringing an off-the-shelf item in here, has been very competitive for us. It’s a price-competitive machine that’s doing 1800 tonnes an hour of coal – you’re talking big tonnages,” he said.

For the coal project, the structural design of the stacker and associated items conform with the engineering company structural design criteria and with the relevant Australian Standards (particularly AS1170 and AS4324.1).

“We’ve done enough of these machines in the country now that we meet all the Australian Standards for electrical, for structures, and in particular in Queensland, we meet the Registered Professional

Fast Fact Timing was a major factor for a Central Queensland thermal coal open pit mine, which purchased two Thor Towerstackers.

Fitted with luffing capability, the stacker can be raised or lowered to ensure that the material discharged is as close as operationally possible to mitigate material degradation or dust generation.

Engineer of Queensland (RPEQ) process,” Watterson said.

“The RPEQ is a very stringent set of engineering checks from an independent party that has to do a sign-off on the design. It’s not about just giving them a brochure, they get full structural drawings and more. So, for these machines to pass that – it’s a huge feather in our cap.

“The Australian Standards are one

thing, the RPEQ is another, so you’re under very stringent controls there to meet – that’s from access to walkways, to any of the safety features that have to be factored into the hydraulics system, to the deflection of the actual conveyor itself, the structure.”

The stacker is fitted with storm anchorage to prevent it moving during intense storm conditions. All maintenance points are easily accessible through a system of walkways or by bringing the machine to ground level.

Watterson expects the conveyor will continue to draw interest and as Lincom continues its collaborations with Thor, more opportunities will arise.

“For the Thor Towerstacker itself, there will be three of these Towerstackers in Australia, and we would continue to promote them in these new mines and/or mine expansions,” he said.

“Thor also has another range, which is its standard radial

stockpilers which are on wheels.”

Lincom supplies Thor’s Top Fold Portable Radial Conveyor, Telescopic Portable Radial Conveyor and Low Profile Telescopic Portable Radial Conveyor, each of which offer their own unique attributes for mining operations.

Watterson believes there are both cost and safety benefits by going with Thor.

“From a cost point of view, it’s a great addition to any setup, saving money by reducing expenses on maintaining a wheel loader and an operator,” Watterson said.

“You plug the thing in, the stacker’s always going to be at work the next day, it’s reliable and will get the job done.”

Tickets are on sale for the 2022 Australian Bulk Handling Awards, and can be purchased at bulkhandlingawards.com.au/awards/

Engineering a better tomorrow

enquiries@page-macrae.co.nz www.page-macrae.co.nz

BULK2022

Sensing a better future Vega Australia’s sensor technology is helping bulk handlers measure their material safely and effectively.

FOR A LONG PERIOD OF TIME, measuring what was in a bulk silo was complex, inaccurate, and often unsafe.

Level switches could tell operators when the material had reached a certain point, but when material starts to be removed, it was difficult to get an exact idea of how much was left.

Some methods involved manually inspecting the silo, which often meant physically climbing the tall structure – putting someone in a risky position. Material can also flow and fill the silo unevenly, making it even harder to get a grasp of how much material is being stored.

John Leadbetter, managing director of Vega Australia, said how we handle grain has dramatically changed over the past few decades.

“With the advent of workplace health and safety regulations, constant working at heights is now frowned upon, as it puts employees at greater risks, so the industry began to look at ways this could be done safer and better,” he said.

Vega’s response was to a changing industry was to develop technology that made life easier. Its range of radar, differential pressure transmitters and level switches make use of Bluetooth technology, allowing operators to use a smartphone or tablet app to instantly check levels.

VEGA has worked to improve its Bluetooth technology, with programming to bring sensors towards broader Industrial Internet of Things compatibility.

68 І Australian Bulk Handling Review: July/August 2022

Technology and automation are key themes of the 2022 Australian Bulk Handling Expo (BULK2022).

The event will bring the Australian bulk handling industry together at the Melbourne Convention and Exhibition Centre to share knowledge, showcase new developments and network.

Vega Australia is the platinum sponsor

“We want to learn what our customers require and how we can make that work for them. It’s crucial we work with the industry as a result” of BULK2022 and will share what it has learned when it comes to automation.

Leadbetter said that inventory management is a critical part of this.

“At the end of the day, inventory is money. Knowing how much you have and where it is gives you better control of how you distribute your product,” he said.

“Everything comes down to automation, and as the industry moves to more advanced IT systems, the need to know where material is will become even more important.”

BULK2022 will host an industry conference, supported by the Australian Society for Bulk Solids Handling, which will focus on themes of safety, sustainability, technology and automation.

In addition to the conference, Vega will also be on the expo show floor, running live demonstrations with staff available to answer questions.

The show is an opportunity for Vega to connect with the industry and listen to what the market, along with meeting up with current and potential clients.

Leadbetter said this is vital for Vega, as it bases its technological developments around customer feedback.

“We want to learn what our customers require and how we can make that work for them. It’s crucial we work with the industry as a result,” he said.

“It also gives us a chance to make face to face connections, which are very important. At the end of the day, we’re not a website or e-shop, we’re real people that can understand someone’s need and demonstrate capabilities.”

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CRANES

Crane rail mountings Large rail mounted machines such as shiploaders, stackers, reclaimers, ship-unloaders, and container cranes require reliable rail systems to operate effectively. Aspec Engineering’s Jeff Brook provides guidance on the selection of rails and rail restraint systems.

CRANE RAIL SECTIONS ARE USED in a variety of applications in

Crane rail sections are used in a variety of bulk handling applications.

heavy industrial, materials handling, mining, and port industries. The runway rails carry the load of the whole machine which may be many hundreds of tonnes.

Other rail systems are used for secondary motions such as shuttling and traversing. Factories and workshops use gantry cranes for operations and maintenance and many of the same issues apply.

Crane rails and wheels Some of the crane rail sections used in Australia for stackers, reclaimers and shiploaders are shown in Table 1 below.

Design aspects of crane rail selection are covered in Australian Standard AS1418. The FEM Rules which are commonly used internationally adopt a similar methodology.

Specifications for the supply of rails are typically in accordance with their country of origin, Rails are manufactured in a range of tensile strength grades from 690MPa to 1080 MPa. Rails for bulk materials handling

Bu ge Figure 1: Crane Rail Mounting Details

machines are normally continuously welded. Common methods of splicing include aluminothermic ‘thermit’ welding or puddle arc welding. Thermit welding relies on a reaction to produce molten steel which solidifies to

Designation

Weight (km/m)

Head Width B (mm)

Head Width H (mm)

Base Width P (mm)

BSC164

166

150

140

230

A150

150.3

150

150

220

CR100

100.2

120

150

155

CR73

73.3

100

135

140

MRS87A

86.8

102

152

153

MRS86

85.53

102

102

165

MRS73

73.63

70

157

146

produce a butt weld. A mould is used to contain the molten metal during the thermit welding process.

Arc welding needs to be carefully planned in terms of selecting the type of welding consumables, preheating and

Fast Fact Crane rail mounting systems are selected to suit the rail, rail loading, and the support structure that the rail is mounted on. The mounting system is selected to enable the rail to be aligned to the design tolerances, which is typically the requirements of AS1418.1.

For heavy loads the rail is generally continuously supported, whereas a discontinuous support can be more economical when the wheel loads are lower.

70 І Australian Bulk Handling Review: July/August 2022

ABHR July

Fast Fact Specifications for the supply of rails are typically in accordance with their country of origin, Rails are manufactured in a range of tensile strength grades from 690MPa to 1080 MPa. Rails for bulk materials handling machines are normally continuously welded. Common methods of splicing include aluminothermic ‘thermit’ welding or puddle arc welding. welding procedure to suit the rail steel type. In Australia, welded rail splices typically use the ‘thermit’ welding process. For light duty applications, rails can be spliced with bolts and ‘fish’ plates. The designer needs to check that the fish plates and bolts do not interfere with the machine bogies and wheels.

Wheels and rails need to be considered together in the design

process. Generally, wheels with a wider tread have a larger load capacity than wheels with a narrow tread. Increasing the diameter of the wheel also increases the load capacity. If large loads are required on a small wheel diameter, it is advisable to choose a crane rail with a wide head.

Wheel failure often manifests itself as excessive wear and spalling of the surface of the wheels rather than a catastrophic fracture. Commonly used standards such as AS1418 and the FEM rules base the selection of the wheel material on material strength with no account for the effects of heat treatment and surface hardening which is commonly used on such wheels.

For wheels with hardened surfaces AS1418 and the FEM rules may be over conservative. The American Iron and Steel Engineers Technical Report No 6 allows for surface hardening and this maybe more applicable when specifying and selecting wheels of this type.

Typically, the wheel will be specified

Figure 2: Prying Forces on a Rail Clip

with a hardness greater than the rail, and this can improve the overall wear resistance of both the wheel and rail.

Crane rail mountings Crane rail mounting systems are selected to suit the rail, rail loading, and the support structure that the rail is mounted on. The mounting system is selected to enable the rail to be aligned to the design tolerances, which is typically the requirements of AS1418.1.

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Fast Fact Generally, rail clips are a proprietary supplied component.

Clips have lateral adjustment for rail alignment and can either have a bolted or weldable base. The selection of the base type depends on the application, but typically the welded bases have a higher lateral load capacity. For improved corrosion protection, the welded base can be welded to the steel base pate, and the component galvanised prior to installation.

For heavy loads the rail is generally continuously supported, whereas a discontinuous support can be more economical when the wheel loads are lower. For long rails on concrete beams a continuous support is generally not practical, and a discontinuous support system is typically used (stacker reclaimer machines on reinforced concrete rail beams – Figure 1).

Rail system supports consist of the following components: the crane rail, a steel base plate rail clips, hold down bolts, levelling grout, rail pads and longitudinal restraint.

Generally, rail clips are a proprietary supplied component. Clips have lateral adjustment for rail alignment and can either have a bolted or weldable base. The selection of the base type depends on the application, but typically the welded bases have a higher lateral load capacity. For improved

Figure 3: Example of a longitudinal restraint

72 І Australian Bulk Handling Review: July/August 2022

corrosion protection, the welded base can be welded to the steel base pate, and the component galvanised prior to installation.

Clip spacing is selected to suit the lateral wheel loads and the strength of the rail to distribute the lateral load. Rail clips can be supplied with a rubber nosing which applies a controlled downward force to the foot of the rail which can assist with controlling movement of the rail while allowing the rail to expand and contract longitudinally.

For load cases where there is a high lateral load and a small or zero downward vertical wheel load (eg, shiploader tied down during a cyclone wind event) the rail clip can be subject

Rail pad walking can be caused by several factors including poor fit of the rail pad restraining lips on the ends of the base plate, base plates that are not level, insufficient confinement provided by the rail clip for lateral moment of the rail pad (more common for longer sole plates relative to the length of the clip), and friction between the pad / rail base and pad / base plate. to high uplift forces caused by prying action as shown in Figure 2. Proprietary rail clips have a limited uplift capacity,

and often additional or special clips are required in the storm park area to transfer this prying force.

Hold down bolts are selected to suit the application. For reinforced concrete foundations these can be cast insitu or post installed chemical anchors. For steel beams supporting the rail, the hold down bolts can be welded studs or through bolts.

Discontinuous or continuous base plates on reinforced concrete foundations are levelled with a high strength grout. The grout is generally selected for the imposed loads and can either be an epoxy or cementation material.

The installation of the grout needs to be carefully planned to avoid air pockets and to ensure that the grout flows completely under the base plate.

For cementitious grout, the installation needs to be in accordance with the supplier’s instructions, particularly for pre-soaking the concrete substrate and curing, to reduce the likelihood of shrinkage cracks.

Rail pads are designed to allow some movement of the rail which can reduce the dynamic compressive forces at the wheel/rail head interface and reduce wear rates. For discontinuous sole plates, rail pads need to be carefully installed in accordance with the suppliers’ recommendations or the pads can move from their installed position (rail pad walking).

Rail pad walking can be caused by several factors including poor fit of the rail pad restraining lips on the ends of the base plate, base plates that are not level, insufficient confinement provided by the rail clip for lateral moment of the rail pad (more common for longer sole plates relative to the length of the clip), and friction between the pad / rail base and pad / base plate.

Longitudinal restraint is typically provided to the rail for the transfer of longitudinal loads and to restrict the rail from ‘walking’ for rails that can freely expand and contract due to thermal loads.

For this type of system, a slot is machined out of the rail foot and a shear block restrains the rail at a designated location (Figure 3).

Intake to Outloading Concept to Commissioning

Contact our expert staff today for all your bulk material handling, processing & storage needs.

1300 005 476 | lgpm.com.au | 47 - 49 Overseas Drive Noble Park VIC 3174

CHUTES

Navigating competing design criteria in transfer chute design Dr Priscilla Freire, Engineer at TUNRA Bulk Solids, discusses some of the competing design criteria that engineers are often faced with when designing bulk material handling systems.

EMERITUS PROFESSOR ALAN Roberts, TUNRA Bulk Solids’ founding director and one of Australia’s most prominent scientists in the field of bulk solids handling, often makes a big claim in TUNRA’s courses: “Bulk Solids Handling isn’t rocket science… it’s harder”. One of the challenges engineers and designers often face is the so-called competing criteria, which often turn a design task into trade-off exercises.

In the design of transfer chutes for instance, rock-box type chutes and/ or ledges are often implemented to reduce abrasive wear of the chute wall.

However, when handling wet and sticky materials, these solutions may often result in material build-up that can lead to blockages or nonoptimal flow patterns. Other examples of competing criteria include the implementation of deflector plates to guide the material stream and ensure that material is loaded symmetrically onto the receiving belt, however potentially increasing wear of the chute itself. After decades of experience, TUNRA Bulk Solids has developed a set of guiding principles for the design of transfer chutes, which have been presented previously in the November 2020 edition of ABHR. This article presents a recent project conducted by TUNRA Bulk Solids’ engineers regarding the design review of as-built transfer chutes for handling highly cohesive materials. All chutes were originally designed and fabricated by third-parties and TUNRA was engaged to conduct a flow assessment prior to the commissioning of these chutes and propose conceptual modifications for improvements where required.

Modelling with Discrete Element Method (DEM) was conducted on the asbuilt geometries with a focus on aspects

74 І Australian Bulk Handling Review: July/August 2022

such as belt tracking, wear of the chute itself and of the receiving belt, propensity to blockages and, in one specific case, propensity to spillage and/or dust generation in a very tall chute. The DEM models were carefully calibrated with material properties through lab tests of all materials handled by the chutes, using the material properties at the worst-case moisture to ensure a conservative analysis.

Considerations on material properties: The two chutes under analysis have been designed to handle, among other materials, fine tailings with very high bulk strength at its worst-case moisture content. Under these conditions, the material has shown high compressibility, with an increase of almost 50% from an unconsolidated value to 50 kPa of consolidation. It should be noted that compressibility often varies significantly with moisture content. Additionally, wall friction testing results showed moderate to high friction coefficients for the liners at the conditions that were tested.

The adequate calibration of DEM models is paramount to ensure that the flow simulated is actually representative of the expected conditions for the given materials at the relevant moisture contents and consolidation pressures.

Although DEM is often applied for the prediction of macro material behaviour, its implementation requires the input of parameters on the micro scale. Some of these parameters cannot be directly measured in a laboratory, and a suite of calibration tests is required to produce a macro characteristic that is dependent on the nature of the bulk material, which are then repeated within the simulation domain, with necessary simplifications, and the micro parameters are optimised to yield the desired macro result/behaviour, as seen in the March 2021 edition of ABHR.

Figure 1: Chute 1, original geometry: stagnant material at the bottom section of the chute.

Chute 1: The first transfer chute transfers material from the feeding to the receiving belt with a 90o angle, and transfers with an angle are often challenging to design to ensure that the material will flow onto the receiving belt in a symmetrical manner.

After calibrating the DEM model with parameters obtained from laboratory testwork, the simulations showed a region of stagnant material in the lower section of the chute (Figure 1).

Material slowly builds up on the lateral ledges located in the bottom part of the chute, and then shears onto itself, falling onto the receiving belt in a non-central manner as shown in Figure 2, which may lead to belt mistracking issues during operation. One

Figure 2: Chute 1 - Non-central loading of the receiving belt with the original geometry.

of the design objectives requested by the client was to eliminate, where possible, all non-central loading cases.

Another design issue identified in Chute 1 was the positioning of the deflector: the simulation of the original geometry showed material spillage at the upper part of the deflector.

TUNRA’s engineers proposed repositioning the deflector both horizontally and vertically, bringing it closer to the discharge pulley, as well as rotating the deflector at approximately

6 degrees in relation to the original position. The other recommendation was the removal of the ledges located at the bottom part of the chute. These combined modifications, when simulated in the DEM environment, showed a significant improvement in the loading profile as material falls more directly onto the receiving belt, as shown in Figure 3.

One of the “side effects” of the proposed modifications, however, is a potential increase in belt wear, caused by the more direct loading of material onto

the receiving belt: Figure 4 shows the belt wear profiles with the original chute geometry and the proposed modifications.

Given that the wear intensity in both simulations uses the same scales, the darker shades of red in the simulation of the modified geometry indicates a higher intensity than with the original geometry.

As such, major modifications of the lower chute will be required to increase the inline component of the stream velocity at the discharge point, aiming at reducing belt wear. It is important to consider that asymmetric loading is a significant issue that, among other consequences, can cause material spillage, belt damage and segregation with consequent downstream processing issues.

Chute 2: The second chute is a bifurcated chute handling two materials with very different properties. This article focuses on the left leg, which, similarly to Chute 1, also handles tailings at a high moisture content with cohesive properties.

Due to structural constraints, Chute

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Front View of the Lower Chute

Side View of the Lower Chute

receiving belt, with little to no material stream velocity in the direction of the outgoing belt. Such high fall with little contact with the side walls may also increase the propensity to dust generation, particularly in the lower section, as a result of the high material velocities due to relatively long periods

of freefall of the material stream.

In order to address the potential operational issues anticipated with the original geometry, TUNRA’s engineers proposed the insertion of two impact plates in the top and bottom sections of the trouser leg, and a training plate in the discharge section of the chute to reduce periods of material freefall and improve the loading characteristics onto the receiving belt. The aim of these plates is to “guide” the material stream inside the chute such that it flows with less material dispersion and is loaded onto the receiving belt in a more centralised manner, thus reducing the propensity to dust and belt mistracking issues, respectively.

The proposed modifications and resulting flow can be seen in Figure 6.

With the suggested modifications, a significant reduction was observed in the wear of the receiving belt, which is likely caused by the reduction in the velocities at which material hits the belt.

On the other hand, an increase in the actual chute wear was also observed, caused by the material stream now being directed onto the chute wall surface, whereas with the original geometry the material stream was freefalling inside the chute. Another point of relevance is that the proposed inserted plates are likely going to experience significant wear due to the direct and ongoing contact with material. Considerations regarding the durability of the plate

Belt Wear with Original Geometry:

Belt Wear with Modified Geometry:

(a) Shear

(a) Shear

(b) Impact

(b) Impact

Figure 3: Chute 1 with modifications on the deflector position and removal of ledges.

2 transfers material from the feeding to the receiving belt at a considerable height of 20 m. Preliminary analysis of the original design indicated that the material freefalls with minimal wall interactions before impacting the discharge chute section, which happens at a relatively high vertical velocity.

Material builds up asymmetrically and shears across itself, loading noncentrally onto the receiving belt with an approximate mass distribution of 47% on the left side and 53% on the right side, which may result in belt tracking issues. The flow of material considering the original geometry can be seen in Figure 5.

Furthermore, relatively stagnant regions of material were observed on the receiving belt and along the length of the skirts in the loading region which may lead to increased belt wear, with a propensity of build-up on the skirts anticipated. It was concluded that the stagnant region is primarily due to the reacceleration of material in the direction of the belt, as the majority of the material falls directly on the

76 І Australian Bulk Handling Review: July/August 2022

Figure 4: Chute 1 – wear on the receiving belt with both the original and modified geometry.

(a)

(b)

(a) End view of the incoming conveyor (b) Side view of the incoming conveyor Figure 5: Chute 2 – original geometry. Free-fall of material onto belt and stagnant regions in the discharge section.

material as well as ease of access for replacement or maintenance should be made in the implementation of the suggested modifications.

Conclusion Some of the greatest challenges in the bulk solids handling field is to accommodate competing design criteria and constraints whilst still to ensure smooth flow and meeting operational requirements. An understanding of material behaviour through appropriate characterisation is the first step to shed light on the different challenges that may be encountered, and computational simulation consists of a good tool for flow visualisation and identification of points of concerns. However, it is not always possible to meet all design criteria simultaneously, and trade-offs are often necessary in order to make informed design decisions.

TUNRA Bulk Solids is committed to the advancement of the bulk solids discipline globally. If you would like to discuss your materials handling challenges and needs, visit us at booth 4443 at the BULK2022 Exhibition.

Figure 5: Chute 2 – original geometry.

Free-fall of material onto belt and stagnant regions in the discharge section.

B U L K H A N D L I N G

AUGUST 24-26 AUSTRALASIA’S LARGEST DEDICATED BULK HANDLING CONFERENCE & EXHIBITION

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WELCOME

Welcome to BULK2022 JOHN MURPHY Chief Executive Officer

80 І Australian Bulk Handling Review: July/August 2022

I take great pride in welcoming all delegates to BULK2022. This is the first time we have held the exhibition, and I am excited to see it help grow the Australian bulk solids handling industry.

At Prime Creative Media, we’re passionate about the industries that strengthen and grow Australia. We know the sector is a vital part of Australia’s future. Without the technology to handle bulk materials, Australia’s successes in mining, agriculture and construction simply would not have been possible.

In the initial discussions of launching this event, we recognised that the industry needed an opportunity to come together under one roof to share best practice, innovation, and ideas. At the time, there had not been an expo that focused on this vital industry for years. We decided to launch the event to help the industry to grow through closer collaboration and meet face to face again following more than two years of remote working.

We are committed to the future of the Australian Bulk Handling Expo and to growing this conference and exhibition for an industry that deserves further focus and attention through an event such as this one.

The show’s conference and exhibition will showcase the latest developments in automation, safety, industry 4.0, sustainability, and export freight.

There will also be ample

opportunities for cross-collaboration through this multi-dimensional and integrated event.

We have worked tirelessly to create a conference program which features Australia’s best and brightest minds in the bulk handling sector who will sit down together and discuss some of the most important topics for today’s industry – including dust control, wear, safe storage and handling, and more.

In addition, we recognise that throughout the bulk handling industry, collaboration is a key factor in any successful operation and have thus ensured that there is representation from every sector at this event.

This year’s event also runs alongside MEGATRANS2022, Australia’s largest multimodal supply chain expo, and I urge you all to connect with this part of your industry.

I also want to thank our sponsors, Vega Australia, Premier Tech Systems and Automation, PROK, LEAP Australia and our association partner, the Australian Society for Bulk Solids Handling. Their contribution and support are greatly valued and appreciated.

While this year’s event is just beginning, I am also excited to announce that the Australian Bulk Handling Expo will be back in 2024. Please come and speak to the team about how you can get involved in Australia’s largest bulk handling event for 2024.

25 AUGUST 2022

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AWARDS

Shining the spotlight on bulk handling The Australian Bulk Handling Awards will return this year at BULK2022. ABHR highlights the finalists that have been nominated for the awards.

Winners will be announced at a gala dinner on 25 August at the Arts Centre, Melbourne.

THE AUSTRALIAN BULK HANDLING AWARDS (ABHA) celebrate and acknowledge the outstanding achievements of companies and individuals in the bulk handling sector.

The annual event was disrupted by the COVID-19 pandemic and associated lockdowns but will return at BULK2022 as the official awards program of the trade show.

This year’s event will include entries from 2020 and 2021, to highlight the achievements of the industry across both years.

The following organisations are finalists for the awards, with winners to be announced at a gala dinner on 25 August at the Arts Centre, Melbourne.

82 І Australian Bulk Handling Review: July/August 2022

INNOVATIVE TECHNOLOGY A technology designed to enhance bulk solids handling and processing.

• 80 gigahertz series of radars – VEGA Australia • FMR Pumping Application – Metso • Fully Mobile Surge Loader – MMD Australia Pty Ltd • Scrap Shred Vessel Discharge – LINX Port Services • PROK HDPE – PROK Conveyor Components

DUST CONTROL TECHNOLOGY, APPLICATION OR PRACTICE A project that helps to keep dust creation in the bulk solids handling process to a minimum.

• M-Sens 2 in coffee roasting – Group Instrumentation

• Rotary Floating Shoe (RFS) Valves – Anval International Pte Ltd • Sun Pharmaceutical: Bat Booth dust suppression system – Mideco Dust Control Pty Ltd • VEGADIF85 – VEGA Australia • Drillrig Dust Suppression System – Enviromist & Action Dril&Blast

EXCELLENCE IN THE APPLICATION OF GEARS, MOTORS OR DRIVES A component or piece of equipment that provides a benefit to bulk solids handling operations.

• Cargill stockpiling operations optimisation – Kilic Engineering • Lithium operation installation using Nord IGUs – Inenco • Tronox gearbox upgrade – SEWEURODRIVE

AUSTRALIAN BULK HANDLING EXPO

EXCELLENCE IN TRANSPORT AND/OR CONVEYING

Chair of the Australian Society for Bulk Solids Handling, Professor Mark Jones.

A piece of equipment or technology that moves bulk solids materials from one location to another.

• Dynamic Under Keel Clearance System (DUKC) – OMC International • Scrap Shred Vessel Discharge – LINX Port Services • Tuff As belt – Fenner Conveyors • SAPO Seal – DASH Engineering • THOR TOWERSTACKER TS 250 – Telescopic C – Lincom Group

BEST PRACTICE IN SAFETY A project or program that emphasises and upholds industry safety standards.

• Hi Roller and CMC collaboration – AGI • Preventative Conveyor Maintenance Program – Kinder Australia • “Splice without a knife” Solution – Fenner Conveyors • Transportable Moisture Limit project – Centre for Bulk Solids and Particulate Technologies • Virtual Reality (VR) safety training platform – LINX Cargo Care Group • Sparcric Belt lifter to change rollers – R.Brunone

SUPPLIER OF THE YEAR A supplier that is excelling in the bulk solids handling sector.

• Conveyor Products and Solutions • Fenner Conveyors • Kinder Australia • OMC International • TUNRA Bulk Solids

BULK HANDLING FACILITY OF THE YEAR An outstanding facility that is for the

processing of bulk solids materials, or manufacture of materials using bulk solids goods.

• Boral Ormeau – Metso • B risbane Idler Plant – Fenner Conveyors • Coopers Brewery malting facility – Ahrens • Newcastle Institute of Energy and Resources – TUNRA Bulk Solids • Conveyor Products and Solutions manufacturing facility – Conveyor Products and Solutions

The winners of the 2019 Australian Bulk Handling Awards.

Australian Bulk Handling Review: July/August 2022 І 83

FLOORPLAN

BULK2022 Floorplan Toilets

3525

4049

4048

4148

4149

4346

4046 4044

4146

4343

4339

3518

4137

3515

3411

4137 4135

4131

4345

4445

4344

4443

4440

4439

4144

3519

3415

4452 4448

3521

3416

4350

4131

4337

4134

4437

4444

4444

4440 4438

4132 Exit

Exit Seminar Theatre

3513 4130

3511

Entry

Networking Lounge

3509 4124

Queuing Area

3409

3508

3408

3507

4020

3506

4016

3407 3405

3404 3403

3400

4318

4118 4312 4114

4116

4319 4314

4422 4418 4414

4010

3503

3501

4001

3500

4002

4108

4100

4110

4306

4300

4308

4412

4307

4410

4302 4301

Entry/Exit Bulk 2022

84 І Australian Bulk Handling Review: July/August 2022

4406 4404

AUSTRALIAN BULK HANDLING EXPO

Stand Directory STAND

STAND NUMBER

STAND

STAND NUMBER

4B Australia

4406

Jenike & Johanson

3511

Absafe Group

4343

Kerman Contracting Pty Ltd

4302

Acoem

4340

Kilic Engineering Pty Ltd

4416

Aerobelt Australia Pty Ltd

4300

Kinder Australia

4002

Aerzen Australia Pty Ltd

4339

Koyo Australia Pty. Ltd.

4318

AGI

3509

LASE Australia

3503

Agridry Dryers

3515

LEAP Australia

4132

Air Automation Group Pty Ltd

4116

LGPM

4134

Allied Grain Systems

3509

LINAK

4301

Altair

4144

Lincom Group

4149

AMMERMANN

4108

MANNAWAYS PACKING

3501

ANNEXUS_WA

3521

MARC Technologies

4448

ANVAL INTERNATIONAL PTE. LTD.

4037

Martin Engineering Australia

4110

AURORA - BULK PACKAGING

4312

Mideco Jia

4439

Australian Bulk Handling Review

4350

MINPROVISE INTERNATIONAL PTY LTD

4314

Azano Pty Ltd

4444

MRA Electrical

4412

Bonfiglioli Transmission (Aust.) Pty Ltd

4146

Nelson Silos

3500

Brelko Conveyor Products (PTY) LTD.

4440

PACKWEIGH EQUIPMENT

4306

Concetti S.P.A

4114

Page Macrae Engineering

3519

Conveyor Products & Solutions

4124

Phoenix Mecano

4048

COREX PLASTICS

4020

Pneuvay Engineering Pty Ltd

4001

Cortex Engineering Pty Ltd

4300

Precisionscreen

4135

Crasti & Co

3403

Premier Tech Systems and Automation PTY Ltd.

4010

Crusher & Screen

4452

Prime Manufacturing Pty Ltd

4410

DIACON Australia

4307

PROK Quality Conveyor Equipment

4118

Dome Technology

3409

Rainstorm Dust Control

4437

DSH SYSTEMS LTD

4445

RR Pacific Pty Ltd

3508

Dust-A-Side Australia

4137

Sew Eurodrive Pty Ltd

4031

Endress+Hauser

4346

Skala Australasia Pty Ltd

4438

enmach

4422

Slimstock

4345

ESS Engineering Services & Supplies

4100

Smart Pack Ltd

3506

Floveyor

4016

Superior Industries/Tricon Equipment

3416

Flow Force

4148

Supplied by Ebro

4337

GE Silos

4044

Terex Jaques

4308

Gough Plastics

4418

Thermalign Pty Ltd

4404

Grydale Solutions

3507

Treotham Automation P/L

4046

H Polesy & Co Pty Ltd

4049

TUNRA Bulk Solids Handling Research Associates

4443

HE Silos

4344

Vayeron

3518

HOSCH International

4319

VEGA Australia

4130

ifm efector

3513

Weigh-More Solutions

4131

Australian Bulk Handling Review: July/August 2022 І 85

2 A

BULK2022 SHOWGUIDE

BULK2022 Conference Program Day 1 – 25 August 2022 Time

Session Type

Proposed Topic

9:00am-9:10am (10 mins)

Welcome

9:10am-9:30am (20 mins)

Keynote

The future workforce: changing skills landscape

9:30am-9:50am (20 mins)

Case Study

Transfer chute case study using Rocky DEM

9:50am-10:40am (50 mins)

Panel Session

Embracing new technology across industry, tangible benefits of Industry 4.0

10:40am-11:10am

Morning Tea

11:10am-11:30am (20 mins)

Keynote

The road to net zero

11:30am-11:50am (20 mins)

Case Study

Setting a sustainability strategy

11:50am-12:40pm (50 mins)

Panel Session

What can companies do now, to help reduce emissions?

12:40pm-1:40pm

Lunch

1:40pm-2:00pm (20 mins)

Technical presentation 1

Advanced automation for centralised stockyard operations

2:00pm-2:20pm (20 mins)

Technical presentation 2

Evaluation of bulk material dustiness and design of suppression systems

2:20pm-2:40pm (20 mins)

Technical presentation 3

Digital inspection - using mobile devices to manage compliance and maintenance in the bulk solids handling industry

2:40pm-3:00pm (20 mins)

Technical presentation 4

Pneumatic conveying operating conditions and the resulting pressure drop

3:00pm-3:10pm (10 mins)

Closing

Day 2 – 26 August 2022 Time

Session Type

9:00am-9:10am (10 mins)

Welcome/ Day 1 recap

9:10am-9:30am (20 mins)

Keynote

Preparing for, prevention of, responding to and recovery from security-related disruptions to bulk handling systems

9:30am-10:00am (30 mins)

Case Study

Employee saftey onsite

10:00am-10:50am (50 mins)

Panel Session

What is being done onsite to mitigate risk and promote safety?

10:40am-11:10am

Morning Tea

11:10am-11:20am (10 mins)

Technical session introduction

11:20am-11:40am (20 mins)

Technical presentation 5

Challenges and solutions of dust suppression during bulk materials unloading into intake hoppers

11:40am-12:00am (20 mins)

Technical presentation 6

Using dynamic simulations to predict the phenomenon of silo quaking

12:00am-12:20pm (20 mins)

Technical presentation 7

"Wear" science & awareness meet there is opportunity!

12:20pm-12:40pm (20 mins)

Technical presentation 8

Optimising a wet screening operation using computational modelling tools

12:40pm-1:40pm

Lunch

1:40pm-2:00pm (20 mins)

Technical presentation 9

Analysis of the influence of material characterisation on reliable transfer operation

2:00pm-2:20pm (20 mins)

Technical presentation 10

Evaluation of bulk material dustiness and design of suppression systems

2:20pm-2:40pm (20 mins)

Technical presentation 11

Recent advances in industrial applications of DEM in bulk materials handling

3:00pm-3:10pm (10 mins)

Closing

86 І Australian Bulk Handling Review: July/August 2022

Proposed Topic

24-26 AUGUST

REIMAGINING T H E S U P P LY C H A I N

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CONFERENCE SPONSOR

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EXHIBITOR LISTING

4B Australia

AUSTRALIAN BULK HANDLING EXPO

Absafe Group

Acoem

4406

4343

4340

Aerobelt Australia Ltd

Aerzen Australia

AGI

4B Australia Pty Limited is a subsidiary of 4B Braime - the international market leader in the field of bucket elevator and conveyor components and electronic monitoring equipment. With its range of components, 4B serves a large range of industries ranging from agricultural to industrial through to mining and heavyduty industries. 4B Australia maintains high stock levels of all its main products to be able to service its local customers quickly and efficiently. www.go4b.co.uk/australia

4300

Aerobelt Australia Pty Ltd is based in Appin NSW and was established over 22 years ago. It now has local agencies in six major countries. Aerobelt Australia has 347 conveyors throughout the world across a diverse range of industries.

Their services range from supply, design, manufacture, delivery and installation.

Their conveyors are supported by a film of air beneath the trough creating smooth movement of product, reduction in power consumption, dust generation, noise and component wear. www.aerobelt.com.au

Absafe Group is a specialist remedial and supply company built around safety. As a multi-disciplined remedial engineering company specialising in working at height, confined space and difficult access, they also offer engineering services including consulting, diagnostic investigation and maintenance, as well as specialist safety equipment supply and support services.

They are the exclusive distributor for ATD Cardox pressurised gas systems in Australia, Skyclimber swing stages and Alpha hoists. www.absafe.com.au

4339

Aerzen Australia is a subsidiary of Aerzen Germany and has offices in Melbourne, Perth and Auckland that provide technical, sales and aftersales support. Their oil-free Delta Blower, Delta Hybrid and Delta Screw packages provide industry leading blower and compressor technology that not only perform but push the boundaries in efficiency and sustainability. With over 150 years engineering experience, they are determined to provide you with technology that is at the forefront of every generation. www.aerzen.com.au

As a trusted provider of class-leading, multi-parameter proactive maintenance, reliability and condition monitoring solutions for rotating machinery, Acoem Industrial Reliability is committed to protecting your critical rotating assets and ensuring that they operate with maximum efficiency — extending the life of your machinery, mitigating risk and avoiding costly repairs or breakdowns. With offices located across Australia, its offers local, New Zealand and Pacific region customers a range of integrated shaft laser alignment and vibration measurement technologies, tailored corrective services, training and remote condition monitoring management. Acoem creates environments of possibility. www.acoem.com

3509

AGI supplies the agri-food industry equipment over five continents. With 3800 employees and 35 manufacturing facilities, AGI has a leading catalogue for commercial and farm equipment supplying five essential platforms.

AGI’s leading Industry equipment ranges from Hi Roller belt conveyors, fertiliser blending, Neco Dryers AGI Silos and Suretrack conditioning technology. The range of equipment allows AGI to provide the industry with a full suite of equipment, making AGI one of the few companies in the industry that can offer a complete turnkey or supply your individual requirements.

AGI has experience across varying commodities, regions, geographies, and environments.

www.aggrowth.com

Australian Bulk Handling Review: July/August 2022 І 89

EXHIBITOR LISTING

Agridry Dryers

Ahrens

Air Automation Group

Agridry design and manufacture bulk commodity dryers and aeration systems for the agricultural and commercial food processing industries. It is a market leader in Australia for mobile and stationary continuous flow, recirculating and batch dryers. Its dryers are designed with versatility at their core, enabling them to process a wide range of commodities.

Agridry is firmly focused on the future, with a robust innovation agenda.

Currently partnering with numerous associations, bodies and universities to deliver cutting edge technology to the market, Agridry designs and manufactures dryers for a range of applications from its headquarters in Toowoomba, Queensland Australia. www.agridry.com.au

Ahrens is a national full-service construction, engineering, mining services and rural infrastructure company with a significant footprint across Australia.

They offer a one-stop shop for all your infrastructure requirements, from concept to completion. Their comprehensive list of in-house capabilities includes complete project management, site erection, workshop detailing, water storage, civil and concrete works, steel fabrication, structural steel painting and blasting. www.ahrens.com.au

Air Automation Group is a powerhouse of industry leading brands focused on delivering world class solutions in pneumatics, industrial vacuum pumps and air Filtration. Australian owned and manufacture, proven solutions to industry for over 70 years. www.airautomation.com.au

Allied Grain Systems

Altair

3510

4144

AMMERMANN

3515

Allied Grain Systems are Australia’s leading engineering, design, supply and installation specialists in grain storage and handling systems.

Connecting Australia to the world’s market leading suppliers provides its customers with superior options in products and technology. This edge is what makes Allied a standout when designing high tech economic solution for your grain handling needs. All structural components are manufactured inhouse at its steel fabrication plant in Young NSW using all Australian steel and shipped nationally.

Allied’s engineering team has over 100 years combined experience.

Rest assured your investment in grain solution will be cultivated by the best in the industry from initial design right through to commissioning. www.alliedgrainsystems.com.au

90 І Australian Bulk Handling Review: July/August 2022

3021

Altair’s comprehensive, open-architecture solutions for AI, CAE, and HPC, enable design and optimisation for high performance, innovative, and sustainable products and processes in an increasingly connected world.

Using simulation tools early in the development process helps maximise productivity, reliability, safety and comfort.

Customers can optimise designs by quickly and accurately simulating the behaviour of bulk materials. Organisations can optimise product performance, gain visibility into the in-service life, know when and where to perform predictive maintenance, and how to extend a product’s remaining useful life. www.altair.com

4116

4108

For almost 40 years Ammermann has supported the Australian and New Zealand industries supplying equipment in the following industry sectors: cement, lime and gypsum, mining and minerals, alumina, ports and terminals, wood and biomass and liquid storage. It provides assistance with initial project concepts, feasibility studies through to complete turnkey equipment supply.

Its experience in this market combined with state of the art technology from its partners ensure your existing or new project objectives will have a successful outcome.

Ammermann also provides door to door service of OEM spare parts from all of its overseas technology partners. www.ammermann.com.au

AUSTRALIAN BULK HANDLING EXPO

Annexus WA

ANVAL INTERNATIONAL

3521

AURORA – BULK PACKAGING

Established in 2013, Annexus WA supplies, installs and maintains the DirtWhacker conveyor belt cleaning system. Its scrapers have a uniquely designed and patented parallelogram and internal bladder system ensuring the blades always remain at a 90-degree angle to the belt no matter the wear. These factors reduce carry back, belt wear and maintenance while offering a safer and cleaner working environment. To complement its bulk handling portfolio it also supplies rollers, idlers, v-ploughs and a variety of belt trackers. It offers a 90-day trial option and can provide demonstrations of the DirtWhacker system. www.annexuswa.com

4037

Anval has built a reputation as the market leader in the design and manufacture of valves, feeders and airlocks, with over 35 years of industry experience to deliver the highest quality equipment to some of the most demanding applications in the world. Anval is constantly developing and widening its range of equipment to cater to its customers’ increasingly demanding needs. From simple powder to raw coal, from sticky biomass to abrasive alumina.

Anval’s in-house engineering teams have provided solutions to a dazzling array of material handling problems. Committed to customer satisfaction, Anval provides an effective design solution and ensure spare parts supply and full-service support. Its solutions have proven themselves across various industries and in some of the most demanding applications. www.anval.net

4312

Azano Pty Ltd

Bonfiglioli Transmission (Aust.)

Brelko Conveyor Products (Pty) Ltd ®

4444

4146

4440

A solutions-based Australian engineering company with over 25 years of experience, Azano specialises in design and manufacture of turnkey automated and semi-automated packaging and filling systems, bulk bag filling and unloading systems, food processing equipment, water treatment systems, chemical metering packages, contamination inspection systems, and dry material batching and liquid chemical batching equipment. www.azano.com.au

Bonfiglioli is a company with more than 60 years of experience in heavy-duty industries. With a global team of over 3700 professionals around the world, Bonfiglioli designs, produces and distributes a full range of gear motors, drive systems, planetary gearboxes and inverters for clients and partners in the industrial automation, mobile machinery and renewable energy sectors. Local stockholding, assembly and service make Bonfiglioli an obvious choice for heavyduty applications. www.bonfiglioli.com.au

Aurora specialises in preparing and packaging your bulk products for market.

Their services include bulk bag filling and unloading, closing, conditioning, conveying, labelling and marking, manual, semi-auto, fully auto and high speed, fertiliser, grain and seed, stockfeed, building and minerals, landscape supplies and more. With services available across Australia and New Zealand, Aurora’s full end-to-end service includes site consultation, design, equipment, installation, commissioning, service, consumable supply and finance. Their expertise is your competitive advantage.

Let them remove barriers to your business growth. www.aurora-nz.com

Brelko designs and manufactures conveyor belt cleaning equipment for a trouble-free flow of materials at transfer and load points. This is backed up by an installation and maintenance package.

It has served as a supplier and advisor on spillage control to the bulk materials handling industry, since 1987 and offers proactive maintenance for preventative spillage control and optimum belt cleaning. www.brelko.com

Australian Bulk Handling Review: July/August 2022 І 91

EXHIBITOR LISTING

Concetti S.P.A

4114

Concetti is a world-leading manufacturer of customised bagging systems turn-key solutions. It makes robust weighing, filling, closing and palletising lines.

Concetti’s challenge is to bag even the most difficult powder and bulk products.

The solutions always assure consistent quality, weight accuracy, highest output rates, environment-friendly operation and user-friendly maintenance.

It provides assistance through its professional technical team. Concetti’s international sales network covers 60 countries. Its production plant is in Italy, but it have two subsidiaries in US and Brazil. Markets served iclude: fertilisers, chemicals, animal feed, seed, pet food, flour, building materials, premix, sugar, salt. www.concetti.com

Crasti & Co.

3403

Crasti & Company specialises in packaging, handling, and storage solutions for bulk products. With over 30 years’ experience and support from its ISO 9001:2008 accredited overseas manufacturer, it custom designs and make its products to suit the customer’s specific requirements.

Crasti & Company are also specialist suppliers to the Australian and regional markets of flexible intermediate bulk containers, container liners and small woven bags, with an extensive range of bulk bags available from its locally held stock, ready for prompt delivery.

Crasti & Company is a founding member of AFIBCA which has been instrumental in promoting the safe use of bulk bags and developing Australian Standard (AS36682019) for bulk bags for packing nondangerous goods. www.crasti.com.au

92 І Australian Bulk Handling Review: July/August 2022

Conveyor Products & Solutions

COREX PLASTICS

Conveyor Products & Solutions (CPS) is an original equipment manufacturer of Australian-made, premium quality, and superior performing rollers, pulleys, and idlers. From introducing Yeloroll, the first all-polymer roller to the Australian market, CPS has grown to become a world-class leader in innovative conveyor manufacturing and technology. www.cpsconveyors.com.au

Corex Plastics is an Australian owned company. They make packaging products from their branded corflute polypropylene, manufacturing everything in a modern facility in Dandenong South, Victoria.

Corex make corflute IBCs, picking trays, tote boxes and reusable transit boxes suitable for tough conditions and are 100 per cent waterproof. They specialise in bespoke products in high and low volume. Their in-house recycling division can offer a range of programs to suit customer requirements. www.corex.com.au

Cortex Engineering

Crusher Screen

4300

4452

4124

Cortex Engineering is a consultant, designer and constructor of bulk materials handling belt conveyors, elevators, storage systems, re-claimers and loaders/ un-loaders to suit ships, road and rail wagons for the mining, construction, agricultural and chemical industries.

Cortex is the Australian representative for Euromecc S.R.L. and is the Australasian representative for Dos Santos International high angle snake sandwich belt conveyors. www.cortex.com.au

4020

Crusher Screen Sales & Hire supply plant and services for the quarry, mining, construction and remediation industries throughout Australia. Plant includes track and modular pugmills, blenders, mixers, mobile cement silos, track and wheel conveyors with automation option and link conveyors up to 45-metres-long offering dual power option. They also offer heavy duty high production track conveyors to operate with jaw crushers at the blast face stocking 300mm minus material or feeding downstream plant operating on the quarry floor. www.crusherscreen.com

AUSTRALIAN BULK HANDLING EXPO

DIACON Australia

Dome Technology

Diacon Australia offers engineered plasticsbased conveyor guarding, spillage and dust suppression solutions.

Providing the safer alternative to steel conveyor guards, Diacon’s signature yellow plastic mesh guarding is tried, tested, and trusted in the material handling industry.

Diacon Australia has been designing and manufacturing plastic conveyor guarding since 2010, after identifying a need for improvement in the areas of conveyor productivity and safety.

All Diacon products are produced on a special-order basis, as sizes are customised to suit the individual needs of each mine site.

Each system is designed, engineered, and manufactured in Queensland, and supplied to a variety of industries both Australia-wide and overseas. www.diaconaust.com.au

More storage. Smaller footprint. Strength to weather any storm. And robust conveyance to match. Introducing the monolithic concrete dome from Dome Technology. The company has built more than 700 bulk-storage industrial and commercial domes worldwide. Dome Technology is driven by the pursuit of innovation and advancement. It got its start by inventing a specialised domeconstruction process, but after 40 years in the industry, versatility is now its strongest suit. It is the world’s leading expert in dome construction because it invented the process and can provide the design and installation of systems required for bulk storage. www.dometechnology.com

Dust-A-Side Australia

Endress+Hauser

Enmach

4137

4346

4422

4307

With a purpose to reduce dust emissions, operating costs and improve mine productivity, Dust-A-Side is Australia’s specialist in dust control and haul road and management to the mining and resources sector. First established in 1973, DAS today services over 70 mines across four continents and has accumulated more than 500 years of combined project experience. DAS offers managed services for establishing and maintaining haul roads and light vehicle access roads, as well as design, fabrication, commissioning and maintenance of mechanical dust suppression systems in fixed plant environments for bulk materials handling applications. DAS also supplies and integrates a wide range of dust suppressant products, binders surfactants and cannons. www.dustaside.com

3409

Endress+Hauser is recognised as a leading supplier of industrial measurement and automation equipment, providing services and solutions for industrial processes all over the world. It offers comprehensive process solutions for flow, level, pressure, analysis, temperature, recording and digital communications across a wide range of industries, optimising processes in regards to economic efficiency, safety and environmental protection. www.au.endress.com/en

DSH SYSTEMS LTD

4445

DSH Systems’ award winning loading spouts, designed initially for the fertiliser industry, discharge dry goods as a tight solid column through free air into any target repository including trucks, railcars, barges, ships, storage containers, bags or stockpiles.

Reduce hazards and health risks no electricity required - no internal moving parts. www.dshsystems.com

Enmach is a renowned leader in the design and manufacture of quality engineered poly moulded and steel fabricated products. Enmach has reinvented and redesigned products made from traditional materials and manufactures them from materials such as polyethylene and stainless-steel to extend lifespan and durability. They offer a range of silos that are suitable for bulk storage of a variety of products and can be used in any industry, from mining to farming, water clarification to breweries, fertiliser to coffee bean storage. www.enmach.com.au

Australian Bulk Handling Review: July/August 2022 І 93

EXHIBITOR LISTING

ESS Engineering Services & Supplies

4100

ESS Engineering Services & Supplies and its subsidiary VSS Vibrations Systems & Solutions aims to provide total material control at transfer points to enable increased output, reduced clean up and maintenance costs and improved plant safety. www.esseng.com.au

GE Silos

4044

GE Silos is a leading manufacturer of high quality transportable silos. Their silos are produced for storing a large variety of products including grains, pellets, mash, meal, crushed grain, or fertiliser. GE Silos services a wide variety of industries from grain farmers to the pig and chook industry right through to feed mills and bulk storage facilities. The new white walled silos are very popular with both galvanised then painted coatings to protect for longer against corrosion. The white is also excellent at keeping the grain cooler with up to 11 per cent cooler than normal zincalume material. www.gesilos.com.au

94 І Australian Bulk Handling Review: July/August 2022

FLOVEYOR

Flow Force Technologies

4016

4148

Gough Plastics

Grydale Solutions

Gough Plastics is a family-owned and operated business located in Townsville QLD, Australia. They manufacture a varied range of products with their highdurability conveyor belt covers and bulk liquid storage tanks servicing countless companies within the bulk handling industry. They also manufacture water storage tanks, waterless toilet systems, durable general storage containers, vehicle underbody toolboxes and water storage, cattle feed troughs, moulded plastic waste entry points and super heavy-duty plastic crane dunnage. www.gough.com.au

Grydale is a manufacturer of an extensive range of fixed, mobile and onboard dust control solutions. Its fixed dust collectors offer a long-term and cost-effective solution to dust and fume control. Its in-house engineering team can custom design units to meet your site requirements and industry regulations. Its mobile dust collectors offer 6m³/s to 60m³/s of air flow in a range of power and mobility options, including drag skid, castor-wheel, hydraulic stepping systems and patented track mounted units. Its mobile dust collectors have developed a reputation for being the most efficient dust collection units in the world and are transforming approaches to dust extraction processes and ventilation design. www.grydale.com.au

Floveyor started in 1958, pioneering and patenting the aero-mechanical method of conveying. Known for versatility and longevity, original Floveyor machinery is used for materials handling in food and beverage, agriculture, manufacturing, mining and resources and chemical processing industries by the world’s largest brands and small manufacturers alike. Authentic Floveyor conveyors and conveying equipment are designed, engineered and manufactured in its factory outside Perth, Western Australia, and are in operation every day in 52 countries. www.floveyor.com

4418

Flow Force Technologies (FFT) is an Australian designer and manufacturer of industrial weighing equipment for the bulk materials handling and processing industries. Impact weighers provide a dust-tight reliable, low maintenance weighing solution for free flowing dry powders and dry bulk materials in applications where there is a continuous flow of particulate material. www.flowforce.com.au

3507

AUSTRALIAN BULK HANDLING EXPO

HE Silos

4344

Supporting Australian farmers for over 50 years, HE Silos continually strive to innovate and manufacture sustainable products suited to all grain storage operations. They strongly believe in social responsibility; focusing designs around safety, efficient operations and protecting stored products to minimise losses occurred during post-harvest storage. HE Silos manufacture a wide range of grain, fertiliser, and pellet and mash silos; field bins, kit and bulk storage silos, livestock feeders and custom design silos built to any scope; offering free site visits to all grain storage operations. www.hesilos.com

Jenike & Johanson

3511

Jenike & Johanson is the world’s leading technology company for bulk material handling, processing, and storage.

It delivers engineered solutions to achieve reliable bulk solids flow based on proven theories and decades of project experience. With its skilled, highly technical team of experts and industryleading innovations, it has successfully delivered bulk material engineering solutions for over 55 years.

Bulk materials and their flow properties are at the core of all Jenike & Johanson’s work. Clients are offered maximum flexibility in selecting services required to meet their bulk material handling needs.

Jenike & Johanson does not follow the “one size fits all” concept –which can be a dangerous pitfall in engineering. www.jenike.com

HOSCH International

4319

HOSCH is the worldwide specialist for conveyor belt cleaning systems for the bulk material handling industry. German engineering and decades of experience help the find the best solution for any kind of bulk material. Their range of belt scrapers, ploughs, tracker rollers and skirting help significantly reduce carryback, increase safety, lower operating costs and minimise unexpected downtime. www.hosch.com.au

Kerman Contracting

4302

Kerman specialises in the design and construction of bulk storage and materials handling facilities and mine site infrastructure as well as the SMP erection of processing plants throughout Australia.

Over 41 years of experience in construct only, design and construction and EPC combined with its mature processes and techniques enable it to tailor a solution most suited to the operational functions, design life, durability, environmental and logistical challenges of any particular project. For Kerman’s clients in the agriculture, resources and infrastructure sectors this translates to cost effective design and construction, timely project completion and greater return on investment. www.kerman.com.au

ifm efector

3513

ifm has a vast product range of innovative, robust and high-quality products for many different industrial applications.

German engineered and manufactured sensor and control solutions for manufacturing, mining industries, food and beverage, and water industries just to name a few. Its portfolio includes position sensors and object recognition, fluid sensors and diagnostic systems, networks and identification systems, control systems, and connection technology. Quality for ifm is a term far exceeding the actual product. All its processes are focused on customer service and product quality. www.ifm.com/au

Kilic Engineering

4416

Producing Australia’s most innovative and hard-working material handling equipment, Kilic Engineering (KE) leverages its 47 years of experience to provide custom solutions to address your storage and material handling problems.

From concept to installation, KE offers a complete turn-key solution or can manufacture and supply to your design drawings. Industries from consumer goods manufacture, to metal recycling, to the agricultural industry – and almost everything in between – have relied on KE to provide solutions. www.kiliceng.com.au

Australian Bulk Handling Review: July/August 2022 І 95

EXHIBITOR LISTING

Kinder Australia

Koyo Australia Pty Ltd

LASE Australia

4002

4318

3503

LEAP Australia

LGPM

LINAK

For 25 years, LEAP has assisted companies from across Australia and NZ to implement digital solutions. Their goal is to help optimise product design and performance using best-in-class engineering software solutions from Rocky DEM, Ansys and PTC. Talk to LEAP about implementing: · Particle Simulation / DEM simulation of bulk materials handling processes / equipment · Multiphysics simulation for flow/thermal, structural design and fatigue (Ansys CFD and FEA Simulation) · Digital twin incorporating Internet of Things (IoT), machine learning and data analytics · Augmented reality for service and maintenance · CAD, product lifecycle management and documentation www.leapAust.com.au

LGPM can trace its heritage back to 1968 and the inauguration of the Sydneybased company Grain Processing Machinery. GPM, as it became known, built its reputation as a specialist in grain processing and bulk materials handling.

In 2004, a generational change in GPM’s management, saw the amalgamation of the Melbourne division with Lynchborough Corporation to form Lynchborough-GPM Corporation Pty Ltd. At LGPM, it can provide you with the right building blocks for all your project needs. Its services range from individual equipment supply, right through to large scale turn-key projects, from design and project management to installation and commissioning. www.lgpm.com.au

LINAK produces electric linear actuator solutions to create smooth movement in a vast range of applications. TECHLINE is a LINAK segment with a focus on reliable and precise movement in extreme conditions, including within the bulk handling industry. By working closely with their customers, they create durable solutions that are capable of heavy and repetitive movements in even the harshest environments. LINAK offers products that have been tested and certified for electrical operation in dust explosive atmospheres and are IECEx approved. www.linak.com.au

Kinder Australia is a privately-owned Australian company, highly respected by its customers and partners. It has earned a reputation delivering excellence in the bulk solids materials handling industries.

Kinder Australia is recognised as a leading supplier and manufacturer of innovative and practical solutions to improve and maintain the running efficiency of conveyor and bulk materials handling equipment used to convey a variety of products. Imaginative design capabilities, lateral thinking, rigid benchmarking and ability to overcome problems makes Kinder Australia an industry leader. www.kinder.com.au

4132

96 І Australian Bulk Handling Review: July/August 2022

Koyo Australia is a group company of JTEKT Corporation. The company’s principal activities consist of the importation and wholesale distribution of anti-friction ball and roller bearings.

In addition, the company supplies drive shafts, oil seals and universal joints to a wide range of industries in Australia and New Zealand. Equipped with a warehouse facility in Sydney and a staff of qualified engineers and experienced sales representatives, Koyo Australia can provide excellent service to meet customer expectation and satisfaction. www.koyoaust.com.au

4134

LASE is a global player in the field of industrial laser measurement technology.

Their solutions support the logistic processes of companies. They ensure the automatic handling of products and provide exact dimensional data of products and goods. The products are used in freight logistics, mining, the timber industry and many other areas. www.lase.de

4301

AUSTRALIAN BULK HANDLING EXPO

Lincom Group

MANNAWAYS PACKING

MARC Technologies

The Lincom Group is at the forefront of significant projects, bringing the world’s best materials handling equipment to essential industry sectors. It is exclusive distributors of Thor Global conveyors, Powerscreen mobile screens and crushers, Pronar trommels and shredders, Rapid Pugmills, OFS filter presses, Neuenhauser star screen and shredders, Morbark chippers and grinders, Kiverco recycling plants, Broadbent process separation, Hercules trommels, McLanahan and Cyclones washing systems and Action vibratory equipment.

It has operations throughout Australia, New Zealand, Papua New Guinea and the Pacific Islands. It remain a wholly Australian owned family business, backed by a team of industry professionals. www.lincom.com.au

Mannaways Packing is a wholesaler and distributor of packaging products, such as FIBC bulk bags, hand and machine stretch film, with customised packaging in Australia. They strive to supply quality packaging products and provide excellent service while maintaining a very competitive price. They have teamed up with known vendors and manufacturers in the country to fulfill their customer’s requirements. www.mannawayspacking.com.au

MARC Technologies has been successfully delivering dust control solutions to the mining and industrial sectors since 1995.

Based in Western Australia, MARC is a wholly owned subsidiary of the Brisbane based multi-national ALS Global, providing a global presence. MARC provides innovative and specialised engineered products and Services for the mining and industrial sectors for dust control, including specialist Dry Fogging, NESCO misting and DustTamer windfences supplied by Dust Solutions Inc. These systems offer unique and comprehensive dust control technologies to provide effective solutions across the mine process and bulk handling operations. www.marctech.com.au

Martin Engineering Australia

Mideco Jia

MINPROVISE INTERNATIONAL PTY LTD

Martin Engineering is a world leader in helping industries handle bulk materials, making their processes cleaner, safer and more productive. Martin offers technologies that boost flow, reduce dust and spillage, extend component life and reduce downtime, resulting in improved operating environments and increased profitability. It is more than just a manufacturer of quality products, it provides expertise, industry education and solutions that work. www.martin-eng.com.au

Mideco offers dust control solutions for mines, quarries and any industrial environment. The company’s products are specifically designed to manage dust particles and ensure that workers and the operating environment are protected from harmful elements. Mideco products such as Bat Boot and Burnley Baffles have been successfully tested and implemented in a wide range of applications both locally and internationally. Burnley Baffles is dust suppression device for intake hoppers, developed by Mideco – a reliable and effective solution for suppressing dust during unloading of any dry raw materials worldwide. www.mideco.com.au

4149

4110

3501

4439

4448

4314

Minprovise are a specialist products, engineering and services company providing expert support to the mining, oil and gas and construction industries.

Their capabilities include the supply of mineral processing equipment, onsite installations, maintenance, repairs and shutdowns, offsite repairs and fabrication, corrosion control and abrasive blasting and scaffolding services, equipment and solutions. They endeavour to be a total solutions provider for their clients to enable the safe optimisation of projects, sites and overall business operations. www.minprovise.com.au

Australian Bulk Handling Review: July/August 2022 І 97

EXHIBITOR LISTING

MRA Electrical & Automation Engineering

Nelson Silos

PACKWEIGH EQUIPMENT

4306

4412

3500

If you need a better way to store dry bulk solids, Nelson can deliver it. Nelson are totally committed to innovative design and product development, and are now engineering silos with a proven 4-leg base design mounted on load cells. This unique Nelson design development ensures accurate weight measurement. www.nelsonsilos.com.au

Packweigh Equipment is a proudly Australian owned manufacturer of equipment for weighing, bag filling, bag closing, palletising and wrapping of bags from 200g to 2000kg. They design systems from manual operation through to full turnkey automated systems for all types of industries. If you put your product into bags, Packweigh Equipment can help. www.packweigh.com.au

Page Macrae Engineering

Phoenix Mecano

Pneuvay Engineering

Page Macrae Engineering have been providing engineering solutions since 1955. Their exciting new generation of port products range from bulk chain grabs to their new generation of EDG diesel hydraulic grabs and electric hydraulic.

The movement in the log industry has also seen solutions in the Log Loader and Grapple areas. Their presence in Australia will see full support in spares, commissioning and product development through industry relationships.

Engineering a better tomorrow! www.page-macrae.co.nz

Established in 1977, Phoenix Mecano Group comprises of divisions specialising in industrial/electronic enclosures, linear technology (linear units, lifting columns, electric cylinders) and mechanical connection systems (tube connectors, aluminium profiles). Geared towards the professional and cost-effective manufacture of niche products, they help to ensure the smooth operation of processes and connections in the machine industry and industrial electronics. www.phoenixcontact.com

MRA is a specialist in machine automation for mine-to-port materials handling and has developed of a suite of award-winning smart automation products that use laser data and analytics for smarter decision making and automation control. The smart products include train load-out and dump station automation, stockyard and quality management, machineto-machine anti-collision‚ ship loader anti-collision and automation. MRA was awarded the Innovative Technology Award at the 2019 Australian Bulk Handling Awards for the 11.3 per cent gains in stockyard throughput using their laser optimisation. www.mra.com.au/electricalengineering

3519

98 І Australian Bulk Handling Review: July/August 2022

4048

4001

Pneuvay Engineering is a specialist in pneumatic conveying, powder handling, industrial vacuum and dust collector systems. It is a successful Australian company that has been trading since 1982 and provides engineering solutions to both large and small companies.

From small, supply-only component jobs to large projects that involve full design, construction, installation and commissioning of multi-million dollar plant, it has you covered. Pneuvay strives to meet and exceed customer expectations by supplying quality pneumatic conveying components, designing reliable pneumatic conveying systems and providing dependable service and maintenance. www.pneuvay.com.au

AUSTRALIAN BULK HANDLING EXPO

Polesy Packaging & Industrial

Precisionscreen

Established in 1950, Polesy has been trading in packaging and textiles for over 70 years. Polesy has warehouses in every mainland state capital, and stocks a comprehensive range of packaging and textiles solutions for use across a range of industries including agriculture, feed and seed, food, construction, civil engineering, mining, landscaping, and recycling.

Polesy is also able to manufacture and print packaging to customer specifications.

Contact us to discuss your requirements and discover how easy it is for Polesy to tailor a solution for your packaging needs. www.polesy.com.au

Precisionscreen are leaders in the design and manufacture of mobile screening, washing, crushing and recycling equipment for the quarry, mining, extractive, materials handling and recycling industries. Precisionscreen prides itself on its innovative design and ability to meet the specific needs of a diverse range of clients. Leading the way in research and development, with a commitment to developing innovative products in the traditional washing, screening and crushing market, as well as the burgeoning recycling market. Precisionscreen is driven by a commitment to providing high quality products with excellent after sales service. www.precisionscreen.com.au

Prime Manufacturing

PROK Quality Conveyor Equipment

4049

4410

Prime Manufacturing is a competitive Australian supplier specialising in bulk material handling components, conveying systems, food processing and packaging equipment. Prime has over 30 years of experience developing and manufacturing handling components. www.prime-mfg.com.au

4135

4118

With more than 50 years of experience, PROK’s focus on developing and manufacturing conveyor equipment has grown its reputation in the industry as the quality standard in bulk material handling applications. Their complete PROK offering includes rollers, frames, pulleys and belt cleaners, safety and control devices. As PROK continues to grow, opening facilities across Australia and internationally, its vision remains the same; to become the conveyor company that customers prefer to do business with.

Their customer-centric focus underpins the service and products they provide to customers, fostering working partnerships that make a significant long-term difference to their customers invested capitals. www.nepeanconveyors.com

Premier Tech Systems and Automation

4010

Premier Tech is committed to creating sustainable solutions that help improve the efficiency of manufacturing facilities in the nutrition, industrial, agricultural and organics market sectors. They offer a wide range of solutions, ranging from weighing, feeding, bagging, case packing all the way through palletising and load securing, bulk handling, and lifting solution. While being a global company, Premier Tech believes the value of its worldwide presence rests in the deep roots its teams have established locally. Being local translates into tailored offers, but most importantly, custom support throughout the life cycle of their products.

Their programs provide the most valuable lifecycle services in the industry. www.ptchronos.com/en-oce/brands/ kockums

Rainstorm Dust Control

4437

Rainstorm is a specialist dust control company that offers a suite of products and specialist services to mines, civil contractors, agriculture, military and local governments. Since their inception in Australia in the early 90s, Rainstorm have been focused on the dust control, soil stabilisation and rehabilitation industries. As an industry leader with onsite experience, their product range and services extend through all areas of dust mitigation. Data validation of the best products and practices enable the client to evaluate cost and benefits while making environmental improvements. www.rainstorm.com.au

Australian Bulk Handling Review: July/August 2022 І 99

EXHIBITOR LISTING

RR Pacific Pty Ltd

SEW-EURODRIVE

Skala Australasia

SEW-EURODRIVE is a global designer, developer and manufacturer of mechanical power transmission equipment, systems and motor control electronics, headquartered in Bruchsal, Germany. Its broad spectrum of integrated solutions includes geared motors and gear units, high torque industrial gear units, high-efficiency motors, electronic frequency inverters and servo drive systems, decentralised drive systems. Plus it has complete engineered solutions and after-sales technical support/training. www.sew-eurodrive.com.au

Skala is a service and equipment supplier specialising in bulk material handling, vibratory and vacuum process equipment.

They provide sales, parts, support, installation and commissioning services to mining, power stations, recycling, biomass, pharmaceutical, chemical and industrial manufacturing industries. Their key capability is to provide innovative, efficient and value solutions to enhance bulk material handling processes. At BULK2022, they will be exhibiting DISAB industrial vacuum systems, MASABA telescopic shiploaders and truck unloaders, and General Kinematics vibratory equipment. www.skala.com.au

3508

4031

Slimstock

Smart Pack

For more than 40 years Reggiana Riduttori have been passionately dedicated to producing planetary gears and wheel gears made entirely in Italy. Top quality raw materials, assembly and storing phases are strongly influenced by a high innovation level backed by constant investments in research and development.

Their mission is to remain on their quality path, provide exceptional and professional sales and after-sales service on time. www.rrpacific.com

4345

Slimstock is a world market leader in inventory optimisation, providing user-friendly yet sophisticated inventory solutions to customers across industries like eCommerce, Retail & Manufacturing.

Headquartered in the Netherlands since 1993, Slimstock has offices in 22 countries including Australia and Singapore.

Slim4 is designed and built to seamlessly integrate with any ERP system. Over 1200 organisations worldwide are backed by Slim4 to date, ensuring they have the right stock, at the right place, at the right time – giving customers the confidence to achieve operational excellence. www.slimstock.com

100 І Australian Bulk Handling Review: July/August 2022

3506

Smart Pack is bringing a fresh approach to specialist bag and sack supply, creating partnerships that last. They supply an extensive range of customised solutions to a wide range of industries, right across Australia. www.smartpack.co.nz

4438

Superior Industries/ Tricon Equipment

3416

Tricon Mining Equipment was founded in 2001 and has been recognised as one of Australia’s leading materials handling solutions suppliers. Continually meeting client expectation and demand for supply, maintenance, servicing, inspection, training, and repair services has made Tricon Equipment what it is today, 21 years on. Tricon Equipment is one of Australia’s leading importers and suppliers of mobile crushing, screening, recycling, conveyor and associated equipment components since operations began. Tricon has a well-established customer base and is dedicated to deliver on customer service, support and satisfaction. www.triconequipment.com.au

AUSTRALIAN BULK HANDLING EXPO

Supplied by Ebro

Terex Jaques

ThermAlign Pty Ltd

Ebro Armaturen is a privately owned and operated German company manufacturing high-quality precision-engineered butterfly and knife gate valves, valve actuation and valve accessories. They produce a range of products with wear and abrasion-resistant components for applications requiring product isolation, control and metering. www.ebro-armaturen.com/en

Terex Jaques specialises in the design, supply and servicing of crushing, screening, washing, conveying and materials handling equipment for quarrying, mining, recycling and sand operations. A sales and service branch network throughout Australia and a global presence through Terex Corporation builds the framework for Terex Jaques’ strong reputation for technical excellence and aftersales support. www.terexmps.com.au

ThermAlign is an innovative and agile predictive, proactive and preventative service provider that specialises in vibration analysis, thermography, motion amplification, laser alignment, in situ dynamic balancing, mechanical services and reliability and lubrication studies.

ThermAlign will be demonstrating their newly commissioned MEDUSA asset diagnostics system and motion amplification. MEDUSA is a portable asset condition assessment tool which integrates condition monitoring, asset telemetry, SCADA and mobile and cloud computing. www.thermalign.com.au/about-us

4337

Treotham Automation

4046

Treotham Automation is a leading supplier of high-quality components and products to all industrial markets. As the exclusive distributor for the many international product lines, Treotham’s customers gain from their local presence, extensive knowledge and experience of their staff.

A brief list of their suppliers include Igus energy chains, Chainflex cables, polymer bearings and linear bearings, LAPP flexible cables and spiral/curly cords, Ilme multipole connectors, PMA industrial conduits and Euchner mechanical and electronic safety switches. www.treotham.com.au

4308

TUNRA Bulk Solids Handling Research Associates

4443

TUNRA Bulk Solids (TBS) provides professional consulting services to industry and has a strong reputation for its cutting-edge research and technological developments in bulk solids handling, processing and conveying. A wide range of material testing services are available as well as conceptual solutions to bulk materials challenges, from fundamental characterisation to development of optimal designs. TBS is committed to forming long term partnerships with businesses to help them overcome existing handling issues and assist with planning projects to ensure trouble-free plant operation. www.bulksolids.com.au

4404

Vayeron

3518

Vayeron is a leading Industrial IoT technology company providing solutions to the challenges faced by bulk materials handling processes. Their solutions anchor physical plant and equipment to the digital world. Innovations that enable agility, reliability and scalability of engineering operations. www.vayeron.com.au

Australian Bulk Handling Review: July/August 2022 І 101

EXHIBITOR LISTING

PLATINUM SPONSOR

Weigh-More Solutions

VEGA Australia

4131

4130

Weigh-More Solutions is a privately owned Australian company that has grown to become one of Australia’s largest and most respected industrial weighing specialist suppliers – with a principal focus on weighbridge systems instrumentation and manufacture. The company invests in ongoing R&D to stay relevant in weighbridge design complemented by their sophisticated cloud software solutions.

Their aftersales technical team is licensed

by NMI and provides service, calibration and verification of industrial scales, weighing systems and weighbridges. www.weigh-more.com.au

VEGA has set itself the goal of developing innovative measurement technology that is easy to install and operate and offers maximum safety and reliability.

VEGA employs over 1750 people worldwide, 800 of whom work at its headquarters in Schiltach in the Black Forest. This is where, for over 60 years now, solutions to demanding measuring tasks are being conceived and brought to realisation: for chemical and pharmaceutical plants, the food industry, drinking water supply systems, sewage treatment plants, landfills, mining, power generation, oil platforms, and ships.

VEGA is active in over 80 countries with its globe-spanning network of subsidiaries and distributors. The company has all the necessary certificates and approvals for worldwide application. www.vega.com

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6 issues of Australian Bulk Handling Review and 1 copy of the Equipment and Services Guide 2 years

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12 issues of Australian Bulk Handling Review and

Sumitomo Drive Technologies ....................................... 45 TAKRAF Australia ............................................................ 59 Tecweigh ......................................................................... 27 Thayer Scale ................................................................... 65 Transmin ........................................................................ IFC Treotham Automation .................................................... 19 TUNRA Bulk Solids Handling Research Associates ....... 35 West Coast Conveyor Services ....................................... 47

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See the full range of fast-payback equipment at flexicon.com.au: Flexible Screw Conveyors, Tubular Cable Conveyors, Pneumatic Conveying Systems, Bulk Bag Unloaders, Bulk Bag Conditioners, Bulk Bag Fillers, Bag Dump Stations, Drum/Box/Container Tippers, Weigh Batching and Blending Systems, and Automated Plant-Wide Bulk Handling Systems

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USA SINGAPORE INDONESIA MALAYSIA SOUTH AFRICA UK SPAIN FRANCE GERMANY

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KK-0528

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6/20/22 3:53 PM