Building this complete production system, the customer ran out of room in the original facility, so we were commissioned to remove and reinstall the complete system.
While the headroom presented a bit of a challenge, and not wanting to remove the room, we came up with a solution to safely carry out the install without damaging the production equipment of the new [existing] facility
Watch for the video in the comments – sorry – cant post videos in comments, so see separate post
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In August this year we had an enquiry to build this 600,000 litre tank and due to the fact we had been rather short of work at the beginning of the year, and knowing we now had a lot of other work on, as the business owner I decided to take the job on as an opportunity to get out of the office and back on the tools for 6 weeks.
Taking on this project was way out of my comfort zone; used to sitting at a desk all day in front of a computer, hating any temperature above 22°, I lost 15kgs stressing that I would get the job completed on time as no end of challenges presented themselves in one way or another; particularly the weather [we were supposed to be in drought, but had maybe an average of 1 day per week raining], but very thankfully we left the tank on Friday 21st December with only a couple of days to go to clean a few more welds and carry out the hydro-static test and we are done.
The tank was reasonably complex with all sorts of baffles and internal parts. The tank is 10,500mm diameter x 7500mm high with a cone top.
P.S. My sincere apologies to our customers who we didn’t give our usual prompt attention over the last 2 months. We have not had this volume of work ever before, which was an accumulation of orders accepted, the project scope increase as well as a couple of customers with breakdowns that were desperate for someone to help them out. A huge thanks to my team who handled this crisis in the best manner possible – they are now enjoying 2 weeks off.
This morning we were having our daily meeting and I brought up a point that had been disturbing me about the way we dealt with a particular aspect of our business and the discussion got pretty heated as we aired our thoughts – but the point was seen, accepted and the implementation got started. Then after lunch 2 of my staff came to me and said they had discussed the issue that had come up and thought that they would like to contribute – they said they could see that if they pushed themselves they would gain from it in the form of increased experience and learning as well as being able to contribute from their experience they had gained in previous employment. I gave them both a $100 gift card on the spot – not that I believe they we looking for a specific reward, but because it was one small way I could show that I really appreciated the gesture.
I always say; a company is only as good as the people it employs – so true and how fortunate I am to have these sort of employees, apart from my own 3 boys who enjoy working in the family business and treat it as their own.
One of our customers had an emergency – a tank that had been failing for some time, finally was no longer usable. Typical story where the accounts/finance department isn’t really interested in the engineering/maintenance teams’ request for budget allocation for equipment that needs to be replaced before it is too late and there is a disaster – even if that disaster is only loss of production [I say “only” in the context that someone didn’t get hurt]
We were able to measure up and fabricate a replacement in 7 days [Sure we could have done it in less with 24 hour shifts but it wasn’t that urgent]#stainless steel tank by Stainless Tank & Mix, #Stainless Tank & Mix, # stainless steel tank repairs, #stainless steel tank replacement, #urgent stainless steel tanks
ONE of the leading challenges faced by the food and beverage industry today is the ability to change quickly to meet market demands.
Manufacturers must often develop a specific product or sign a contract to manufacture a product, not knowing whether this time next year the market will have changed and the product no longer has market appeal. Product innovation keeps any manufacturer at the front of his field, but what if the new product requires an equipment change, upgrade or replacement? Companies must therefore acquire equipment that is as flexible and as multi-purpose as possible, as well as meeting quality and efficiency requirements.
Having worked in stainless steel fabrication in the food and beverage industry since 1987, and with extensive experience in liquid and powder blending as well as transfer/handling area, this has been my experience. Moreover, a flexible approach is supported by Lean principles, which we use, together with the SolidWorks 3D modelling program, to put proposals in clear perspective for our customers.
At Stainless Tank & Mix, we seek to provide our customers with the most efficient options in terms of energy usage, time and labour, while offering insight into potential areas that may in the future need to be adapted to meet change requirements.
At the end of last year, a global chemical company that had not ever manufactured in Australia before, but had instead imported finished product from its parent company overseas, approached Stainless Tank &Mix. Initially the enquiry was for the prices for mix tanks but, as a newcomer to the industry, the company wanted a contractor to handle the whole project. Stainless Tank &Mix handled the complete installation including access and loading platforms, pipework, electrical and process control to eliminate issues of scope creep and the like. We also used our industry experience to work with the customer to come up with the initial concept, and we were able to help the customer sift through the conflicting advice from their global associates to come up with the most cost effective solution that incorporated the benefits experienced by these existing plants.
Stainless Tank & Mix didn’t offer the company anything stunningly innovative – the key benefits were industry knowledge and application, a high quality build and a high level of automation. The result was a production facility which is the best it has in the world, according to the company.
Although the main obstacle to creating a flexible production system is cost, there is substantial hidden cost in a production facility that is not well designed. The morale of operators baby-sitting under-performing equipment can suffer, and constant ongoing repairs on-the-run, and equipment and process workarounds, are often difficult to quantify. In an era where the operator does matter, the best way of motivating them is to have a good quality, easy-to-use plant to remove these frustrations.
The chemical company now has a plant that more than meets its initial needs in terms of capacity, accuracy, repeatability and traceability of their product, and the ability to more than double its production capacity easily.