Air International 

Fast Facts 

• Air International engaged SEMF to build a new assembly plant for the production of seats and HVAC components at Ford’s manufacturing site in Broadmeadows
• SEMF designed a customised seat module controller tester for the new plant
• The plant took 12 months to complete, from concept to final design

Established in Victoria in 1967, Air International is one of the country’s leading automotive providers. It specialises in the production of integrated heating, ventilation and air conditioning (HVAC) systems for the motor industry.  In 2002, Air International commenced plans to build a new assembly plant for seats and HVAC components at Ford’s manufacturing site in Broadmeadows. The new plant works in tandem with Ford’s build schedule to manufacture up to 1200 seats per day on an on-demand basis.

Air International engaged SEMF to provide the design and commissioning for the site’s electrical systems and software. We were also charged with developing an external scheduling system based on Supervisory Control and Data Acquisition (SCADA) technology.

The assembly line uses Radio Frequency (RF) tags to track the seats at various stages of the production process and is powered by two programmable logistics controllers, which utilise a DeviceNet field communications network. SEMF also installed a sophisticated supervisory system for receiving build schedule information, recording quality assurance testing  and providing operator selection prompts as well as alarming and diagnostic facilities. The plant took 12 months to complete, from concept and feasibility to final design.

In addition to this, SEMF designed a customised seat module controller tester for the new plant. This PC-based tester relies on a testing sequence program written in Visual Basic and communicates product information and technical specifications to the RF tag reader. The unit is highly portable and housed in a lightweight aluminium case. 

Bryn Estate Automated Lime Dosing System

Fast Facts 

• Hobart Water is the largest supplier of bulk drinking water to homes and businesses in Tasmania

• Hobart Water stores and supplies enough water to fill 4,400 Olympic-sized swimming pools

• SEMF designed a new automated lime dosing system to improve efficiency and quality control

• The new system incorporates automated closed loop fine dosing control and remote SCADA monitoring and control

Tasmania’s largest water and wastewater provider, Hobart Water plays a central role in maintaining and facilitating water supply throughout the state. It operates eight reservoirs around the city, which serve as storage points for 11 billion litres of water – enough to fill 4,400 Olympic sized swimming pools. Hobart Water’s supply system comprises a network of dosing stations, powered by the latest Supervisory Control and Data Acquisition (SCADA) technology.

As part of an effort to improve efficiency and quality control, Hobart Water engaged SEMF to replace their outdated manual lime dosing system, a piece of equipment responsible for dosing water across the greater Hobart area. SEMF designed, commissioned and built a replacement control system to meet Hobart Water’s rising supply demands.

The new system incorporates state-of-the-art features such as automated closed loop fine dosing control and remote SCADA monitoring and control. It also offers greater operational flexibility by providing a wide range of dosing options as well as local Human Machine Interface (HMI) monitoring and control across the dosing area.

SEMF worked closely with Hobart Water through every stage of this project from concept study and design to in-house testing and site commissioning. We also designed and installed the HMI and SCADA technology and procured new Programmable Logical Controller (PLC) hardware. 

Dairy Farmers Manufacturing Facility Lidcombe

Fast Facts

• SEMF successfully minimised interference to the plant’s demanding production schedule, with just 48 production hours sacrificed over a 13 week period.
• SEMF created significant cost savings for Dairy Farmers by using equipment supply at fixed price and employing installation contractors on a time and expenses basis.

Established in 1900, Dairy Farmers is one of Australia’s leading providers of dairy products with a countrywide network of manufacturing and processing plants.

In 2005, Dairy Farmers introduced a new program in an effort to consolidate operations and increase its production capacities. It enlisted SEMF to provide a feasibility study and concept design, for the installation of a new filling and packaging line at a facility in Lidcombe, NSW

SEMF initially carried out engineering and project management work was initially carried out at the Sydney office, later moving on-site for detailed design and construction supervision. The project saw SEMF dramatically modify existing infrastructure such as the existing crate supply and install new components such as an empty bottle conveyer and access platforms.

The production line is fully automated by using PLC and SCADA control systems and it can operate with minimum operator intervention. The packaging line includes automated filling, case packing and crate stacking. The existing CIP system was utilised, and the manual handling of chemicals for cleaning of the equipment was practically eliminated by providing a closed automated system. The pipework was designed with hygiene and access for maintenance at the key objectives.

SEMF minimised production interference by using regular weekend shutdown periods to carry out the bulk of the work – the project was significantly delivered within budget and ahead of schedule.

The Lidcombe facility has been successfully operating since November 2005, with a proven capacity for delivering product within specification.

Darrell Lea Chocolates Manufacturing Facility

Fast Facts 

• Darrell Lea is the country’s largest privately-owned confectionery retailer
• SEMF partnered with Darrell Lea to build a fully automated manufacturing plant incorporating bagging and case packing facilities
• We created time and cost benefits for Darrell Lea by installing a palletising system driven by robotics technology 

Established in 1927, Darrell Lea is the country’s largest privately-owned confectionery retailer. The company is headquartered in Kogerah, New South Wales and manufactures and distributes chocolate assortments, pick n’ mix sweets and signature products such as Rocklea Road, Darrell Lea Bites and Liquorice Lovers liquorice.

As part of its nationwide expansion plans, Darrell Lea engaged SEMF to design, engineer and construct a high-performing manufacturing plant for its liquorice business. In response to this, we built a fully automated manufacturing plant incorporating bagging and case packing facilities. SEMF also created major time and cost benefits for Darrell Lea by installing a palletising system that drew on leading edge robotics technology.

In the last few years, Darrell Lea has strived to adopt sustainability principles. SEMF addressed this priority by designing processes to minimise wastewater. We also implemented an automated Cleaning-in-Place (CIP) system to simplify and streamline the cleaning process.

The project took just 18 months to complete, from concept and commissioning to construction and final design.

FEA Timber Mill

Fast Facts 

• SEMF designed and installed a new chip handling and storage system for FEA Timber
• The new system combined new and second-hand components
• The mill set new performance standards for FEA Timber  

Launceston-based FEA Timber is a leading supplier of hardwood and softwood chips to timber giant, Carter Holt Harvey. The company operates a high-turnover small pine log sawmill in the waterside suburb of Bell Bay.

In 2003, FEA Timber joined forces with SEMF in a bid to reduce operational costs and replace the pre-existing chip mill, which was destroyed by a fire early in the year. After an extended collaborative research process, we designed and installed a new chip handling and storage system which combined existing, new and second-hand components.

The resulting mill set new performance standards and helped FEA Timber maintain a strong presence within Tasmania’s thriving timber industry.

Grade Sawmill 

Fast Facts 

• SEMF designing and constructing a high-turnover sawmill in Colac, Victoria
• We designed installed a sophisticated PLC to allow for steady production and seamless, automated processes
• The sawmill processes  approximately 150,00 cubic metres of pine a year

Victoria’s timber industry relies on relentless innovation and technological evolution to stay competitive.

SEMF helped a major timber provider achieve this competitive advantage by designing and constructing a high-turnover sawmill in regional Colac. This $11 million greenfield project saw SEMF provide full project management service as well as detailed documentation and mechanical design. We also designed, commissioned and installed a sophisticated Programmable Logistics Controller (PLC) to enable steady production and seamless, automated processes.

SEMF carried out post-commissioning support and further development of the PLC from the Hobart office, using cutting-edge online techniques developed as part of the project. The sawmill continues to performance optimally and processes  approximately 150,00 cubic metres of pine a year.

HyroMet Manganese Sulphate Plant

Fast Facts 

• SEMF provided the engineering, procurement and construction management services for Hydromet’s new manganese sulphate plant in Risden, Tasmania
• We oversaw the process development and design for the plant’s sulphate gas supply and leaching sections
• Total project value was $8 million

HydroMet specialises in commercial metal processing as well as the production of metal bearing residues. It develops processes and applications for minerals such as zinc sulphate, cobalt sulphate and manganese sulphate and extracts arsenic trioxide from chemical manufacturing waste and lead nitrate from lead garnet and smelter wastes.

The company oversees production and waste treatment facilities in Wollongong and Newcastle, New South Wales and operates a plant at the Pasminco Smelter, just outside Hobart.

HydroMet joined forces with SEMF to design and construct its Hobart plant – a partnership that commenced in an engineering, procurement and construction management (EPCM) capacity and evolved to include design and engineering support.

The plant is engaged in the extraction of pure, crystalline manganese sulphate from impure, stockpiled manganese sulphate residue. It accomplishes this through a set of processes including counter-current decantation, filtration and neutralisation as well as purification, crystallisation and spray drying.

SEMF delivered the process development and design for the plant’s sulphate gas supply and leaching sections. 

Lafarge Plasterboard Plant Upgrade

Fast Facts

• Lafarge Plasterboard’s Matraville and Altona plants are high-output manufacturing sites for plasterboard and related products.
• SEMF implemented several cost-saving measures such as the recasting of an accumulation conveyor as a pre-stacker.
• SEMF worked closely with Lafarge Plasterboard to dramatically modify the PLC software.

Lafarge Plasterboard is a major manufacturer and distributor of plasterboard and related products. The Melbourne-based company oversees two high-output production facilities in Matraville and Altona.

Lafarge engaged SEMF to investigate potential measures to help improve dry end line speed across its manufacturing sites, as part of a wide-scale effort to improve productivity. SEMF addressed this by producing a comprehensive project development report, which served as the basis for a significant plant upgrade.

SEMF spearheaded and delivered every phase of this upgrade, providing design and commissioning services as well as site supervision and project management throughout the process. Some of the critical improvements included the modification of a right angle transfer table to double the amount of boards that could be handled at any time, the total overhaul of the cross conveyor to create two distinct conveying  zones and the division of the plasterboard “booker” into two zones.

SEMF also implemented various measures that made the most of the plant’s existing features and assets and dramatically cut down costs. For instance, we recast an accumulation conveyor as a pre-stacker – an innovative move that required significant mechanical adjustments as well as changes to this item’s control philosophy. SEMF also increased transfer table in-feed speed by altering gear ratios and variable speed electrical drives.

However, the modification of existing PLC (programmable logistics controller) software proved to be the most complex and challenging aspect of the project. SEMF overcame several pressing commissioning issues by collaborating closely with the client.  

Pacific Terminals

Fast Facts 

• SEMF spearheaded the expansion of the Pacific  Terminal’s Area C at Coode Island
• We also  installed a new SCADA system based on PLC technology
• The new system draws on sophisticated instrumentation and control processes, allowing for precise tank management

Pacific Terminals Australia specialises in the handling and storage of bulk flammable and combustible liquids such as chemicals, petroleum products, fats and edible oils. The Sydney-based company operates terminals at Coode Island, Melbourne with sister facilities in China and New Zealand. 

SEMF played a pivotal role in the expansion of the company’s Area C terminal at Coode Island. Through the course of this project, SEMF constructed 16 new 1.2 million litre tanks, facilities for truck loading, tank heating and trade waste and established new roads and infrastructure to enhance the site’s operational effectiveness. We also  installed a new supervisory control and data acquisition system based on programmable logistics controller technology. The new system draws on sophisticated instrumentation and control processes, allowing Pacific Terminals to precisely manage its fleet of tanks. 

SEMF worked closely with Pacific Terminals to ensure minimal disruption to operating activities during the construction process. We also drew on project management skills to effectively navigate various challenges, including a request to partially commission the site and accept a large shipment into the terminal during construction. 

Port Botany Terminal

Fast Facts 

• The Port Botany shipping terminal in NSW is now Australia’s largest fully automated container terminal that facilitates the automated transfer of containers to and from trucks by Autostrads™

As well as SEMF being the lead agent for delivery of the control system for all yard infrastructure SEMF played a significant part in the electrical design from HV to ELV.

SEMF Needed to demonstrate safety compliance throughout the system lifecycle. This was achieved by referencing and meeting relevant clauses of safety standards AS 4024, AS 61508 and AS 60261 throughout the assessment, design, implementation and testing phases of the project.

The main challenge was the size and scale of the site required technology such as fibre optic networks to communicate with approximately 100 I/O racks. The system was implemented on an operational  brown-field site, reducing accessibility during installation and commissioning. To reduce maintenance and support costs the system was designed to be as centralised which necessitated the use of a single PLC, however significant attention needed to be paid to the processing speed in order to meet the safety response time requirements for each of the safety functional elements of the system. Significant complexity was also introduced by the systems that the PLC system needed to communicate.

This system was delivered to Patrick as a fully validated package. This was achieved by SEMF participating as consultants, designers, developers and test engineers in concert with Patrick’s larger team. This model allowed Patrick to leverage off SEMF’s knowledge of risk assessments and safety in the early requirement setting phases as well as SEMF’s capability to design develop and implement.

Read 'Sydney's Patrick terminal goes automated, with fewer staff but dancing robots' in The Sydney Morning Herald here.

Riverland Oilseeds Odour Control Plant Upgrade

Fast Facts 

• SEMF reduced odour emissions across the Riverland Oilseeds plant by designing an innovative biofilter involving microbe populations.
• SEMF undertook a thorough air modeling process using AUSPLUME software.
• SEMF designed and installed a state-of-the-art ducting network to capture odorous air.

Riverland Oilseeds is a canola seed crusher and vegetable oil refiner producing canola oils and meals for the Australian and international markets. It operates manufacturing plants in Numurkah, Victoria, Millicent in South Australia and Pinjarra in Western Australia.

Riverland engaged SEMF to complete a major odour management upgrade at its Numurkah site. In responses to this, SEMF designed a new ducting network to capture odorous air from the oilseed plant as well as replacement fans, humidifiers and air handling systems to transfer the air rapidly and effectively.

SEMF also constructed an innovative biofilter to remove odours from the air stream. This filter incorporated a packed bed of woodchips, which maintained sufficient moisture levels to aid the growth of microbe populations. The microbes then consume the odorous compounds on a daily basis.

SEMF partnered with Riverland Oilseeds through the design, project management and commissioning stages of the project and tackled the complexities that stemmed from the plant’s brownfield location. SEMF also collaborated with Victoria’s Environmental Protection Authority and embarked on a comprehensive air modelling process using AUSPLUME software.

The new system successfully reduces the site’s odour emissionsc and creates a more pleasant environment for the local community.

Robotics End-effector

Fast Facts 

• SEMF completed a 3-D design and drawing of an articulated robot end-effector 
• We ran nine FEA simulations on components and sub-assemblies throughout the design process
• The robotics end-effector was designed using the SolidWorks CAD software suite 

SEMF is breaking new ground in the dynamic robotics technology arena. We recently completed a comprehensive 3-D design and drawing of an articulated robot end-effector by drawing on new functionality offered by the SolidWorks CAD software suite. The software’s capacity to handle complex models and create multiple configurations of generic components made for a seamless design phase.

The brief saw SEMF thoroughly review an existing robotics process and modify the design to create deeper levels of automation. We ran nine Finite Element Analysis (FEA) simulations on components and sub-assemblies throughout the design process, keeping critical considerations (such as payload versus distance of the end-effector’s centre of gravity) in mind.

The project illustrates SEMF’s machine design capabilities and powerfully responds to the industry’s shift towards robots that can perform process-driven tasks within the end-effector tooling itself – a benefit that minimises capital costs and creates major resources savings.

Rosebery Flotation Projects 

Fast Facts 

• Tasmania’s Rosebery Mine produces 700,000 tonnes of ore a year
• SEMF has provided engineering, procurement and construction management processes to zinc rougher project and a high-grade copper project at Rosebery
• SEMF also made major extensions to the mine’s mill building

Located on Tasmania’s west coast, Rosebery is a major underground mine which is mainly engaged in the production of polymetallic base metals. The mine makes a significant economic contribution to the region and has the capacity to produce an estimated 700,000 tonnes of ore a year, which is then processed into lead concentrate, zinc concentrate and gold and silver dore. Rosebery Mine primarily uses mechanised underground mining  with crush, grind and flotation serving as its core processing methods.

SEMF has provided engineering, procurement and construction management processes to various flotation projects at Rosebery, including a large-scale zinc rougher project and a high-grade copper project. The first saw SEMF demolish pre-existing zinc roughers and an obsolete pyrite circuit, replacing them with a new, high-capacity zinc processing line. SEMF also made major extensions to the mill building and replaced the zinc concentration storage and thickener. 

Through the course of the second project, SEMF created major productivity and resource gains for the mine by  installing a new high-grade copper line along with a new copper conditioner.

Both projects were completed during restricted mill shutdowns.

Toyo Ink Varnish Plant Upgrade

Fast Facts 

• SEMF built and installed a high-capacity kettle to improve processing speeds for varnish at the Toyo Ink varnish plant.
• SEMF designed an innovative, gas-fired heating plant to maintain high temperatures and optimal performance
• SEMF improved Toyo Ink’s processing capacity by 50%.

Toyo Ink is a major manufacturer and distributer of inks and printing-related products. Wholly owned by Japanese-based parent company Toyo Ink Group, it operates a manufacturing plant in Kilsyth, Melbourne and is a leading supplier of printing and ink products across Australia and New Zealand.

Toyo Ink joined forces with SEMF, as part of an effort to streamline processes and increase production capacities across its Melbourne manufacturing plant. In response, SEMF designed and installed a jacketed 10,000 litre kettle engineered to improve the speeds at which the ink varnish is processed as well as a piping system for oil, water, varnish and nitrogen, which implemented heat exchangers and actuated valves.

SEMF also erected three additional storage tanks and built a new oil heating plant, powered by natural gas. This plant ensures that the kettles maintain the high temperatures required for optimal performance.In addition to efficiency, Toyo Ink faced challenges in the areas of recalibration and measurement. SEMF addressed these by constructing three new tanks, complete with load cells that accurately measured the varnish.

As a result of these measures, Toyo Ink was able to increase production capacity for printing ink by 50%. 

UMT Spreyton  

Fast Facts 

• SEMF constructed a dairy processing plant for UMT at greenfield site in Tasmania
• We created major cost savings by incorporating wastewater systems into the design process
• The $60 million project was UMT’s biggest capital investment to date 

United Milk Tasmania (UMT) is the state’s leading manufacturer and distributor of dairy products. The company currently operates as part of Fonterra Foods, the world’s largest milk processor with a presence in 140 countries.

In June 1995, SEMF was engaged by UMT to conduct a site selection, design and construction process as part of its plan to establish a processing plant  on a greenfield site in northern Tasmania. The $60 million project represented UMT’s largest capital works investment to date.

The proposed facility would manufacture butter, oil, frozen cream, cheese, lactose and spray dried milk powders and was to be designed with respect to sustainability principles and strict environmental controls.

SEMF prepared the site’s masterplan and was responsible for obtaining all environmental approvals. We also successful carried out the detailed design for the site’s buildings, services and infrastructure, oversaw the pre-commissioning process and managed contractors and sub-consultants.

All design work was completed in line with the Australian Code of Practice for Dairy Factories and helped power agile responses to specific operational requirements.

SEMF also created considerable  cost and resource savings for the client by incorporating water and wastewater management systems into the design process.