We recently wrapped up an exciting project for a leading manufacturer of industrial-scale biochar production systems. We wanted to give our followers an exclusive behind-the-scenes look at the processes that made it all possible.

🔹 Pre Fabrication:

• Consultations began with our client after providing them with a number of similar items in the past.
• They were impressed with the service and the quality of the assemblies provided to them previously.
• A new drawing package was thoroughly reviewed, and pricing provided.
• With a strong capability to meet diverse machining and fabrication needs, along with a year-to-date DIFOT of over 90%, AI&S was awarded the contract by this valued local customer in South East Queensland.

🔹 Lid and Plate Fabrication:

• QA checks ensured plates are free of sharp edges and burrs from the laser cutting process.
• Pipes were cut and holes machined for precise fitting, while lifting lugs, bosses, and sockets were carefully tacked and welded to spec.
• Flanges and tubes were sub-assembled and welded for optimal functionality.

Challenges for this part of the process were the possible distortion of the plates which was counteracted by a process call contra-heating using an oxy-acetylene torch to heat and cool the material to shrink the material back to it’s original shape.

🔹 Machining the Bottom Plate:

• 304 stainless steel presents unique challenges due to its hardness and corrosion resistance, making machining a delicate task.
• We drilled, milled, and refined 240 holes with a high level of precision, ensuring every pocket was made to exact tolerances.

Challenges for this part of the process were not only the difficultly in machining 304 stainless but also the possibility of burning a lot of endmills due to the sheer number of holes, the tight tolerances and multi-step process.

🔹 Turning Bars and Bosses:

• Bars and bosses, which ensure proper alignment and sealing, are turned, drilled, and threaded for perfect fitment.
• Our advanced boring and facing processes achieve excellent surface finishes and tight tolerances.

Challenges for this part of the process were the boring process needed to fed slow to gain a good finish and achieve a fine tolerance.

🔹 Sealing & Fabrication of the Box:

• The box was fabricated – meticulously welded together to ensure structural integrity.
• Once the main structure was assembled, gussets and stiffeners were added for reinforcement.
• The base plate was welded, followed by careful machining to ensure a perfect seal with the lid.

🔹 Final Checks and Passivation:

• Every component underwent rigorous QA before being sent for passivation, ensuring durability and quality are maintained throughout.

Our customer was thrilled with the result, and so were we. Delivering precise, high-quality work with tight tolerances is our expertise—and it’s what sets us apart.

#EngineeringExcellence #Fabrication #Manufacturing #QualityAssurance #Machining