Back Ground
Melbourne Cement
Port Melbourne
Melbourne Cement, a joint venture between ICL and Cement Australia, was established in 1992 to manage the unloading and redistributing of bulk cement and fly ash. Handling 15,000 to 20,000 tons of powder daily, the company plays a crucial role in supplying construction materials to the Victorian market.
Melbourne Cement uses Air Slide Conveyor Systems in its Port Melbourne facility. An Air Slide Conveyor System transports dry bulk powders like cement using gravity and low-pressure air. The system consists of a sloped, porous fabric over which the material is placed. Low-pressure air is introduced beneath the fabric, aerating the material and making it behave like a fluid. This enables the powder to flow smoothly down the inclined surface without moving parts, making it an energy-efficient and maintenance-friendly option for industries like cement, flour, and chemical manufacturing.
Challenge
Melbourne Cement faced challenges isolating its air slide conveyor system sections during maintenance. Due to the fluid-like behaviour of cement powder, backflow during maintenance posed a significant risk. Isolating specific sections was crucial to prevent contamination and ensure the system could continue operating without shutting down entirely. Previous methods, such as foam blocks, proved ineffective and posed risks of broken pieces falling into the system. Melbourne Cement sought a cost-effective, reliable solution, allowing them to isolate parts of the system efficiently and safely while minimising downtime.
Specialised Solution
Giant Inflatables Industrial’s Plug-Up Low-pressure Isolation Plugs provided the perfect solution. These inflatable plugs were designed to block airflow and cement powder movement during maintenance. Melbourne Cement could insert the Plug-Up into small access hatches, inflate it quickly, and create an effective seal. Tethering ensured the plug remained in place, preventing it from falling into the system. This solution allowed Melbourne Cement to isolate specific conveyor sections for servicing without interrupting overall operations. The Plug-Up plugs significantly improved efficiency and reduced costs by reducing maintenance time and eliminating the need for after-hours work.
Results
With the introduction of Plug-Up plugs, Melbourne Cement experienced enhanced operational efficiency, reducing downtime and eliminating costly overtime work. The Plug-Ups’ simplicity and reliability made them an ideal solution, allowing the company to service valves and other critical components during regular hours. The low-pressure isolation plugs’ cost-effectiveness, increased efficiency, and safety ensured a positive return on investment.
Plug-Up Isolation Plugs are custom built to your size and shape
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Debris and Equipment Fall Protection
Debris and equipment fall protection can be ensured with the use of inflatable isolation plugs during maintenance and repairs of ducts.
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