ASSDA Member and Accredited Fabricator TFG Group has showcased its exceptional expertise in stainless steel design, fabrication and installation through the delivery of a greenfield project in New South Wales. Completed in September 2023, the Horsley Park Mixing Plant is a state-of-the-art liquid manufacturing facility set to redefine operational excellence in the production of household and personal care products.
The facility features world-class capabilities, including five standard production lines and a high-volume line capable of filling bottles ranging from 250mL to 5L at speeds of 30 to 100 bottles per minute.
Innovative design and sustainable execution
Engaged in late 2022, TFG was tasked with the fabrication and installation of support structures, stainless steel pipework and valves, along with the integration of free-issue equipment such as tanks and heat exchangers. Stainless steel was the material of choice for all pipework, offering unmatched sanitary properties and chemical tolerance critical for cleaning processes in such environments.
TFG’s proactive role in the design phase proved pivotal. Recognising the project’s goals and the circular economy principles of the client, TFG proposed substituting the initially specified galvanised mild steel support structures with stainless steel. This recommendation not only met the client’s expectations but also revolutionised the project lifecycle.
The adoption of stainless steel delivered numerous benefits, including reduced lead times, improved structural integrity, and a simplified supply chain. Welded connections replaced bolted joints, saving valuable time while enhancing durability and hygiene. By eliminating the need for galvanising, TFG further reduced project complexity and environmental impact.
This forward-thinking approach exemplified TFG’s commitment to long-term sustainability, creating an installation that seamlessly combined functionality, aesthetic appeal, and operational efficiency.
Precision in stainless steel fabrication and installation
The scale and precision of the Horsley Park project are demonstrated in its key installation components:
- 10,000m of grade 316 stainless steel tube
- 2,000m of grade 304 stainless steel hollow sections (SHS)
- 1,200m of jacketed pipework
- Installation of a 70m long central pipe rack
Over 15,000 welds were completed across the project, highlighting the complexity and attention to detail required to meet the stringent standards. The service gantry alone used nine tonnes of SHS, while all tubes, couplings and fittings were manufactured from grade 316 stainless steel, fully compliant with AS1528.1 Tubes (stainless steel) and tube fittings for the food industry, Part 1: Tubes. Additionally, the clamps were made from grade 304, and stainless steel was incorporated into the electrical conduits to enhance durability. All stainless steel materials for the project were supplied by ASSDA Members Stirlings Performance Steels and Atlas Steels.
Leveraging its national workshop network, TFG strategically divided pre-fabrication works between facilities in Melbourne and Brisbane. Key components, including pipe fences, valve trees, jacketed pipework and flow plates were prefabricated in 12m modules before being transported to the site. The off-site preparation reduced on-site installation time and enabled comprehensive quality assurance checks.
TFG employed orbital welding extensively throughout the project, with parameters such as amperage, gas flow rate, and arc timing carefully calibrated to achieve consistent weld quality. This automated technique is particularly advantageous for stainless steel as it minimises heat distortion and preserves the material’s corrosion resistance.
Delivering excellence
The Horsley Park Mixing Plant stands as a testament to TFG Group’s capability to deliver large-scale, technically complex projects. Despite its ambitious scope, the project was delivered on time, within budget, and with zero safety incidents – an achievement that underscores the professionalism and expertise of TFG Group.
With stainless steel at its core, the Horsley Park facility reflects the material’s enduring appeal and practical advantages, setting a benchmark for future industrial projects.
Photographer (Horsely Park Mixing Plant): Shannon Johnston - Risen Film.
This article was featured in Australian Stainless Magazine 81.