Thanks to the hard work of our staff, as of July 2015, we have now gained three ISO (International Organization for Standardization) certifications. We are always continually trying to satisfy our customer needs and requirements, improve the quality of our products, reduce environmental waste and have a greater emphasis on health and safety within the company.
Such is the demand for the processing of thicker plates that the existing CR profile cutter has been upgraded with the installation of an larger cutting capacity plasma power source. The Hypertherm HPR260 'Hy Definition Plasma' unit now allows Keogh's to process mild steel plates up to 60 mm thick and other thicknesses for stainless steel and aluminium.
Production cuts at 60 mm thick mild steel requires pre-drilling of the pierce plasma points with the resultant cutting surface like that of thinner plate. This new power source allows Keogh's to cut at around 4 times the feed rate compared with the gas powered profile cutter previously used. This amounts to a large reduction in plate processing times whilst giving a cleaner cut, less heat distortion, a smaller HAZ (Heat Affected Zone) and a more effecient plate and part nesting.
Whilst offering Keogh's and its customer the ability to cut thicker plates, the same power source also cuts down to 1.2 mm thick simply by changing settings and cutting hardware..
What was previously an optional extra is now standard supply along with an ammeter for load monitoring of the MILL. All Keogh ROLLER MILLS now include a softstarter to properly control the units motor/s. All standard MILLS have 1 softstarter and 1 ammeter while all TWINBANK MILLS are supplied with 2 softstarters and 2 ammeters.
A softstarter is an electronic device which ramps up the motor speed over a time. The softstarter is set to around a 5 second ramp up time (longer for bigger motors) and can also be set with 'kick start' torque incase the customers supply voltage is variable. This is done to adequately protect the drive train of the MILL including the motor, belts, pulleys, shafts and gears.
The softstarter is a simple 'wire in' device and in the smaller size units (those up to 25 amp) require no control voltage as they are wired directly between the contactor and the motor. The larger units require a control voltage (usually 240 VAC) to be applied to the starter to begin the speed ramp up.
The smaller units are available in 2 sizes being 15 amp and 25 amp and are multi voltage and multi phase (240 VAC 1 phase, 480 VAC 2 phase (SWER) and 415 VAC 3 phase). The larger units are only available in 415 VAC 3 phase to 45 amps.
These softstarter units are also available for seperate supply.
For years Keogh's had been getting a large amount of thier machined parts supplied by an outside company. Scheduling the supply of such parts was always a bit troublesome. This coupled with the amount of parts that had to be purchased to make the process effecient forced Keogh Management to re-think the process. After intensive investigation a Daewoo Puma machining center was decided on and procurred.
The machine is mainly used for the processing of raw shaft stock into items such as auger drive spigots, roller mill shafts and our own range of gland seal assemblies. While initially becoming familiar with the unit the machinists could see other possibilities as the unit is equipped with a 12 station tool turret with live tooling. This meant that milling, drilling and reaming could also be achieved on a range of products.
Such was the extent of our reliance on outside suppliers that even with the introduction of this machine not 1 job has been lost. The fitters and machiners that were employed before the machine was installed are still in the same jobs manufactuing all of the other parts too large for this machine. This machine is equipped with a bar feeder to further enhance its capabilities.
Keogh's plan on advertising this machine to other companys in Bendigo and the surrounding area as a local source for fast machined and cost effective parts manufacture.
After 20 years of service Laurie Smith has retired. It was 1987 and times were tough on the land. Laurie was previously a grain farmer at Nullawil in Victoria. After enough of that sort of work he applied for a labourers job at Keogh's which he succeeded in securing. First job was to assist in concreting duties as Keogh's also made factories then.
After many years of general labouring duties Laurie was promoted to Despatch Manager, a career that would see him out and one that he excelled at. Duties obviously included despatch of items, sourcing of products and materials, assisting in Production Management and other duties too numerous to catalogue.
As can be seen in the photo's below a BBQ lunch was organised for the workers to wish Laurie a happy retirement. The usual speeches and such went on and Laurie was firstly presented with a gold watch by Keogh's Production Manager, John Manning, after which the workshop representative, Ron Poulter, presented Laurie with a gift voucher collected from a whip around of the factory floor staff.
That night a send off meal was put on courtesy of Keogh's Management at a local restaurant. A great time was had by all and many speeches were made.
Laurie and his wife plan on touring the country in the near future. We wish them both a happy and safe time on the road and all the best for thier future. He will be sorely missed.
In late 2004 Keogh's were contacted to supply a design and quote for 2 custom bucket elevators for an expanded ammonium nitrate plant for Orica at its Yarwun plant in Gladstone QLD. This plant upgrade is estimated to cost $110 million dollars (AUD).
The quote brief included the usual requirements such as product and capacity but also included special requests directly linked to the product being conveyed, the duty or service factor of the 2 bucket elevators and the driving motors and gearboxes.
Extensive engineering by Leeding Edge was undertaken to calculate loads on the chain, buckets, head and tail shaft bearings, head and tail shaft segmented sprockets and hubs, head and tail shafts and also the lifting points of the units. Finite element analysis was used to ensure that end lifting of the units would not be detrimental to the elevator structure.
Ammonium nitrate is a product primarily used for explosives. When in contact with petroleum based products (fuel, oil, grease, etc...) and materials such as zinc, gal and copper there is potential for chemical reaction and subsequent fire or explosion. Therefore these types of products hade to be excluded from the design and manufacture.
All fasteners were to be from a 304 and 316 stainless steel mixture to limit galling. Both the head and tail shafts were machined from 304 stainless steel. Segmented head and tail shaft sprockets complete with hubs were manufactured to allow for replacing of the sprockets without removal of the shafts. Special hardened chains were sought from Rexnord and custom stainless steel buckets were manufactured inhouse.
After final painting with a rubber pased paint and then assembly the 2 units were erected in preparation for individual 4 hour running tests. Each unit preformed perfectly with minimal adjustments required. The initial chain stretch was adjusted for, temperatures taken for head and tail bearings and also the drive motor and gearbox.
The below picture shows the units being erected for thier 4 hour running tests.
"Plasma cutting parts simply was not enough" was what customers were telling us. "We need finished parts. Pressing, rolling, drilling and such" was also required. So with this in mind 2 new pieces of equipment were purchases, an NC Pressbrake and a heavy Plate roller.
The Haco NC Pressbrake has been a long time requirement of Keogh's as the old machine was getting tired and un-reliable. The new unit is rated at 220 Tonnes and can press sheets 4000 mm long. A segmented blade setup allows for 'box pressing' and a universal die completes the process by allowing for bending of various sheet thicknesses, types and grades.
The NC control guarantees accurate bends, time after time. Coupled with the ability to 'program and store bend sequences' including the presing depth, automatic backguage and pressure settings, this machine is an all round bonus for Keogh's internal requirements and those of it's customers.
The Haco Plate Roller has been a real boon for Keogh's with a myriad of outside work now being accomplished. The machine is capable of rolling practically all materials up to 10 mm thick and 3000 mm long (some material grades and length restrictions apply). This machine is completely hydraulically driven with the 2 non-working rolls having digital readouts for position and also being able to be individually controled and tapered for cone rolling.
In the near future a digital readout will be fitted to the driving roll to give greater accuracy for rolling to end stops or positions.
In March, KEOGH'S placed an order for a large format NC controlled (numerically controlled) 'Hy Definition Plasma' cutting machine. This aquisition will result in enhanced manufacturing capabilities to broaden KEOGH'S market share and also to improve the effeciency and quality of existing KEOGH equipment.
'Hy Definition' basically means that the cut stream is more accurate that a conventional plasma and that the cut material edge quality is laser like. Actual cutting speeds are greatly increased when compared with a conventional plasma.
The aquisition of this machine was mainly for Keogh's internal use but plans were put into action for the cutting of external parts and jobs. If you are interested in having parts cut please contact us with your requirements and we will be happy to furnish you with a quote.
With a bed capable of holding 6 metre by 2.4 metre plates, our ability to cut large and complex shapes will be increased, and the addition of a full CNC control system will result in higher accuracy, repeatibility and turnover.
June 2004 saw the machine commissioned and available for part processing. Materials such as mild steel, stainless steel, aluminium and bisalloy can all be cut and optionally marked (holes, fold lines, part numbers). The range of material thickness is from 1 mm to 32 mm (in mild steel) and limited thicknesses in stainless and aluminium.