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ianhansen
Contact me Ian HansenConsultantBrisbane, Sydney, Melbourne, Adelaide, Perth - Australia T: + 61 420 903 039E: ianhansenconsult@gmail.com Copyright 2025 ianhansen
some of my projects
I specialise in the rotational moulding sector including process, material & quality assistance to your company.
powder testing
Created a documented quality manual for client. Provided training to operations staff on use of equipment and frequency of testing. Why is testing powder important?
Whether you purchase powder or make you own, the grinding process is one of the DNA variables that are difficult to control. The powder is produced by grinding polymer, and is typically produced on a batch basis, so variations between batches of powder are normal. Testing the powder to confirm it is within specification, or within normal boundaries, is an important quality assessment.
Dry flow is the measure of how a powder will tumble and flow in the mould during the rotational moulding process. The dry flow affects the heat transfer in the powder pool and how the powder distributes itself over the mould surface and into narrow recesses.
Dry flow is the most important single tests that you can undertake to assess powder quality.
Whether you purchase powder or make you own, the grinding process is one of the DNA variables that are difficult to control. The powder is produced by grinding polymer, and is typically produced on a batch basis, so variations between batches of powder are normal. Testing the powder to confirm it is within specification, or within normal boundaries, is an important quality assessment.
Dry flow is the measure of how a powder will tumble and flow in the mould during the rotational moulding process. The dry flow affects the heat transfer in the powder pool and how the powder distributes itself over the mould surface and into narrow recesses.
Dry flow is the most important single tests that you can undertake to assess powder quality.
product quality certification
A rural based rotational moulder required existing range of water and chemical tanks to be Product Certified to the Australasian tank standard. Work commenced on documenting systems to AS/NZS4766:2006 Tank Standard, which included regular interviews with management and production supervisors spaced over a period of 2 weeks. An integrated Product Certification and quality management system was designed and ready within 3 weeks. Management were given a draft copy of the quality management system for review. Management took just over 1 week to review the completed documentation.A final copy of the quality system was prepared and management and shop floor staff were trained in the operation of the integrated Product Certification and quality management system. After the new system was implemented and practiced by the manufacturer over a period of 8 weeks, an official audit was scheduled to be undertaken by an independent third party accredited JAS-ANZ Product Certification company. Just over 4 months after commencement of the process toward certification, the moulder was certified to AS/NZS4766
faster cooling times
A client moulding water and industrial tanks needed to increase production output and reduce costs by reducing cycle time of a specific tank that had high sales volume. The existing system only utilised external cooling of the moulds.Working on site with the moulder I designed an internal cooling system that was able to reduce their cooling cycle time by 35%, and still achieve consistent demoulding times by the operators.The client was very happy that we reduced the cooling time significantly, which we achieved by balancing the cooling process, utilising both external and internal cooling.We achieved a Step change that decreased the manufactured cost and increased product profitability.
welding repair
Client reported failure in 5,000L water tank; a split above the outlet hole. Repair was preferred instead of replacement because of long distance tank was from factory. Cause of failure was analysed to determine if failure was a design fault, manufacturing fault or installation fault.
Practical advice was provided on how to undertake the repair, using two different solutions. The solution included written procedures, with step by step pictures, on how to clean up and prepare the area of failure, using both extrusion welder and hot air speed welder.
Practical advice was provided on how to undertake the repair, using two different solutions. The solution included written procedures, with step by step pictures, on how to clean up and prepare the area of failure, using both extrusion welder and hot air speed welder.