HOW WE BUILD HEAT EXCHANGERS THAT MEET YOUR NEEDS

Published on October 30, 2020

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Air Radiators is known for their quality and reliability in design and manufacture of heat transfer solutions that best suits our customer requirements. For over 45 years, we have been committed to innovative design and quality manufacturing across a variety of industrial markets including mining, heavy truck, power generation, process cooling, rail and defence.

Over the years, we have invested significantly throughout the value chain in plant optimisation and engineering capability to ensure the latest methods and technologies are utilised to deliver the most efficient and cost-effective solution for our customer.

Our end-to-end process in building the right solution for our customersstarts at defining the customer scope through to design, manufacture and testing of each product before final delivery.

Step 1: CUSTOMER SCOPE
What are your requirements and what is theproblem we need to solve?

One of our key business purposes is “to offer high value, reliable and efficient heat transfer solutions engineered to meet our customers’ exacting needs”. Having been in a technical manufacturing environment for decades, we understand the critical need of identifying the problem and creating the absolute best possible solution at the earliest.

Whether it’s the first customer interaction or resolving any after sale service queries, our team of trained and motivated professionals are always willing to help. When we are presented with a new business opportunity, one of our key account managers gets in touch with the customer to gain an in-depth understanding of the customer requirements and their problem. Reliability and trust are our key drivers while establishing a new partnership. To help build trust in our brand, our key account managers take you through the entire journey of explaining who Air Radiators is, how we work and how we go about finding the right solution for you.

Step 2: APPLICATION
Solving the problem through application engineering

Our in-house team of experienced Application Engineershave the in-depth knowledge and experience to ensure that the right product is designed and manufactured to your specifications. We share this knowledge with the customer throughout the selection process, providing the best solution for the application – first time, every time.

Taking the customer’s design specification and user application, we develop a custom fit-for-purposesolution, meeting thermal specification via in-house thermals program and industry standards such as HTRI and KULI thermal design software that includes design features to match the job at hand. Irrespective of the application, Air Radiators has the background to optimize the product for you whether it’s a complete packaged radiator solution, an engine oil cooler or a mobile HVAC system.

Step 3: DESIGN & DEVELOPMENT
Creating a solution through mechanical engineering and product development

Our well-equipped in-house R&D laboratory and our team of engineersplay a crucial role in developing solutions for our customers. We mechanically design every new cooling package whether it be a radiator, Charge Air Cooler (CAC) or an oil cooler using 3D CAD software (SolidWorks).The significant advantage of this is in understanding precisely how each component will fit andinteract with allother components – critical in complex 3D assemblies.This approach assists us in generating a large amount of metadata that is associated with the product and parts (for example, material grade and gauge, finish and paint spec, purchased part or manufactured, weight, COG, outline dimensions, and so on), that straight-away goesthrough to the manufacturing and our customer delivery ERP system.

We also extensively use in-house Finite Element Analysis (FEA)to ensure that the structure is relatively well optimized for cost, weight and performance for any new design and Computational Fluid Dynamics (CFD) capabilityto determine the pressure drop and flow paths through complex geometry – especially on the airside of the heat exchanger where good airflow through core matrices is critical to overall performance.

Step 4: MANUFACTURE
Fabrication, core making and assembling the product/s

Our one-of-a-kind in-house fabrication capacity enablesus to produce complex products with a high precision towards quality control in short lead times as part of each of our solution offerings.Wecan easily customize products in low volumes while meeting all necessary compliance regulations for our customers including materials specifications, dimensionrequirements and traceability.

The fabrication workshop showcases significant capability in cutting, punching, folding and welding using the latest equipment and machinery to produce parts.Our team has the capability to provide pressure code welding as per ASME and AS1210 standards.

The manufacturing capabilities across our plants in Victoria, South Australia and Thailand utilize a wide range of manufacturing techniques that enable our flexibility to work with aluminium, steel and stainless steel as we manufacture specialized heat transfer products and oil cooler packages for our customers across the globe.

Step 5: TEST & VALIDATE
Testing the product to ensure it meets the customer scope and provides the solution

Our highly experienced team of engineershave the skills and capability to offer an end to end service experience.Not only does our team test your plant and equipment to understand the performance and upgrade paths available for your equipment, we ensure efficient installation and commissioning of the industrial cooling system, Air Radiators offer a complete ‘know how’.

Data logging and other non-destructive testing methods including Salt Spray test and Shaker testing, help us to ensure that the team can unlock the mysteries of the performance of your existing system. We analyse this data that allows diagnosis, modification and redesign as required to be made.

Step 6: SERVICE
Committed to our customers, offering comprehensive after sales support and service centre

Air Radiators is not only committed to the design and delivery of innovative heat transfer solutions and air movement solutions we understand how to keep our products running optimally.

Ourcommitment to customers is driven by our comprehensive after sales support system which offers:

• An extensive range, and continued supply, of OE replacement parts for their products
• Technical assistance from ourskilled team on application, installation and maintenance
• Field service support provides specific advice with regard to service, maintenance and the operation of Air Radiators products.

Our support team of Installation, Commissioning and Service engineers have experience in assisting their customers with proper installation and optimizing the product that they manufacture all around the world.

How Air Radiators Delivers a World Class Service

Published on August 01, 2020

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Excellent customer service should be at the heart of any business. At Air Radiators, we are always pushing for innovation and excellence so that we can keep delivering world-class products and unrivalled services for our customers, every time.

As leading manufacturers of industrial engine cooling solutions in Australia, we understand that cutting edge technologies are crucial for streamlining processes, reducing waste and improving efficiency. Our advanced processes help keep the costs down and make sure you get what you need when you need it.

Reduce waste to increase efficiency

With the high labour costs of producing a labour intensive product in Australia, we know that efficient systems are essential for keeping costs down for our customers. Minimising waste in our system is a top priority at Air Radiators because waste leads to inefficiencies which can cause the price of products to increase.

With a number of innovative methodologies, we are able to minimise wastage, increase efficiency and offer high quality products at competitive pricing.

Effective communication and coordination

One of the biggest areas of wastage that we have been able to eliminate is the time taken to coordinate information between our different departments.

There are many steps of communication involved in the day-to-day of our business. Information from our customers needs to make its way through administration to the shop floor, then out onto the truck to get the product to our customers. Passing information like this from one department to another has the potential to eat up precious time. In a fast paced environment where scheduling can change quickly, it is critical that information is passed on as effectively and efficiently as possible.

Through the use of innovative digital systems called Pronto and Cognos, we are able to eliminate much wasted time on communication. The result is a more efficient process from start to finish.

How we use digital systems to streamline our processes

In order to streamline our processes, we have implemented digital systems which make things simpler and smoother for our team, and allow us to deliver a world-class service to our customers.

This digital system involves having touch screens on the shop floor, meaning our employees do not need to leave the shop floor in order to complete certain tasks. This digital system results in a much faster and more efficient process.

What’s more, the digital interface Pronto allows our information to be available to all departments immediately. Instead of taking hours to manually update information and coordinate with different departments, Pronto allows us immediate, live updates straight from the shop floor.

We believe that this advancement is what puts us in a class above the rest. Digitising all of our information to make it available and live throughout the production cycle gives us the opportunity to focus on what we do best: delivering our customers the highest quality industrial engine cooling products and excellent customer service from start to finish.

What our digital processes mean for you

At Air Radiators, we are committed to satisfying our customers’ engine cooling needs and are continually striving to be the best. We understand that being the best requires innovative thinking and advanced technologies which improve customer experience and keep prices competitive.

How does our world-class digital system benefit you as a customer?

1. Quick, efficient deliveries for our Just in Time customers.

For some of our customers who require regular daily deliveries, we offer a Just in Time service. Thanks to our Pronto digital system we are able to receive updates daily from these customers and respond immediately and efficiently to meet their requirements.

2. Improved communication with our administration.

Our digital system has streamlined our administration tasks, helping us give our customers a speedier service without any hassle. By not relying on paper copies to pass on important information, we save time on printing and delivering the papers to the different departments. With this saved time we are able to focus on looking after our customers needs.

3. Real-time accurate information whenever you need it.

When our customers call up about the status of their job, our administrators are able to give them real-time accurate information without delay. Any changes in scheduling or order requirements can be communicated immediately and accurately through our digital systems.

4. Competitive pricing thanks to less waste in our processes.

Waste in any business leads to inefficiencies which are in turn reflected in a higher cost product. By having less wasted time in our processes, we are able to offer efficient services and more competitive pricing for our customers.

5. Giving you world-class products that are made in Australia.

Though it’s not always easy to be a manufacturer in Australia, we are always striving to be world leaders in industrial engine cooling. Our advanced digital systems make it possible for Air Radiators to keep offering world-class products that are made in Australia and respected on an international stage.

AR Oil Coolers

Published on July 23, 2020

Air Radiators’ range of oil coolers are world-class products which are suitable for applications across the hydraulic, fuels, process and transmission drive cooling markets. Manufactured from a number of different materials including aluminium, steel and copper, Air Radiators supplies AR oil coolers that are suitable for small, medium and heavy duty applications.

For applications that require unique specifications, our range of oil cooler designs can be customised to suit your requirements. We offer both packaged oil systems, which are installed with radiator systems, and stand-alone units, which have self-contained motors and fan drives to manage the heat.

Pin Fin Coolers

Australian-made Pin Fin coolers are compact in size and offer excellent performance for a wide range of applications. They are the ideal choice for fuel, transmission oil and other cooling needs. Manufactured from steel and copper, Pin Fin coolers offer high performance and extended longevity.

Pin Fin coolers use a high thermal efficiency heat transfer tube. Using wound copper wire, the external fin is mechanically bonded to the base tube in all Pin Fin coolers which helps to increase strength and robustness. The density of the external fin and internal turbulator can be varied to optimise the cooler for specific applications.

Wire wound internal turbulators are added to enhance thermal performance for a variety of applications using viscous fluids such as oil and gases including compressed air and steam.

Aluminium Tube and Fin Coolers

Aluminium Tube and Fin coolers are heavy duty coolers that are ideal for large earthmoving and materials handling machinery as they offer excellent performance and efficiency in high temperature applications. Lightweight and durable, these Australian-made oil coolers are custom manufactured to meet your specific sizing and scheduling requirements.

Aluminium Bar and Plate Coolers

Manufactured entirely from aluminium, the Bar and Plate cooler is the industry ‘go-to’ cooler for good performance across the board. It is lightweight and offers excellent thermal efficiency. What’s more, its modular construction method means it can be configured to suit a range of different application requirements and is suitable for a variety of internal fluids including oils and gases.

Aluminium Bar and Plate oil coolers perform well in high pressure and high temperature environments, they are fouling and impact resistant and come with internal turbulators to enhance thermal performance. Aluminium Bar and Plate oil coolers offer a wide range of flexibility in design, construction and application.

Steel Coolers

Made from steel, the Kim Kool oil coolers are the ideal choice for tough environments and heavy duty applications. They are robust and corrosion resistant, offering superior durability and longevity even in high pressure and high temperature environments. These qualities make them a reliable oil cooler for a wide range of applications.

Kim Kool steel oil coolers have been built for pressure applications reaching 5000PSIG and are able to be certified to ASME(U).The cooler’s durable steel fins can be power washed without deformation and an integral by-pass (pressure or thermal) can be included in the design. For applications that require unique specifications, our steel coolers can be designed accordingly.

Copper and Aluminium Coolers

The aluminium plate fin coolers are ideal for small to medium sized applications that require high heat rejection. They have low internal pressure drops, are corrosion resistant and can cope with high pressure and high temperature environments. Air Radiators’ range of Dunham-Bush Aluminium Plate Fin oil coolers are suited for both mobile and stationary applications.

Packaged & Stand-Alone Coolers

The entire range of AR oil coolers are available as custom designs or ‘like for like’ replacement panels. We offer both packaged oil systems and stand-alone units. The fully packaged systems are installed with radiator systems and can come in vertical or horizontal configurations. They include a base frame, fan, fan shroud, guard and motor. The stand-alone units have self-contained motors and fan drives to manage the heat.

For applications that have unique requirements for oil coolers, Air Radiators can accommodate by altering designs to meet your specifications. Our standard and custom-manufactured oil coolers provide first class solutions for innovative heat transfer across multiple industries. When you choose Air Radiators, you choose excellent performance and unmatched quality.

Need More Information About AR Oil Coolers?

For more information about the range of oil coolers that Air Radiators manufactures and supplies, please download the AR oil coolers brochure below.

https://www.airradiators.com/wp-content/uploads/2020/06/AR-Oil-Coolers-Brochure.pdf

Air Radiators is a world-class business committed to the design and manufacture of innovative heat transfer and air movement solutions. We are renowned internationally for our quality products which thrive in challenging conditions. From radiators for engines to air and oil coolers, plate heat exchangers and fans for radiators, the wide range of Air Radiators technology empowers a variety of industrial markets including mining, heavy truck, power generation, process cooling, rail and defence.

To discuss your oil cooler needs or find out more about our other products and services, please get in touch with the team at Air Radiators. We look forward to hearing from you.

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Air Radiators recognised as Victoria’s Leader in Innovative Product Development 

Published on May 15, 2019

Air Radiators were awarded the inaugural Leader in Innovative Product Development and Commercialisation Award last night at the 2019 Victorian Government Manufacturing Hall of Fame Gala event in Docklands, Melbourne.

The Gala theme was centred on the Industrial Evolution highlighting the resilience of Victorian manufacturing and the people who drive the industry, supporting hundreds of thousands of jobs.

With Air Radiators’ focus on continuous improvement and progressing with Industry 4.0 and advanced manufacturing practices, the company has invested in its innovative product development through its new Alu Fin technology.

Air Radiators General Manager, Jamie Baensch, said the award recognised Air Radiators’ commitment to survive and grow as an Australian Manufacturer. 

“New product development in traditional markets such as heat exchanger manufacture is critical to our survival as an Australian manufacturer against the head winds of globalisation,” Jamie Baensch said.

“Coming up with a new idea is one thing – getting it to market is another.

“This award recognises our efforts to remain a proud, viable Australian manufacturer creating jobs and value for the Australian economy,” he said.

Alu Fin technology was developed and is manufactured in-house at Air Radiators, being the next generation in heat transfer products with its unique design developed to solve current industry limitations.

“Our new Alu Fin product is a game changer in industrial engine cooling and is already creating growth in both our local and export markets,” Jamie Baensch said.

“All credit and thanks go to the Air Radiators team who made our Alu Fin product a reality.”

Minister for Jobs, Innovation and Trade, Mr Martin Pakula attended the event and highlighted the Victorian manufacturing industry’s contribution of more than $30 billion to the state’s economy each year while employing 280,000 people.

“We know that recognising the outstanding achievements of the state’s manufacturing industry is important, and the Victorian Manufacturing Hall of Fame Awards are a vital part of this,” Mr Martin Pakula said.

Led by Air Radiators’ Business Development and Marketing Manager, Jove Manev, the innovative Alu Fin product range has been showcased to the company’s market sectors at various tradeshows, both nationally and internationally, including Bauma in Munich, Germany, Avalon Airshow here in Victoria, InnoTrans in Berlin, Germany and LandForces in Adelaide to name a few.

The Hall of Fame has been running since 2001 and recognises Victorian manufacturers who have made an ongoing impact on the industry through innovation, investment and trade and supply chain connections.

Air Radiators was inducted into the Manufacturing Hall of Fame in 2006.

For the full winners list, please click here.   

To see all finalists in the Souvenir Booklet, please click here.  

Air Radiators RECOGNIsED as top manufacture in hall of fame

Published on May 10, 2019

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Air Radiators have been shortlisted as finalists at the Victorian Manufacturing Hall of Fame awards, which is being held on Tuesday the 14th of May 2019.

With a focus on innovative and visionary businesses working to keep Victoria’s manufacturing industry strong, Air Radiators are finalists in the Leader in Innovative Product Development award category.

The theme for the 2019 Manufacturing Hall of Fame is Industrial Evolution – highlighting the resilience of Victorian manufacturing and the people who drive the industry, supporting hundreds of thousands of jobs.

The Hall of Fame has been running since 2001 and recognises Victorian manufacturers who have made an ongoing impact on the industry through innovation, investment and trade and supply chain connections.

Air Radiators was inducted into the Manufacturing Hall of Fame in 2006.

Victoria’s manufacturing industry contributes more than $30 billion to the state’s economy annually and employs nearly 280,000 people.

Minister for Jobs, Innovation and Trade, Martin Pakula, said, “We know that recognising the outstanding achievements of the state’s manufacturing industry is important, and the Victorian Manufacturing Hall of Fame Awards are a vital part of this.”

“Our manufacturing industry is innovative and internationally competitive, with strong growth in exports, business confidence and capital investment over the past year,” he said.