To address the ongoing issue of inefficient and unsafe calcite loading at the Water Treatment Plant, Scott Easton and his team developed a practical and ergonomic solution.
The Problem
What was the problem that you experienced?
Every 4–6 months, approximately 4–6 tonnes of calcite are required for pH correction at the Water Treatment Plant (WTP). The calcite is transferred from ground level via a Farm King auger into a feed hopper located 6 meters above. Traditionally, this was done using 1-tonne bulky bags suspended over the auger by a contractor’s skid steer with a forklift attachment. However, this method lacked flow control, leading to:
- Overloading the auger
- Product loss
- Pieces of plastic bag entering the process
A manual alternative using 22kg individual bags was trialled once but proved physically exhausting and inefficient.
How did the problem impact you or your work situation?
- The manual loading trial took ~6 hours over two days and was halted due to operator exhaustion.
- Operators reported discomfort in the lower back and upper body from repetitive bending, twisting, and lifting.
- The task posed significant ergonomic risks and was not sustainable.
How long had the problem been occurring?
This problem has been an issue since 2020.
The Solution
How did you come up with the solution?
Scott Easton, inspired by a farming mate’s grain feed setup, initiated brainstorming sessions with his teammate to adapt a similar concept for the WTP. Together, they:
- Discovered the fled bag dispenser
- Collaborated with trusted local fabricator Tony (FazFab)
- Designed a custom steel stand to safely support the 1-tonne bag over the auger feed
Who helped work on the solution?
Scott Easton engaged and collaborated with the below to bring his vision and solution to life. Teammate and WTP operator Justin Burley Faz Fab master local fabricator and trusted contractor Tony Fazioli Safety and Wellbeing Ergonomic specialist Carlee Ackland OHS TL Jodie Coutts Treatment TL Allan “Bulky” Miller Describe the solution.
- A fled bag dispenser speared into the bottom of the bulky bag allows precise control of calcite flow.
- A custom steel frame supports the bag,eliminatingthe risk of suspended loads.
- The solution:
- Removes manual handling and ergonomic risks
- Prevents auger overloading and contamination
- Speeds up the loading process by 4–5 hours
How has it helped you at work?
- Significantly improved loading speed and efficiency
- Eliminated ergonomic and manual handling risks
- Prevented plastic contamination
- Enhanced overall OHS outcomes
Suggest improvements, if time or financial limitations were not a factor.
- Install a gantry crane to lift bulky bags directly over the hopper
- Construct a new steel structure to safely release product into the hopper
- This would eliminate the need for the Farm King auger entirely
Any other comments you would like to make?
Scott Easton’s initiative exemplifies practical problem-solving and collaboration. His idea has:
- Delivered immediate benefits to team members
- Improved safety, efficiency, and task ergonomics
- Demonstrated outstanding leadership and innovation
With support from the team and investment from the business, this solution has become a game changer.
