Biography

Andrew has over 30 years energy industry experience including senior roles working in retail sales and marketing, renewable energy project development, stakeholder engagement, policy and regulatory reform and consumer advocacy. For the last 7 years Andrew has been Chief Executive Officer of the Energy Users Association of Australia (EUAA) during which time he has positioned the organisation as a progressive, respected thought leader and advisor to industry, regulators, governments and member companies. In the 16 years prior to his current role Andrew worked with leading Australian renewable energy company Pacific Hydro where he negotiated the connection and revenue contracts for Australia’s first non-government wind farm and played a key role in establishing the Australian renewable energy industry.

Synopsis

While dispatchable fossil fuels have long been the backbone of Australia’s energy supply, the landscape is shifting rapidly. The rise of weather-dependent renewables, evolving regulatory frameworks, and increasing market complexity mean that large commercial and industrial (C&I) energy users can no longer afford to take a passive approach to procurement.

To secure the best outcomes in cost, reliability, and sustainability, businesses must not only become more informed, adaptive, and engaged with the energy transition, they must be active participants.

In this keynote, Andrew will demystify the complexities of today’s energy markets, highlighting key trends in electricity and gas pricing, the risks and opportunities for large energy users, and the critical issues that keep him up at night. He’ll also explain why, despite the challenges, there are strong reasons for optimism as Australia moves toward a more modern and diversified energy future.

** Following Andrew’s presentation we will host a Q & A  session with Andrew and some of our Industry’s largest Energy consumers.

Presentation Link:   EUAA AFI Conference Slide Deck October 2025 – Read-Only

THE PANEL

Alan Cooke – AFI  National Vice President

Brett Lawrence – General Manager Intercast & Forge

Dean Lalor – General  Manager Castings Tasmania

  Joe Vecchio – AFI Nat. Secretary and Operations Manager NIBF

  Francesca De Luca – Environment and Sustainability BP

  Keith Cooke – Global Energy Leader

Biography

Charlie Anderson is the Founding Director of Monocure3D, an Australian manufacturer with a long-standing reputation in UV-curable coatings and resins. The company was originally established by his father, Alan Anderson, who spent over 40 years developing and manufacturing innovative materials for a range of industries. Alan’s legacy of practical product development and local manufacturing continues to shape the business today. Before joining the family business, Charlie spent 20 years in the television industry, working as a director in broadcast production. Eventually stepping away from the TV industry, he took on the challenge of growing the Monocure brand by shifting its focus toward 3D printing and additive manufacturing. That move led to the launch of Monocure3D, which has since become known for its specialised resin formulations for professional users. Charlie now leads the development of purpose-built materials for industrial use, including Tensile resin for reusable sand casting patterns, BurnAway, a clean-burning, wax-free investment casting resin, and ThermaCAST, a high-temperature resin designed for direct metal casting of zinc and other non-ferrous alloys. He works directly with foundries, patternmakers, and manufacturers to help them adopt resin-based 3D printing workflows using affordable desktop MSLA and DLP printers. With a unique mix of creative background, product development and with over 10 years of 3D printing experience, Charlie brings a grounded and solutions-focused perspective to the integration of additive manufacturing into traditional casting environments.

Synopsis

Desktop Resin Printing for Industrial Casting

This session explores how affordable desktop resin 3D printers, combined with high-performance materials, are being used to produce durable, accurate, and reusable patterns for sand, investment and direct metal casting. Charlie will share practical examples using Monocure3D’s Tensile resin for sand casting, BurnAway for investment casting, and ThermaCAST, a heat-resistant resin designed for making moulds that can be used for direct metal casting of alloys up to 550c. The session will highlight how foundries can reduce tooling costs, speed up production, and adopt additive manufacturing without major capital investment.

Presentation link:

https://www.australianfoundryinstitute.com.au/vooneboa/16.-Charlie-Anderson-Desktop-Resin-Printing-for-Industrial-Casting.pptx

Biography

James Asquith is a Mechatronic Engineer BEng (Honours) who is currently working at Weir Minerals as the Smart Factory Lead. Over the last 6 years in this role, he has overseen, and implemented various industry 4.0 systems. These have included: Manufacturing Execution System (MES) rollout, real-time connectivity including RFID reading for tooling and condition monitoring systems for predictive maintenance. James enjoys making Weir’s processes simpler for operators, by creating a great user experience that enables all tasks to be completed with one or two presses on a screen. As part of his role, he has been able to travel globally, identifying best practices and the latest in Automation Technology to implement within Weir.

Synopsis

Overview of Smart Factory Systems.

Introduction to the Digital Manufacturing Ontologies to ensure everyone is aware at a high level the overall systems required to achieve points 2/3 identified below. This will be presented generally and tailored to a wide audience. This presentation will outline the core interconnected systems and the overall approach for starting or continuing an Industry 4.0 journey.

Importance of User Experience in system design.

With recent delivery of a successful, globally resourced User Experience (UX) system in our Beforecast process, this section will share key learnings and highlights. This will include operator feedback in the form or quotes or videos highlighting how the system has improved their day to day work. Often as Engineers, we focus heavily on the technical solution, seldom considering the experience from an operator’s point of view. Even the design of buttons, power of language simplicity and iconography make or break adoption and engagement. As a result, this can make or break the desired outcome the system was installed to achieve in the first place

Presentation Link: JamesAsquith

Biography

2020 – Graduated with a Degree in mechanical engineering.

2021-2022: I was employed as a Mechanical engineer for a trailer manufacturing company.

2022 – Present: I began working as a Foundry methods Engineer for Austral Alloys Australia Pty Ltd

2023 – Graduated with a master’s in project management

2023 – Awarded the NSW Young Achiever in the metal casting Industry

2024 – Did a presentation with Peter Morrison at the 58^th AFI Conference in Christchurch.

Synopsis

Implementing methoding software to increase profits in small foundries.

Methoding software is an essential tool to assist in controlling costs & increasing profits in foundries. Austral Alloys has 29 years of experience using 4 different software packages. In that time, we have benefited from greater certainty and controlled costs in our foundry. Our paper addresses some of the barriers to entry and highlights the benefits available for small to medium foundries.

Presentation Link: PeterMorrison_PushpaBale

Biography 

Sales leader with 38 years of experience in enterprise technology, the past 11 years in additive manufacturing. A consultative sales professional that listens to his clients and recommends solutions specifically based on their requirements and applications. Representing 3D Systems, with a broad 3D printer portfolio of commercial technologies, Bob’s focus is on high performance industries.

Synopsis

Core Additive and 3D Systems offer the largest suite of additive manufacturing solutions for metal casting, with hardware, software and materials specifically developed for foundry applications. 3D Systems has decades of expertise in metal casting solutions development. While investment casting foundries have been using 3D printing to produce casting patterns for decades, sand casting shops have been taking advantage of additive manufacturing in the recent years. In both cases, we have developed specific and integrated additive manufacturing (AM) solutions that maximize your productivity, reliability, flexibility, and yield – delivering your customers high quality parts while reducing total cost of ownership (TCO).
The presentation will focus on these specific technologies, including the production of re-useable patterns and core boxes,  that are applicable to the foundry institute members.

Biography 

Alan is a retired metallurgist with 33years at Ford Motor Company in the Casting Operations and Quality System areas. Alan is heavily involved with the Australian Foundry Institute as National Vice President and AFI(Vic) Secretary. This work includes advocating for the industry on energy costs, training offerings and industry promotion through school workshops, attendance at career expos and manufacturing exhibitions.

Synopsis

2025 Industry Data Report – Details of a Survey of the Cast Metal Industry Australia

This presentation is a report on the annual industry survey of the Australian metal casting industry. Included in this report are trends in total tonnage cast, energy costs and usage, employment, and the challenges that we deal with.

Presentation Link:  AlanCooke  

Biography 

Keith Cooke is a global energy leader with over 40 years of hands-on experience in the utilities industry. Throughout his career, Keith has tackled everything from utility mergers and acquisitions to running power plants, overseeing commissioning and decommissioning projects, and leading asset management and engineering programs. He’s the kind of person who’s seen the industry evolve—and helped shape that evolution.

Lately, Keith’s been focused on what’s next: guiding organizations as they build out strategies for new nuclear energy, including Small Modular Reactors (SMRs) and traditional nuclear technologies. If you’re thinking about the future of energy, Keith’s someone you’ll want to hear from.

Synopsis

Australia has committed to Net Zero by 2050. The path to get there continues to be a challenge, with electricity demand in Australia forecast to double by 2050. 3 main drivers of this increased demand are population growth, electrification of transport and industry, and the massive growth in AI. With an ageing coal generation system that will close, nuclear energy (base load) fills the gap that solar and wind (variable load) can’t. A combination of micro reactors, small modular reactors and advanced large scale nuclear deployment – together with renewables – can assure a Net Zero future, if we take action now.

Presentation Link: KeithCooke 

Biography

Kiwi, based in Melbourne Australia. Over 30 years of specialized Crucible application experience across all market segments, furnace types and geographies. Global Product Manager -Crucibles role includes all phases of supply chain from formulations to production to extending life cycle for all market segments. Previously employed by Morgan in various roles including business development, application specialist and technical service manager for Australia, Regional- Asia and Pacific and more recently Global. Expertise that is available to optimise processes, extend life of crucibles and offer sharing of global best practice. Proven problem solving and novel solutions provider

Synopsis

High Performance Crucible Technology

This paper will touch on some of the technologies that are being used today to keep the crucible at the forefront of the foundry industry to help foundryman reduce energy costs, optimize crucible lifetime and to match the ever-changing furnace technology of today and tomorrow. The earliest recorded use of crucibles melting metal was dating back to 3500 BC, some 5525 years ago, to melt copper alloys. Since these times advancements in furnace designs and material technology has required that Crucible manufactured today is a very complex refractory. A unique understanding of technical ceramics covering clay glasses/frits carbon refractory mixes is required along with powder processing and metallurgical melting practices and how all these materials, alloys and fluxes work together. Crucibles are being used to cast non-ferrous low temperature alloys such as Zinc < 400°C through to Copper Nickel alloys > 1400°C in Electric Resistance, Oil and Gas, and Induction furnaces. For Crucibles to offer the best performance for the foundryman the crucible must be tailored to suit the specific furnace requirements and specific temperature range where it is being asked to operate. To achieve this the crucible manufacturer must focus on the key features and benefits of the crucible refractory furnace design and sometimes deal with aggressive fluxes being used in heavy refining applications to optimize the performance of the alloy being cast. Globally in the non-ferrous metals industry aluminium melting & holding is the largest market segment that we/Vesuvius focuses on which covers Sand, Diecasting, Low-pressure, & Gravity casting segment. 40 years ago, the 500kg crucible was considered large, today 4500kg crucibles are supplied in indirectly heated furnaces driven by customers’ demands to improve metal quality, reduce emissions, capitalize on energy savings and have melting flexibility.

Biography 

Kevin has more than 30 years experience working in a number of engineering and operations roles in the Automotive and Manufacturing sectors in Australia, Europe and Asia. Prior to joining Hanwha Defence Australia, Kevin spent the past decade developing and managing a network of 50 engineering and related businesses in his home town of Geelong to access new markets and win work across Australia.
Now as the Industry Lead for Hanwha Defence Australia, Kevin is responsible for strengthening Australian manufacturing supply chains, increasing local content and exploring opportunities for industry to work with Hanwha and its partners, to deliver its defence programs.

Synopsis

How to become Defence Ready with Hanwha

• An overview of Hanwha locally and internationally alongside updates on both the Huntsman and Redback vehicle programs
• Ways to engage with Hanwha Defence Australia (HDA) directly and through our Australian Industry Portal (BenchOn)
• What HDA is looking for from the Australian supply chain to improve your visibility with us on current and future opportunities
• Commonwealth and State Government funding options to support developing your business to be defence ready

Presentation Link: KevinFoard

Biography

After completing an apprenticeship as a toolmaker Georg Grassl studied “Foundry Technology” at the University of Applied Sciences in Friedberg (Germany) and graduated with a degree in engineering. He has worked for over 30 years in various positions in the global foundry industry for German, Canadian, American and Finnish foundries and foundry suppliers. During this time, he gained deep insight into various areas of the foundry business and now has extensive knowledge of foundry processes. Today, Georg Grassl is the Global Product Manager at Chemex Foundry Solutions, located in Germany. He supports his colleagues in the HA branches and their sales partners worldwide with application-related questions on feeder technology.

Synopsis 

Nowadays, the demands placed on castings are becoming increasingly stringent. In order to remain competitive, foundries must meet the highest standards of productivity and casting quality. Innovative feeding technologies such as Chemex’s Tele-Feeder technology, Exo- or IsoPlast technology, etc. play an important role in this. The ‘telescope principle’ developed by Chemex,  in combination with the flourine-free feeder material, offers clear advantages. It is an innovative solution that is being used by more and more foundries. The two-part design of the cold box-bound Tele-Feeder and its special composition offer decisive advantages such as high feed efficiency, no damaged feeders, less reworking and greater design freedom for the foundry. Chemex’s Exo or IsoPlast technology is an exothermic or insulating kneading compound. This new technology enables foundries to create their own ‘contour-breaker cores’ or exothermic and insolating pads, thereby positively influencing the feeding behaviour. In addition, innovative feed developments like the telescope spherical feeder in shell technology or solutions for vertical parting we will present. Foundries worldwide are opting for the impressive feeding technology from Chemex and the HA Group.

Presentation Link: GeorgGrassi

Biography

Dickinson’s has been a significant supplier to the foundry industry for over 30 years , with Andrew a key member for 28 of those years. Starting his career with Dickinson’s in 1997 in a blue-collar role, driving forklifts and front-end loaders, he quickly progressed to a production management role overseeing the alloy crushing, screening and blending operations. Andrew has worked on a number of strategic business transformation projects within the company including navigating complex international supply chains and the key to commodities trading. He has worked hard to strengthen and build long standing relationships with global leaders within the international Ferro Alloys markets. Aspiring to greater things Andrew took lead of the company 4 years ago as General Manager and together with the Director and staff, has continued to grow the success of the company. During his free time, you will find Andrew fishing, 4-wheel driving and searching for lost treasure, joining expeditions as a technical deep underwater diver.

Synopsis

Commodity Metal Pricing and Supply Trends

Presentation Link: 8. Andrew Johnstone- Commodity Metal Pricing and Supply Trends

Biography

Alexander Keller is an accomplished leader in industrial technology with over 15 years of experience advancing system sales, project management, and supply chain operations. As Head of System Sales at ABP Induction Systems GmbH, he drives global growth initiatives and leads teams focused on delivering innovative heating and melting solutions for the metalworking industry, particularly in the steel and aluminium sectors. He also spearheads the replacement of traditional cupola furnaces with state-of-the-art induction technology.

Alexander’s career foundation was laid through a cooperative university program in mechatronics, where he earned dual qualifications as an industrial mechanic and a graduate engineer in production engineering. His early professional experiences gave him broad exposure to process optimization, lean manufacturing, and production planning. International assignments expanded his expertise in testing, compliance, and system reliability, while project-focused roles sharpened his skills in introducing new technologies and managing complex technical transitions. Over time, he developed a distinctive profile that combines engineering depth, operational excellence, and a global mindset. Since joining ABP, Alexander has held key leadership roles across project management, supply chain management, sales, and product management. Today, his work is defined by ABP’s guiding principle “Your partner on the way to zero emission”, with a strong focus on solutions that address the four megatrends shaping industry: decarbonization, digitalization, demographic change, and deglobalization.

By aligning cutting-edge induction technologies with these megatrends, Alexander is committed to helping the global metalworking industry transition toward a more sustainable, digital, and resilient future.

Synopsis

A contribution to decarbonization in the foundries and steel plants by Induction Technology 

Presentation Link: ABP Induction Furnaces decarbonisation solutions

Biography

Began career in the foundry industry June 1985 at an aluminium diecasting plant in Sydney (Lawrenson Diecasting). At Lawrenson’s I held positions in all areas of Administration (including product costing, accounts payable / receivable ,human resources and management information systems). I transferred as Financial Controller to our Adelaide iron foundry in 1997 which was subsequently replaced in 1998 with a greenfield site which doubled the output capacity. Following the 2006 installation of an additional furnace and the largest vertical moulding line in Australia I became General Manager of the site. Our foundry has a capacity of 45,000 MT sold p.a. with up to 60% of our output exported, primarily for the rail infrastructure market. My qualifications include Associate Diploma of Business – major in Accounting , Graduate Diploma in Business Management (Executive).

Synopsis 

Synopsis – The WFO World Foundry Summit – Takeaways

Presentation Link: Brett.Lawrence

Biography

Dr Kevin J Laws is an Associate Professor within the School of Materials Science and Engineering at the University of New South Wales (UNSW), Australia. He is the Director of the UNSW Physical Metallurgy and Metallography Laboratories and heads the Metal Physics and Advanced Alloy Research Team at UNSW. He is also the Founder, Director and Chief Scientific Officer at Advanced Alloy Holdings Pty Ltd. He has held positions with the Australian Research Council – Centre of Excellence for Design in Light Metals, the Swiss Federal Institute of Technology (ETH Zurich) and the US Air Force Research Laboratories Materials and Manufacturing Directorate. He has worked/consulted for external companies Volkswagen, AW Fraser, AMPCO, ALMAG, Edmünd Bühler and many more.

Synopsis

Perspectives on Industry Engagement with the University Sector and Government Supported R&D Grants.

This presentation shall highlight and explain the range of opportunities for the foundry and industrial manufacturing sectors to engage in product research and development activities within the Australian University sector.  We shall explore the range of support activities and programs available for industry, including student placements, student research projects, professional consultation and contract research, and also the larger government supported/funded grants and schemes for 2-5 year R & D projects. As a metallurgist, an academic and someone that runs their own company that has heavily utilised these opportunities, I look to provide a unique and honest perspective on these types of University engagement activities for attendees with an interest product research and development.

Synopsis

Kevin Laws AFI Conference Presentation

Biography

Since 1993, Jeff Meredith has been a Director of Casting Solutions Pty Ltd. Casting Solutions are an Australian based foundry consultancy specialising in casting design and methods, metallurgy, defect diagnosis, training and casting simulation software. Casting Solutions have consulted on casting projects in Australia, USA, Russia, Canada, New Zealand, United Kingdom, China, Taiwan, Korea, Malaysia, Indonesia, UAE and Philippines. Between 1980 and 1993, Jeff worked as a Product Manager for Foseco Pty Ltd. From 1972 to 1980, he worked as Foundry Methods Engineer and Technical Manager for Mason and Cox Foundries. Jeff started his foundry career at Horwood Bagshaw Pty Ltd in Adelaide in 1966 where he worked as Foundry Trainee and Metallurgist until 1972. Jeff has authored in excess of 80 foundry related technical papers published in journals such as Modern Castings and Metal Casting Technologies. He has presented more than 40 papers at trade conferences in Australia, England, Taiwan, China, Philippines, New Zealand and USA.

Synopsis

Designing Casting Methods using 3D Models & Simulation Technology

One of the most fundamental problems facing the foundry engineer is developing a casting method design which is practical, economical and meets the customers quality requirements. The approaches taken by foundries to design adequate casting feeding requirements vary widely.  Some rely on experience and instinct, which takes the design process essentially into the realm of art. Others rely on simple calculations to estimate relative solidification time and order to determine feeder size and location. Using modern casting simulation software, the solidification time of every point within a casting can be determined very quickly, and does not need to be estimated. It is possible to run a simulation of the casting within just a few minutes, using the Finite Difference Method, to obtain solidification time information throughout the casting. The next question was how to relate this information to potential risers/feeders of various sizes and types which might be attached to the casting. The answer to this question was the development of a calculation which could convert the solidification times in the casting to equivalent thermal modulus values.  This would allow the user to directly compare a riser with the casting, since a modulus value for a riser can generally be calculated easily. In order to develop such a procedure, it was necessary to devise a formula which would take into account the wide range of properties of the diverse array of casting alloys which are poured today, so that the resulting modulus values would be accurate no matter what alloy was being poured. Using this approach, what amounts to an almost automatic calculation of required risering for a casting is achieved. This presentation will endeavour to demonstrate this methodology on a selection of actual casting examples.

Presentation Link: Jeff.Meredith

Biography  

At 15 years of age, I completed work experience at B & J Patterns in Bankstown NSW, where my father was also a tradesman patternmaker. 1979, Commenced my patternmaking apprenticeship at B & J Patterns Pty Ltd. 1982, I received the AFI national Patternmaking award. 1983-1985, I worked in the pattern shop at Shaw Process Castings as a tradesman, making Investment Casting dies. 1985-1986, I was the patternmaker at Stamford Industries, producing their Vacuum forming tooling. 1986-1993, I was production manager at Hycast Metals, investment casting foundry. 1993, with 2 others purchased the old Peninsula Foundry at Brookvale NSW and we commenced trading as Austral Alloys Pty Ltd. June 2000, we moved premises to the current site in Bankstown NSW. August 2021 the business was sold to new partners & re named Austral Alloys Australia Pty Ltd. I was appointed General Manager. August 2023, we purchased the M & M Patterns business & relocated the pattern shop to our Bankstown site. This represents 46 years in the patternmaking & foundry industries.

Synopsis

Implementing methoding software to increase profits in small foundries.

Methoding software is an essential tool to assist in controlling costs & increasing profits in foundries. Austral Alloys has 29 years of experience using 4 different software packages. In that time, we have benefited from greater certainty and controlled costs in our foundry. Our paper addresses some of the barriers to entry and highlights the benefits available for small to medium foundries.

Presentation Link: PeterMorrison_PushpaBale

Biography

Tracey Murray is acknowledged by her peers, Government and industry alike as one of Australia’s pre-eminent tax practitioners, and her unique dual specialisation in both R&D tax and international transfer pricing sets her apart as an advisor within the professional services industry. With more than 20 years working with clients to ensure they are best positioned to fully harness the benefits from their investment in innovation, Tracey has established and led R&D tax and innovation advisory practices within PwC and Australia’s largest intellectual property firms. But what sets Tracey apart as an R&D tax advisor to some of Australia’s most innovative companies is her extensive ‘real world’ experience, gained from her 10 years as an auditor in the ATO, as an R&D tax Director for an ASX top 100 company and as a taxation manager for iconic international companies such as British Rail. Tracey is able to draw from this unique blend of professional services, regulatory body and commercial experience, to provide her clients with technical, practical and implementable  advice around  how to best position themselves to successfully access innovation initiatives, including the Federal Government’s cornerstone R&D tax incentive program,  whilst navigating the numerous commercial and people considerations that can impact the robustness of  client’s R&D Tax Incentive claims.  Tracey’s expertise as an R&D Tax Incentive advisor and her passion for innovation led to her being invited to advise Federal Government Ministers for both the major political parties on proposed changes to the R&D tax program, as well as her being invited to present in front of 2 Australian Federal Senate committees and regularly presents on a range of R&D related topics at key industry forums and associations. In addition to regularly contributing to innovation related content in the Australian Financial Review, Tracey is also a published author, including contributing a chapter to the ASX-NAB ‘Entrepreneur’s Guide’ concerning ‘Funding Issues and Innovation’. For her sins, Tracey is also an accountant (CA and CPA), has a Masters of Professional Accounting and was awarded an Advanced Diploma in Transfer Pricing from the Thomas Jefferson School of Law.

Synopsis

Funding Innovation – Give me the money!!

Funding the development of innovative products, processes or services is often as challenging as the innovation itself.  This is especially the case when these opportunities present themselves organically or arise from an urgent technical issue impacting foundry related processes and equipment or from an unexpected customer request, but the business doesn’t have the cashflow to pursue the opportunity because capital spend for the year has already been earmarked for other projects or company requirements. With a lack of funding the most commonly cited reason for businesses not engaging in the R&D required to pursue innovative opportunities, what can your business do to best position itself to take advantage of various government programs aimed at funding the R&D often required for  Australian businesses to take advantage of these R&D opportunities, for the benefit of both the business and the broader Australian economy.

This session aims to provide conference participants with a high level overview of the most common and accessible sources of government financial support to drive R&D projects and innovation that will benefits the overall Australian economy, with a specific focus on the R&D Tax Incentive program, as well as a range of state and federal government grants that (in the main) seek to incentivise innovation in specific industries (such as manufacturing), regions of Australia or to achieve specific employment or capital investment outcomes.

The takeaway from this session will be a clearer understanding of the forms of Government support that are designed to incentivise innovation in target industries or areas of the Australian economy and how, with a bit of advanced planning (in anticipation of a grant being released) a company can better position itself to successfully secure Government grant funding or access the benefits associated with the R&D tax incentive program to fund your company’s future R&D opportunities .

Presentation Link: Funding_Issues_and_Innovation_Tracey Murray

Biography 

Kevin is a skilled HSEQ, Sustainability and Risk Management Systems Professional with over two decades of hands-on operational and strategic experience in diverse sectors such as Automotive, Packaging, Engineering, Infrastructure and Utilities across Australia, New Zealand, and Southeast Asia. With a PhD in Eco-efficient New Product Development Activities of Australian Manufacturing Organisations, specialising in regulatory frameworks and organisational behaviour, Kevin brings a strategic and systems-based approach to managing environmental risks in complex, high-impact industrial settings. For over two decades, Kevin has worked closely with manufacturing and industrial facilities helping them navigate increasingly stringent environmental regulations while remaining commercially viable. His work focuses on translating complex legislation into actionable compliance programs, with particular emphasis on sectors facing operational constraints and high regulatory exposure, including foundries. Kevin’s expertise directly intersects with the environmental challenges that the Australian foundries face today ranging from emissions control and hazardous chemical management to waste reduction and energy efficiency. In addition to his technical focus, Kevin is a strong advocate for organisational culture, worker wellbeing, and psychosocial risk management, ensuring that sustainability initiatives are integrated across both systems and people.

Synopsis

Environmental Challenges & Compliance in Australian Foundries

Foundries across Australia are under growing pressure to meet stricter environmental standards while remaining economically viable in a highly competitive global industry. This paper explores the complex relationship between environmental responsibility, regulatory compliance, and operational sustainability in the Australian foundry sector. Key environmental challenges include air and water pollution, solid waste generation, hazardous chemical management, and high energy consumption, much of which stems from energy-intensive melting processes, raw material handling, and outdated infrastructure. While compliance with evolving environmental legislation is critical, particularly under the state-based Environment Protection Act and regulations, compliance often brings increased operational and financial burdens. Rising costs associated with emissions controls, waste treatment, reporting requirements, and infrastructure upgrades are pushing some manufacturers to reconsider investments or, in some cases, relocate operations offshore. For small-to-medium-sized foundries, the challenge is especially acute, as limited resources make compliance efforts harder to sustain without external support or incentives. The paper also highlights emerging solutions that offer a balance between compliance and competitiveness, such as energy-efficient furnace technology, dust and emission control systems, reclaimed sand systems, and digital environmental monitoring tools. By addressing both the opportunities and the obstacles of environmental compliance, this paper aims to provoke open, constructive discussion on how the foundry sector can navigate the road ahead embracing innovation while advocating for realistic, industry-supported pathways to environmental improvement.

Biography

Luciana Stuewe is the Chief Operating Officer of MAGMA Engineering Asia-Pacific, overseeing operations and technical support across Southeast Asia. With a master’s in metallurgical engineering, she specializes in casting process simulation and optimization, supporting foundries in improving quality, efficiency, and sustainability. She is actively involved in industry training and conferences focused on digital casting technologies.

Synopsis 

Evaluation and Reduction of Reoxidation Inclusions in the Steel Casting Process with Casting Simulation

Reoxidation inclusions are a common defect in steel castings, forming when deoxidized steel is re-exposed to oxygen during mold filling—often as a result of excessive flow turbulence. The removal of these oxide inclusions and subsequent repair procedures are both labour-intensive and costly, representing a significant challenge within the steel casting industry. This study presents a series of industrial case studies that investigate the primary mechanisms leading to reoxidation inclusions and demonstrates how these defects can be effectively predicted and mitigated through the application of MAGMASOFT® casting process simulation. By virtually analysing and optimizing key process and project parameters, foundries were able to achieve a substantial reduction in inclusion formation, minimize post-casting repairs, and enhance overall product quality. The findings underscore the critical role of simulation technologies in enabling proactive defect prevention, reducing production costs, and supporting data-driven decision-making in steel casting operations.

Presentation Link: Luciana.Stuewe

Biography

Glen Thiele has been a director at Spectrosource Pty Ltd since 2014 and is responsible for sales and servicing of Belec Spektrometrie Opto-Elektronik GmbH arc/spark Optical emission spectrometers in Australia and New Zealand. Belec Spektrometrie Opto-Elektronik GmbH has been developing and manufacturing arc/spark Optical emission spectrometers for metal analysis since 1986. Glen has a HD in Electronic Engineering from CPUT, a BCom from UNISA, a MPM and MBA from University of Wollongong. Glen is the current Treasurer of the Australian Foundry Institute, NSW branch.

Synopsis

Arc/spark optical emission spectroscopy (OES) is the most widely used method for analysing the concentrations of chemical elements in solid metal samples in the foundry environment. It is quick, effective method of analysing solid metal samples to widely accepted precision and accuracy levels. The method is a relative technique which relies on the calibration of the OES using known standards. The precision and accuracy of chemical analysis result is dependent on a well-prepared sample which is sparked on a calibrated spectrometer in a temperature controlled industrial laboratory environment. This presentation will explore methods of optimizing chemical analysis results and informing traceability of those results to widely accepted standards.

Presentation Link: 20251017 Glen Thiele – Optimal Spark Optical Emission Spectroscopy Analysis Results – conf V3