The extraction of sugar from cane stalks involves passing crushed stalk material between a series of large metal rolls to squeeze out the juice. Roll arcing, the roughening of mill rolls through a welding process, represents a major maintenance cost for mills, and is also a significant health, safety and environment (HSE) risk. Roll arcing is a tedious, repetitive task during which staff work near high energy, rotating machinery, often in the presence of high temperature vapour. Contaminants in welding fumes and ultraviolet radiation in the welding arc are classified as Group 1 carcinogens. The need to eliminate this practice is a high priority for both financial and HSE reasons.

This project is testing a range of long-life coating technologies, involving MIG welding and laser cladding, that are designed to eliminate the need to undertake roll arcing during the cane crushing season. All Australian sugar milling companies have expressed their support for this work.