Italian company Bonfiglioli is providing bulk handling operations with simple, sustainable and reliable gearboxes.
It’s no surprise that the Australian bulk handling sector is experiencing a skills shortage. According to Jobs and Skills Australia, the country has a national shortage of key professions across the entire resources sector.
Part of this is due to an increasingly challenging and competitive labour market. The Organisation for Economic Co-operation and Development found in 2022 that labour markets had globally tightened across all countries and sectors.
Martin Broglia, managing director at Bonfiglioli Australia, told ABHR that the labour shortage is prompting organisations to improve their equipment maintenance and plant performance.
“Customers are increasingly seeking out standardised, modular solutions that are easily customised, installed and maintained, and which offer a long service life,” he said.
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“Bonfiglioli has invested in research and development at a group level to meet the needs of our customers in the bulk handling space.
“Part of that is keeping the design simple.”
The company’s unique design offering helps set its gearboxes apart. Bonfiglioli can provide hybrid helical bevel and planetary gearboxes as a combination unit.
Suitable for any heavy-duty applications that require slow, controlled movements, the combination unit can provide the best of both worlds while having a significantly reduced weight, lead time and cost. This provides an economical and lightweight solution, providing the same power output as two separate devices.
Another part of the company’s focus on simple designs is ensuring they are long-lasting with low maintenance requirements. This not only helps to keep the total cost of ownership down, but it also reduces the amount of time required for intensive servicing and repairs.
Broglia said Bonfiglioli’s collaboration with original equipment manufacturer brands and customers lets it design equipment that meets the sector demands, as well as the application requirements.
“For example, our solutions for bulk handling applications are designed to be extremely resilient, ensuring high performance in harsh environments where extreme temperatures, sandstorms, humidity and salty air are commonplace,” he said.
“Through our worldwide network of branches, distributors, and service companies, we are able to extend technical support and comprehensive after-sales service to customers, ensuring they achieve optimal productivity, uptime and profitability,” he said.
Sustainability is also important to the company, which has adopted a new mindset at the highest level. The company headquarters in Italy meets the latest in energy efficiency standards. It was awarded ISO 50001:2018 certification for its energy management system.
The company has also designed its new headquarters to be a nearly zero-energy building. It features geothermal heat pumps and radiant ceilings to save energy, as well as a green garden to promotes natural ventilation of the building. To make the best use of natural light, the roof of the building is slanted to enlarge the north-facing side of the building, while the roof and south-facing façade are cladded in a customised, pleated aluminium mesh inspired by Bonfiglioli gears.
Broglia said the company continues to develop new products with a special focus on energy efficiency, recovery, as well as lower fuel consumption.
“In the wind turbine industry – a sector that’s crucial to the renewable energy industry – we are a global leader, with market share of over 30 per cent,” he said.
“The gearbox systems we deliver to local industries offer exceptional power and torque, compactness, are easily customised and robust. With low maintenance requirements, these offer a low cost of ownership. We also offer a wide range of gearbox customisation options and accessories, to meet a diverse range of application requirements.”
Bonfiglioli’s gearboxes have proven to be popular throughout the quarrying sector, with the company’s HD solutions in high demand.
This high demand has led to local investment into the company’s local manufacturing capabilities. Bonfiglioli opened a new warehouse in Melbourne last year as part of its aim to decentralise its operations in Australia. The new facility spans 1800 square metres and generates 40 kW of solar power. It is currently producing several gearbox ranges, with plans to expand further.
The company’s Sydney assembly plant had, until recently, processed several gearboxes each week. Broglia said the company plans to expand its Sydney facility with a new HD assembly machine from the group’s headquarters in Italy, allowing it to almost double production.
“Our New Zealand branch is also planning a relocation to larger facilities, which will facilitate greater stock holding, faster delivery, etc. This is in response to market growth in the region,” he said.
“We plan to grow our market share locally, through the consistent supply of top-quality products, coupled with expertise, extensive local stock holding, as well as prompt service and support. The expansion of the Sydney and New Zealand facilities will facilitate this.”