In the rugged and demanding landscape of regional Western Australia, one mining operation has taken a major leap forward in safety and efficiency by modernising its aging conveyor safety infrastructure.
With support from Pacific Automation and a trusted local contractor, the mine became the first in Australia to implement the innovative Smart Series conveyor safety system—bringing reliability, simplicity, and diagnostic visibility to the forefront of its operations.
The mine’s original conveyor safety system was no longer supported, and its performance was steadily declining. Nuisance trips, inconsistent event detection, and high maintenance burdens were becoming increasingly disruptive to operations.
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Leadership at the site knew a replacement was necessary—but it had to be cost-effective, easy to install, and simple enough for general site personnel to maintain without relying on specialised skills.
What was needed was more than a product—the mine needed a system that would enhance safety, reduce downtime, and provide long-term peace of mind.
A smarter solution
Pacific Automation’s Smart Series, a modular and intelligent conveyor safety solution engineered for industrial environments, was selected for the task.
This upgrade was the first of its kind in Australia, and its success hinged on delivering three critical outcomes: ease of installation, reliable performance, and long-term support.
The Smart Series offered clear benefits:
- Distributed control and monitoring with intelligent signal-line nodes
- Pre-configured and tested components for plug-and-play installation
- High-grade hardware built to withstand harsh conditions
- Operator-level diagnostics to streamline fault detection and response
Working in collaboration with a local contractor, Pacific Automation provided complete engineering documentation, layout drawings, and ongoing technical support throughout the process.
Simplicity meets performance
The installation spanned over 2km of conveyor infrastructure and has delivered:
- Zero nuisance trips in the 10 months since commissioning
- Operators reported the system is intuitive and easy to manage
- Significantly faster commissioning and reduced wiring complexity
- Long-term supportability with standardised, locally available components
Feedback from the site has been overwhelmingly positive. So much so, the mine has committed to using the Smart Series system for all future conveyor safety upgrades.
This project underscores the importance of reliable, modular safety systems in modern mining. By replacing an obsolete system with the Smart Series, the mine not only improved operational continuity but also laid the groundwork for long-term safety and maintainability.
As the mining industry faces increasing pressure to improve safety while reducing costs and complexity, projects like this demonstrate how thoughtful system design and strong local partnerships can deliver both.
