Conveyor safety is critical for productivity in bulk handling operations. At a regional Western Australian mine, an ageing safety system had become increasingly unreliable, causing frequent nuisance trips, inconsistent detection, and costly maintenance challenges. With the system no longer supported, the operation needed a future-ready upgrade.
To address these issues, the site partnered with Pacific Automation to implement the Smart Series Conveyor Safety System. This intelligent, modular, and plug-and-play solution was designed to minimise disruption while delivering clear diagnostics, rugged reliability, and long-term support.
Installed across 2 km of conveyor infrastructure by a local electrical contractor, the Smart Series solution significantly reduced on-site wiring and terminations, enabled faster commissioning, and provided operators with real-time diagnostic visibility. Since commissioning, the system has eliminated nuisance trips entirely while lowering maintenance overheads and improving overall reliability.
Feedback from site personnel has been overwhelmingly positive, with operators praising its simplicity and improved safety visibility. Maintenance teams have reported easier fault identification and reduced downtime. The system’s strong performance has led the mine to commit to using the Smart Series in all future conveyor safety upgrades.
This case study demonstrates how modern conveyor safety technology can transform bulk handling operations, enhance operator confidence, and deliver long-term value in demanding industrial environments.
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