Boom Gate Design Project – Case Study
Client: Pet Food Manufacturing Facility
Partner: MNA Solutions
Service: Engineering Design & Safety Layout Planning
Applied Project®, in collaboration with MNA Solutions, undertook the design of a comprehensive boom gate and plant maintenance layout to enhance safety, access control, and operational efficiency within a busy pet food manufacturing facility.
Although the project did not proceed to final approval, our approach demonstrated rigorous design thinking, stakeholder collaboration, and industry-aligned safety planning—exemplifying the quality of work we deliver across all industrial design projects.
Project Objectives
Improve Workplace Safety: Introduce a controlled boom gate system to reduce vehicle–pedestrian conflicts.
Optimise Facility Layout: Integrate access control with a reworked maintenance layout to streamline movement across the site.
Meet Compliance Requirements: Align the design with relevant industrial safety standards and regulatory obligations.
Future-Ready Solutions: Develop scalable concepts that support future facility upgrades or operational changes.
Our Approach
1. Site Analysis & Stakeholder Engagement
To understand the complexities of the site, we conducted a detailed operational study, focusing on:
On-site traffic assessments to identify congestion points and high-risk zones.
Consultations with plant managers, maintenance teams, and safety officers.
Close coordination with MNA Solutions to ensure strategic alignment with long-term operational goals.
These insights formed the foundation of a design strategy tailored to real-world conditions.
2. Boom Gate System Design
The core of the project centred on a customised boom gate solution. Our design recommendations included:
Automated boom gates with integrated safety features—sensors, warning lights, and emergency override capability.
Strategic positioning to control traffic into critical areas such as loading docks and maintenance zones.
Technology integration, including RFID and keycard access, to streamline entry for authorised personnel and vehicles.
Traffic simulation tools were used to validate optimal placement and reduce the potential for bottlenecks.
3. Plant Maintenance Layout Redesign
To complement the access control system, we delivered a refined maintenance layout featuring:
Zoned pathways separating forklifts, vehicles, pedestrians, and maintenance activities.
Clear directional signage and floor markings to support safe traffic flow.
Dedicated maintenance access points that avoid interference with production operations.
This coordinated design created a safer, more efficient flow across the site.
4. Safety & Compliance Integration
Our design adhered to applicable safety standards and industrial facility guidelines. Key considerations included:
Compliance with OH&S requirements.
Inclusion of fail-safe mechanisms to minimise operational risk.
Recommendations for onboarding and staff training to support safe adoption of the proposed systems.
Project Challenges & Solutions
Complex Traffic Patterns: High forklift and pedestrian activity required careful planning—addressed through modelling and scenario testing.
Budget Constraints: We proposed modular, phased implementation options to manage cost while retaining long-term scalability.
Stakeholder Priorities: Workshops and joint reviews ensured alignment between all parties, improving clarity and decision-making.
Outcomes
Although the project did not advance to implementation, it delivered several valuable outcomes for the client:
A comprehensive, ready-to-implement design package targeting safety, efficiency, and compliance.
Strengthened stakeholder confidence through collaborative planning and clear documentation.
Enhanced internal knowledge base for future industrial design and safety-focused initiatives.
Key Learnings
Early stakeholder engagement ensures smoother alignment and faster decision cycles.
Modular design approaches enable flexibility where budgets or timelines are uncertain.
Data-driven analysis—traffic modelling, site data, and risk assessments—provides objective foundations for safer layouts.
The Boom Gate Design Project highlights Applied Project®’s capability in tackling complex industrial safety and access-control challenges with precision and a people-first mindset.
While not executed, the project reflects our commitment to quality, innovation, and safe design principles—values we bring to every client collaboration.
Need Assistance With Your Industrial Design or Engineering Project?
If you’re exploring safety upgrades, access control solutions, or layout optimisation, our team is ready to help.
Let’s bring clarity, compliance, and efficiency to your next project.
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