Hopper Cover Design Project
Client: Pet Food Manufacturer
Partner: MNA Solutions
Service: Engineering Design & Drafting
Status: Concept Developed (Not Implemented)
In the pet food manufacturing industry, where precision and safety underpin every process, an effective maintenance environment is critical. Applied Project partnered with MNA Solutions to develop a redesigned Hopper Cover for a leading manufacturer, aiming to transform an outdated and hazardous maintenance layout into a safer, more efficient workspace.
Although the concept did not proceed to final approval, the project showcased our commitment to innovative, practical engineering design and reinforced our focus on improving workplace safety through thoughtful solutions.
The Challenge
The existing maintenance layout surrounding the plant’s hoppers—large containers central to material processing—posed significant safety risks. Maintenance staff frequently worked in areas exposed to:
Falling debris
Pinch points
Restricted access
Ergonomically unsafe positioning
These hazards put workers at risk and increased the potential for downtime—an expensive outcome in high-volume manufacturing. The challenge was clear: develop a Hopper Cover solution that eliminated risks without compromising productivity.
Our Approach
We began with a collaborative, on-site assessment alongside MNA Solutions and the manufacturer’s maintenance team. Understanding real operational constraints ensured the design addressed practical needs, not just theoretical scenarios.
Using advanced 3D CAD modelling, we visualised the plant environment in detail, simulating maintenance workflows and identifying potential hazards early. This iterative process allowed us to refine the concept with precision, ensuring seamless integration into the existing setup.
The Solution
The final concept balanced innovation, durability, and ease of use. Core design features included:
Modular Construction
Detachable sections simplified installation and future maintenance, reducing disruption and enabling fast component replacement.
Durable, Industrial-Grade Materials
We selected high-strength, corrosion-resistant materials suited to constant exposure to dust, moisture, and vibration.
Improved Accessibility
Ergonomic handles and strategically placed access points enabled safer, more comfortable maintenance activities.
Integrated Safety Features
Built-in guards and sensor provisions were included to allow machinery to automatically shut down if the cover was opened—adding a proactive layer of protection.
The design was engineered to fit effortlessly into the plant’s infrastructure with minimal changes required—an essential consideration for continuous manufacturing operations.
Projected Benefits
While the project did not move to implementation, our analysis demonstrated the potential impact:
Reduced Injuries: Key hazards effectively eliminated, enhancing worker safety.
Greater Efficiency: Streamlined maintenance access and modular parts reducing downtime.
Compliance Ready: Designed in alignment with relevant Australian safety standards.
Client feedback during development highlighted the strength of our methodology, attention to detail, and practical understanding of maintenance requirements.
What We Learned
This project provided valuable insights into the unique operational pressures within pet food manufacturing. Collaboration with MNA Solutions and plant personnel strengthened our ability to convert frontline challenges into efficient, safety-focused design outcomes.
It also cemented our continued investment in 3D modelling and simulation as essential tools in our workflow—helping us deliver more accurate, risk-aware design solutions.
Conclusion
The Hopper Cover Design Project remains a strong example of our dedication to safety, innovation, and meaningful collaboration. Even without final deployment, it reflects the high level of thought, engineering rigour, and client focus that defines Applied Project.
As we continue to grow, we bring these lessons and capabilities to every new challenge—working to create safer, smarter workplaces across all industries.
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