Boom Gate Design Project
Engineered for Safety - Boom Gate & Plant Layout Design for a Pet Food Manufacturing Facility
When a high-throughput pet food manufacturing facility needed to reconcile heavy vehicle movement, pedestrian safety, and round-the-clock maintenance access, KEVOS® — in partnership with MNA Solutions — delivered a design response built on precision, foresight, and uncompromising safety standards.
The site presented a familiar industrial challenge in a complex form: dense forklift traffic, fragmented pedestrian routes, and access points that no longer served the operational tempo. Our brief was to re-engineer the flow without disrupting production, while embedding compliance and scalability into every decision.
We began with deep site analysis — traffic mapping, stakeholder consultations, and operational diagnostics — to ground the design in real conditions rather than assumptions. From this foundation, our team developed an integrated solution: a custom automated boom gate system with sensor-driven safety features, RFID and keycard access control, and strategic placement validated through traffic simulation. This was paired with a fully reimagined plant maintenance layout featuring zoned circulation, dedicated maintenance corridors, and intuitive wayfinding — engineered to OH&S standards and built around fail-safe principles.
Modularity was central to the approach, allowing phased implementation aligned with budget realities and future expansion. Although the client ultimately chose not to progress to construction, the engagement produced a complete, implementation-ready design package and elevated internal benchmarks for industrial safety planning.
The project stands as a clear demonstration of the KEVOS® methodology: data-driven, collaborative, and resolutely focused on outcomes that serve people first.
Key Highlights
- Custom Access Control System — Automated boom gates with integrated sensors, warning indicators, and RFID/keycard authentication
- Traffic Simulation–Validated Layout — Evidence-based positioning to eliminate bottlenecks and high-risk conflict zones
- Zoned Plant Maintenance Design — Segregated pathways for forklifts, pedestrians, and maintenance crews
- Compliance-First Engineering — Full alignment with OH&S standards and fail-safe operational protocols
- Modular, Scalable Framework — Phased implementation strategy designed for long-term operational flexibility
