Hopper Cover Redesign
Engineering Safer Maintenance for Pet Food Manufacturing Client: Leading Pet Food Manufacturer | Partner: MNA Solutions | Service: Engineering Design & Drafting | Status: Concept Phase
In high-volume pet food manufacturing, maintenance safety is non-negotiable. KEVOS®, in partnership with MNA Solutions, was engaged to reimagine the hopper maintenance environment of a major production facility — an area compromised by falling debris, pinch points, restricted access, and ergonomically unsafe working conditions.
Our approach began on the plant floor. Through a collaborative, on-site assessment with maintenance personnel, we mapped real operational constraints before translating them into a precision-engineered concept. Leveraging advanced 3D CAD modelling, we simulated workflows, stress-tested access scenarios, and refined the design to integrate seamlessly into existing infrastructure — without disrupting continuous operations.
The resulting concept introduced a modular Hopper Cover system engineered for durability, accessibility, and proactive protection. Detachable sections enabled rapid servicing, while industrial-grade, corrosion-resistant materials ensured longevity in demanding conditions. Ergonomic access points and integrated safety provisions — including sensor-triggered machinery shutdown — elevated the standard of operator protection well beyond compliance baselines.
While the concept did not advance to implementation, the project delivered a robust, compliance-ready blueprint aligned with Australian safety standards, validated through client feedback that highlighted the depth of our methodology and engineering rigour. It reaffirmed KEVOS®' position as a trusted partner for solving complex, frontline industrial challenges through thoughtful, human-centred design.
This engagement strengthened our expertise in simulation-driven engineering and reinforced a core principle that defines our practice: safer environments are designed, not retrofitted.
Key Highlights
- Modular architecture enabling rapid maintenance and minimal operational disruption
- Industrial-grade materials engineered for dust, moisture, and vibration resilience
- Integrated safety systems with sensor-based automatic shutdown provisions
- 3D CAD-driven validation ensuring seamless plant integration
- Aligned with Australian safety standards — compliance-ready by design
