Enhancing Safety in Pet Food Manufacturing

In the fast-paced world of pet food manufacturing, where precision and care are non-negotiable, safety stands as a cornerstone. It was with this priority in mind that we partnered with MNA Solutions to design a Hopper Cover for a leading pet food manufacturer. Our goal was ambitious yet clear: to redesign the plant maintenance layout into a safer, more efficient workspace. Though the project didn’t reach the approval stage, our team poured expertise, creativity, and dedication into crafting a solution that showcased our commitment to innovative design and workplace safety.

Safeguarding Maintenance Operations

The pet food manufacturing plant faced a pressing issue: the existing maintenance layout around its hoppers—large containers critical for processing pet food materials—presented significant safety risks. Maintenance workers were routinely exposed to hazards such as falling debris, pinch points, and awkward positioning during upkeep tasks. These conditions not only threatened worker well-being but also risked operational downtime, a costly concern in an industry where efficiency is paramount. Our task was to design a Hopper Cover that would eliminate these dangers while preserving the plant’s productivity.

Collaboration and Innovation

From the outset, we embraced a collaborative strategy with MNA Solutions, blending our design expertise with their engineering insights. We kicked off the project with on-site assessments, working directly with the plant’s maintenance team to pinpoint their challenges and needs. These conversations revealed the real-world stakes of the design, grounding our work in practicality.

To bring our ideas to life, we harnessed cutting-edge tools like 3D CAD modeling. This technology allowed us to visualise the plant layout in detail, simulate maintenance scenarios, and preemptively address safety risks. Through iterative design sessions with MNA Solutions’ engineers, we refined our concepts, ensuring the Hopper Cover would integrate seamlessly into the existing setup while pushing the boundaries of safety and functionality.

A Tailored Hopper Cover Design

The result of our efforts was a Hopper Cover design that balanced innovation with usability. Here’s what set it apart:

• Modular Construction: We engineered the cover in detachable sections, simplifying installation and maintenance. This modularity meant workers could replace or adjust parts without overhauling the entire system, saving time and effort.
• Durable Materials: Built to endure the rigors of a manufacturing environment, we chose high-strength, corrosion-resistant materials. This ensured the cover’s longevity, even under constant exposure to dust, moisture, and wear.
• Enhanced Accessibility: Ergonomics were front and center. The design featured intuitive handles and access points, allowing workers to perform tasks comfortably and safely without straining or risking injury.
• Integrated Safety Features: We embedded guards and sensors into the cover, designed to halt machinery automatically when opened. This proactive measure aimed to prevent accidents before they could occur.

The Hopper Cover was crafted to slot into the plant’s infrastructure with minimal disruption, a testament to our focus on practical, client-friendly solutions.

A Safer, More Efficient Workplace

Though the design didn’t move to implementation, its potential was undeniable. Had it been deployed, the Hopper Cover could have delivered transformative benefits:

• Fewer Injuries: By neutralizing key hazards, the design promised to protect workers, reducing the likelihood of accidents and fostering a safer environment.
• Boosted Efficiency: Streamlined maintenance processes—thanks to modular components and better access—could have cut downtime, keeping production humming.
• Regulatory Alignment: Our solution adhered to industry safety standards, positioning the manufacturer to meet compliance requirements effortlessly.

During the design phase, the client praised our thoroughness and the ingenuity of our approach, feedback that underscored the value of our work even without final approval.

Growing Through Experience

This project, while unfinished, was far from fruitless. It deepened our understanding of the pet food manufacturing sector, particularly the interplay of safety and operational demands. Collaborating with MNA Solutions and the plant team honed our ability to translate frontline insights into actionable designs. We also sharpened our technical process, leaning further into 3D modeling and simulations—tools we’ve since made staples in our workflow.

Perhaps most importantly, the experience reinforced a core belief: every project, approved or not, is a chance to refine our craft and prepare for the next challenge.

Ready for What’s Next

The Hopper Cover design project may not have reached the plant floor, but it stands as a powerful example of our dedication to safety, collaboration, and innovative problem-solving. We take pride in the effort we invested and the solutions we devised, carrying forward the lessons learned into every new endeavor. As we look ahead, we’re eager to apply our expertise to future projects, delivering designs that not only meet but redefine industry standards—creating safer, smarter workplaces one idea at a time.

Let’s Build Together

If you or your clients need expert engineering design and drafting support, we’re here to help. Our team is ready to provide the guidance and expertise you need to make your project a success. Contact us at info@kevos.com to explore how we can collaborate on your next venture!