Pit-to-Port Materials Handling Engineering

Materials handling problems do not need more opinions. They need clear engineering.

Independent pit-to-port consultancy. Surface and underground, from ROM bin to shiploader and every conveyor and transfer in between. Conveyors are our core discipline. The whole handling chain is our scope.

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Pit-to-Port

Full handling chain, one consultancy

18+

Years in bulk materials handling

100%

Independent, no equipment sales

What We Solve

From a single failing transfer to a pit-to-port handling strategy.

Conveyors are where we go deepest, but the scope runs pit to port. If it stores, moves, or loads bulk material, it is in scope. We work across coal, iron ore, hard rock, grain and agribulk, and port terminals.

System & Safety Audits

Mechanical, structural, electrical, and control assessments of conveyors and handling plant. Including underground fire, ventilation, and access constraints. Plus detailed AS/NZS 4024.3610/.3611 guarding audits with gap registers, and prioritised rectification plans.

Underground & Overland Conveyor Design

Feasibility and route studies through to detailed design and dynamic analysis. Overland flights, underground trunk and drift conveyors. Transient starting and stopping analysis, drive and brake sizing, and energy optimisation.

Failure Investigation & Uprating

Root cause analysis of belt rips, splice failures, pulley and shaft failures, fires, and structural incidents. Plus capacity uprating and debottlenecking studies: speed, tension, and drive upgrades that sweat existing assets before you commit capital to new ones.

Remediation & Asset Strategy

Phased, budgeted and risk-assessed programmes that shift plant from reactive repair to planned improvement. Replacement scheduling, RAMS analysis, and capital planning sequenced to shutdowns, mine plans, and throughput forecasts.

Controls, Sequencing & Automation

Plant-wide sequencing and interlock logic, drive coordination and VFD integration. Plus functional safety: SIL assessment of emergency stop and interlock systems. From single transfer towers to full port and overland networks.

Transfers, Chutes & Material Flow

Chute geometry, trajectory and DEM (discrete element modelling) analysis, bin and hopper flow, skirting, and dust management. Targeted at spillage, blockages, carryback, and flow-related downtime anywhere in the circuit.

Buyer-Side Procurement & Independent Review

We sit on your side of the table, and only yours. Supplier design auditing, tender evaluation, cost benchmarking, and comparison studies built around lowest total cost of ownership, not lowest purchase price. As owner's engineer we provide independent design verification, HAZOP and safety-in-design participation, and technical due diligence on projects. We provide expert witness support for warranty claims, contract disputes, and insurance assessments. No supply agreements, no commissions. We work with you to buy the right equipment on the right terms.

Technical Capability

The full pit-to-port chain

Deepest in conveyor engineering, with working depth across every machine and structure from pit to port.

Conveyors

Underground Conveyor Design & Auditing Belt Selection & Splicing Pulleys, Idlers & Take-ups Dynamic Analysis, Overland & Underground Capacity Uprating & Debottlenecking Horizontal & Vertical Curves Energy Efficiency & LRR Belts Trippers, Turnovers & Intermediate Drives

Handling Plant

Stackers, Reclaimers & Shiploaders Bins, Hoppers & Feeders Crushing & Screening Interfaces Train Load-outs & Sampling Stations DEM & Trajectory Modelling Structural & Foundations

Controls & Electrical

Plant Sequencing & Interlocks VFD & Starting Methods Control Architecture Functional Safety & SIL Assessment Condition Monitoring & NDT

Operations & Commercial

Commissioning & Tracking RAMS & Availability AS/NZS 4024 Guarding Audits Fire Detection & Suppression Failure Investigation & RCA Supplier Design Auditing Cost Benchmarking & TCO Studies Tender Evaluation & Negotiation Owner's Engineer & Due Diligence Expert Witness & Disputes Training & Competency Development

Working to

AS 1332 AS 1333 AS 1755 AS/NZS 4024.3610 AS/NZS 4024.3611 AS 4324.1 ISO 5048 ISO 5049.1 ISO 340 ISO 283 ISO 703 DIN 22101 DIN 22131 ISO 15236 ISO 14890 EN 12882 IEC 62061 IEC 61508 AS/NZS ISO 12100 AS 4100 AS 3990 AS 1170 AS 1403 AS 1418.1 AS 1418.2 AS 3569 ISO 4308.1 AS 4991 CEMA 7th Ed.
Our Approach

Engineering judgement, not equipment catalogues.

No supply agreements, no preferred brands, no commissions. When we audit a supplier's design or benchmark their price, we answer to you alone. Recommendations driven by engineering merit and your total cost of ownership, nothing else.

We have designed, commissioned, and troubleshot handling systems in the field. From feeders and crushing circuits to overland conveyors. That practical depth shapes every recommendation: solutions that work on paper and on site.

Audits that drive decisions. Every finding links to a standard, a failure mode, or an operational consequence, with costs and timelines your planners can act on.

Strategies that survive reality. Plans phased to capital cycles and production commitments, with decision gates and room to reprioritise.

Analysis before opinion. Dynamic modelling, first-principles calculation, and standards-based assessment. Not rules of thumb.

Knowledge transfer as standard. We brief your teams, document thoroughly, and deliver structured training. The aim: leave your operation more capable, not more dependent.

Contact

Ready to talk about your handling systems?

A plant audit, a dynamic analysis study, a failure investigation, buyer-side support on a major equipment purchase, or a second opinion on a chronic problem. Get in touch to discuss your requirements.

Based in Sydney & Regional NSW, Australia

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Tell us what you are dealing with and we will arrange a no-obligation call.

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