Meet Smart Series:

Built for Bulk Material Handling.
Tailored to Your Operation.

Discover how Smart Series delivers a complete conveyor safety solution that helps eliminate nuisance trips, reduce

downtime, and keep conveyors running in tough Australian conditions.

 

Mining and Bulk Handling Operations in Australia Are Plagued By

Costly Unplanned Downtime

When nuisance tripping from poor connections occurs, costs increase as production slows, creating cascading delays throughout your operation.

Safety Hazard

Slack wire tensioning issues can lead to false tripping, posing significant safety risks and disrupting operations.

Excessive
Maintenance Costs

Poor switch contact quality and increasing maintenance and system failures create a continuous drain on resources and operational budgets.

Mining Conveyor Safety & Protection Systems That Prevent Downtime

Purpose-Built Safety

 

Engineered specifically for Australia's bulk material handling sector with the robust Smart Pull Wire Switch at its core, supported by a comprehensive suite of safety solutions.

Fully Compliant

 

Fully compliant with AS/NZS 4024.361:2015 standards and SIL2 (IEC 61508) certification, ensuring your operation maintains regulatory compliance whilst improving productivity.

Low-Maintenance Operation

 

A tailored conveyor safety solution designed to reduce nuisance trips, enhance safety, and minimise downtime in harsh Australian conditions — whether you're retrofitting an existing system or planning a new one.

 

Versatile Adaptability

 

Adaptable to a wide range of site layouts and conveyor setups, providing seamless integration across diverse operational environments.

 

Preventing Unplanned Conveyor Shutdowns

Unplanned conveyor shutdowns are one of the most costly events in mining operations. A single belt failure or undetected drift condition can halt production across an entire plant or export chain.

Smart Series is designed to detect faults early and initiate controlled responses before minor issues escalate into catastrophic belt damage or extended outages.

 

The system provides:

 

  • Early detection of belt misalignment and drift

  • Real-time speed monitoring to prevent belt slip

  • Rip detection to stop tearing before it spreads

  • Blocked chute detection to prevent overload events

Rather than reacting to failures, Smart Series enables proactive fault detection and controlled shutdown strategies, helping mining operations reduce downtime, minimise repair costs, and maintain throughput targets.

Smart Series Products You Can Use

Pull Wire Switches

Pull & Slack and Pull only wire types,

designed for durability.

Conveyor Safety System

Belt Misalignment Detector

Belt Rip Detector

Chute Block & Tear Feed Detection

Tensioning Kit with Visual Indicator

Ratchet for quick setup & built-in safety tensioning check.

Engineered for Fail-Safe Operation

Conveyor safety systems must operate reliably under all conditions, including power loss, cable damage, and device failure.

 

Smart Series is designed around fail-safe principles to ensure that any detected fault, communication loss, or device activation triggers a safe and controlled response.

 

 

 

Key fail-safe features include:

 

  • Normally closed safety circuits for emergency stop devices

  • Continuous line monitoring to detect open circuits or cable faults

  • Positive shutdown confirmation

  • Clear diagnostic feedback to maintenance teams

 

When integrated into a correctly designed safety circuit, Smart Series helps reduce downtime and risk while supporting compliance with mining safety requirements.

Smart Series Fits Your Project

Chat To Us Today

Want advice on the right Smart Series products for your site?

Fill out the form and we’ll send you tailored info, product recommendations,

or a quote.

 

Choose what you need for your operation—all components are retrofit-ready or can be installed from new, designed to work seamlessly together for comprehensive conveyor protection.

Bulk Handling Conveyor Protection for Mining Operations

Mining conveyors operate in some of the harshest bulk material handling environments, iron ore, coal, bauxite, grain, and other abrasive materials place extreme stress on belts, drives, and transfer points.

 

Smart Series Mining Conveyor Safety & Protection Systems are engineered specifically for long overland conveyors, transfer stations, stackers, reclaimers, and ship loading systems. Our distributed architecture allows protection devices to be installed directly along the conveyor structure, reducing field cabling while improving fault visibility.

 

By integrating belt drift detection, pull-wire emergency stops, rip detection, speed monitoring, and blocked chute detection into one coordinated system, Smart Series ensures safe, reliable bulk material handling with reduced downtime risk.

 

Brownfield (Retrofit)

Upgrade part of your existing conveyor system with plug-and-play Smart Series safety components. Our solutions are designed for minimal disruption during installation, with quick commissioning and immediate safety improvements.

 

Greenfield (New Builds)

Design a complete conveyor safety solution with help from our team. We'll work with you to create a tailored system that meets your specific layout requirements and operational goals from day one.

 

CASE STUDY | 3 MIN READ

Real Results: Smart Series Transforms WA Mining Site

In this case study, you'll learn how a WA mine eliminated nuisance trips and improved conveyor safety with the Smart Series system.

 

Tested & Trusted

 

Pacific Automation upgrades Smart Series Pull Wire Switch

 

Pacific Automation’s Smart Series Pull Wire Switches are now even smarter and fully optimised for Australian conditions and compliance, with enhanced design features based on end-user feedback.

 

Read the Full Article

 

Meets IEC 61508 requirements for functional safety of electrical/electronic/programmable electronic safety-related systems.

Fully compliant with AS/NZS 4024.361:2015 for safety of machinery requirements.

Built and tested for reliability in real Australian conditions including extreme temperatures, dust, and vibration.

Conveyor Control

Conveyor control is essential for safe, reliable and efficient material handling. The right combination of safety, protection and monitoring devices helps reduce downtime, prevent nuisance trips and protect conveyor assets in harsh industrial and mining environments. Built to withstand vibration, dust and moisture, modern conveyor control solutions enable fast fault identification and continuous operation. Explore our range of Conveyor Control options to find the right solution for your site.

 

Discuss your operational challenge and discover how Smart Series solutions can improve performance and reduce downtime.