Industrial Machinery & Plant Systems Design

Consulting-led mechanical engineering for mining, processing and manufacturing operations

Practical, engineered solutions for brownfield and greenfield industrial facilities

Hamilton By Design provides consulting-led mechanical engineering for complex industrial systems across mining, mineral processing, manufacturing and heavy industry.

We specialise in designing, upgrading and optimising machinery and plant systems that must perform reliably under real operating conditions — high loads, abrasive materials, continuous duty cycles, demanding shutdown windows and strict compliance requirements.

Whether you’re introducing new equipment, modifying existing systems or expanding production capacity, we help you move from concept to construction with clarity, accuracy and confidence.

How We Support Your Plant & Machinery Projects

Our consulting team works from the problem outward — understanding your operational objectives, constraints and shutdown timelines before we begin design.

We help clients:

Upgrade brownfield equipment while minimising downtime and rework
Design new machinery and plant systems aligned to production targets
Resolve recurring performance, wear, or reliability issues through redesign
Integrate OEM equipment into complex existing facilities
Coordinate mechanical, structural and access requirements in one model
Prepare fabrication-ready documentation that installers and workshops can rely on

Our engineering process combines real site experience, 3D CAD modelling, FEA where needed, and — for brownfield work — engineer-led 3D LiDAR scanning to ensure accuracy.

What We Design

Hamilton By Design delivers mechanical systems and plant layouts across a wide range of industrial applications:

Bulk Materials Handling Systems

Conveyors (fixed, shiftable, overland, tripper gantries)
Transfer towers and conveyor galleries
Chutes, hoppers, bins and wear lining systems
Feeders, vibratory equipment and discharge systems

Processing & Production Equipment

Screens, crushers, mills and separation equipment interfaces
Pumping systems, pipework, manifolds and slurry line transitions
Tanks, vessels, agitators and mechanical supports
Mechanical upgrades to maximise throughput or reliability

Plant Layouts & System Integration

Space-constrained brownfield layouts
New plant expansions and tie-ins
Mechanical–structural interface design
Access, maintenance and safety systems

Support Systems & Ancillary Equipment

Platforms, walkways, stairs and guarding
Maintenance stands, frames, skids and lifting/handling devices
Mobile and fixed equipment support structures

If it moves material, processes ore, mounts equipment or supports production, we can help design it.

Our Design Approach

Industrial plant design is never one-size-fits-all. Every project has operational realities, shutdown limits and site constraints. Our approach reflects that:

1. Understand the Operating Environment

We begin by understanding:

Production goals
Wear mechanisms
Availability targets
Maintenance constraints
Compliance and site standards

This ensures the design is grounded in how the plant is actually used — not how it looks on paper.

2. Capture Accurate Existing Conditions

For brownfield sites, we integrate 3D LiDAR scanning to ensure all tie-ins, clearances and interfaces match reality.
This significantly reduces rework, clashes and on-site modification.

3. Develop Practical Mechanical Concepts

We generate design options that consider:

Material flow
Access and maintenance
Installation sequence
Transport and modularisation
Cost, complexity and risk

Options are presented with pros and cons so you can decide the best path forward.

4. Engineer the Details

Using SolidWorks and analysis tools, we refine:

Load paths and structural capacity
Wear management and replaceability
Supports, fixings and serviceability
Safety, guarding, access and compliance
Liner systems and flow optimisation

5. Verify Performance & Reliability

Where appropriate, we perform:

FEA for stress, fatigue and buckling
Check calculations for structural and mechanical compliance
Flow and material behaviour assessments
Vibration or modal checks for dynamic equipment

6. Produce Fabrication & Installation Documentation

We deliver:

3D models
GA drawings
Fabrication details
BOMs and cutting lists
Installation notes
Tie-in and interface details

All documentation is prepared with fabricators, installers and shutdown teams in mind.

Where This Service Adds the Most Value

Hamilton By Design’s industrial machinery and plant system design services are ideal for:

Shutdown-driven upgrades where every hour matters
Debottlenecking and throughput improvements
Wear and reliability redesigns of problem areas
Capacity expansions requiring new equipment or system reconfiguration
Brownfield integration of OEM machines into existing plants
New plant development where early layout and mechanical decisions set project success

Why Work With Hamilton By Design?

Engineer-led design process — not drafting-first
Strong brownfield capability using 3D LiDAR for accuracy
Deep experience in mining and processing plants across Australia
Fabrication-ready deliverables developed with real workshops in mind
Clear, actionable advice grounded in practical engineering
Single-source accountability from site capture to drawings

We bridge the gap between concept and install — reducing risk, improving reliability and ensuring your plant systems actually work in the real world.

Let’s Talk About Your Next Plant or Machinery Project

Whether you’re planning a major upgrade, resolving a long-standing performance issue, or designing a new facility, our team can support you with clear, practical and engineering-driven solutions.

Contact Hamilton By Design to discuss your upcoming project, or explore our related services: