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:

• Mechanical Design & Custom Equipment Layouts
• 3D CAD Modelling & Mechanical Drafting
• 3D LiDAR Scanning for As-Built & Brownfield Engineering
• FEA & Mechanical/Structural Assessment
• SolidWorks Sustainability Tools & Material Optimisation

We’re ready to help you design industrial systems that perform — safely, reliably and efficiently.

Our Clients