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SAGE designed and implemented a safety solution to minimise workplace risk, collaborating with a university and a special purpose machinery builder.


Product Development / OEM Support


Collaboration with university and machine builder to design, prototype and develop a machine to reduce the amount of manual handling.


Safety design, electrical and control design, control panel manufacture, solution concept development, prototyping, assembly and fit out, HMI programming, FAT, SAT, training.


Melbourne, Australia

Director Melbourne Airport

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To increase storage efficiency, a material provider was vertically storing aluminium extrusions up to six metres long. The movement of these extrusions occurred up to six thousand times a day.

The manual handling and repetitive movements required to transfer these extrusions in the warehouse was contributing to the risk of workplace musculoskeletal injury.

The client extensively searched for a solution to remove the risky repetitive movement, consulting with Flinders University. The university conducted feasibility and time and motion studies, engaging SAGE to create a solution for the client.


SAGE was engaged to design and implement a solution to minimise this safety risk, collaborating with special purpose machinery builder Automation Innovation

The solution was determined following a comprehensive study of possible solutions, considering things such as safety, process efficiency and workplace suitability.


SAGE safety engineers collaborated with the client and an external Safety Engineer, extensively consulting with workers and management to develop a customised client trial system that has built-in ergonomics.

The collaborative solution implemented a rotator machine to minimise the manual handling. The special purpose machine accepts the extrusions from a horizontal position and rotating them for racking. The machine utilises an Omron PLC and SEW MoviDrive and gearbox.

Initially implemented in the client’s Melbourne warehouse, the safety system can be rolled out in the national workplace and can act as an example of industry safety processes.

Want to know more about SAGE's capability with Product Development and Special Purpose Machinery? Find out more here.

SAGE's safety design implementation


  • Research and development collaboration with university
  • Safety engineering
  • Safety in design
  • Product development
  • Concept design
  • Optioneering
  • Electrical design



  • Omron PLC
  • SEW MoviDrive
  • HMI touchscreens
  • Safety PLCs

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