Conveyors for a Cause: Final Community Conveyor Delivered to Kestrel Resources

Fenner Conveyors, in partnership with Kestrel Coal Resources, has successfully completed the delivery and commissioning of four advanced maingate conveyor systems for the Emerald-based mine, marking the culmination of the “Community Conveyors” campaign. This project not only demonstrates engineering expertise and a commitment to operational excellence, but also created a colourful contribution to the Australian mining industry and local central highlands community.

In 2022, Fenner Conveyors embarked on a collaborative journey alongside Kestrel Coal Resources, one of the world’s largest producing underground metallurgical coal mines.

Engineering Scope and Technical Delivery

The project required the design, manufacture, installation, and commissioning of four bespoke maingate conveyor systems, each engineered to integrate seamlessly with Kestrel’s existing underground infrastructure.

Leveraging Fenner’s original equipment manufacturer (OEM) capabilities and the specialist expertise of portfolio brand, Australian Conveyor Engineering (ACE), the team delivered end-to-end solutions incorporating the latest advancements in conveyor technology:

Variable Speed Drives and Electrical Braking: Each conveyor system features state-of-the-art direct drive gearboxes coupled to electric motors, with speed and torque precisely controlled via substation and PLC systems. The control architecture continuously monitors for regenerative power conditions, automatically feeding energy back into the grid to optimise efficiency and minimise heat generation

Advanced Belt Monitoring: Integrated belt monitoring and diagnostics enable real-time assessment of system health, supporting predictive maintenance and maximising operational uptime

Custom Engineering and Retrofit: The final maingate conveyor was engineered for full retrofit into existing site infrastructure, demonstrating Fenner’s capability to deliver tailored solutions for complex underground environments

Importantly, each system was painted in a bright, distinct colour to represent and support four different community organisations operating in the central highlands community: Emerald Neighbourhood Centre (purple), Breast and Prostate Cancer Association of Queensland (blue), Headspace Emerald (green), and the Emerald Men’s Shed (orange).

Collaboration and Project Management

The success of the Community Conveyors campaign is underpinned by robust collaboration between operator, Kestrel Coal Resources and OEM/supplier, Fenner Conveyors. The project teams maintained continuous communication, with structured weekly meetings and transparent reporting, ensuring alignment on technical requirements, delivery milestones, and safety standards 

This partnership model enabled knowledge sharing and joint problem-solving, resulting in highly customised conveyor solutions that meet both operational and community objectives. The collaborative approach has strengthened long-term relationships and set a precedent for future value-creation in mining projects 

ACE General Manager, Mark Wilcock, reflected on the project:

"As each maingate conveyor system was delivered, we and Kestrel engaged with the local community groups, serving as an opportunity for our people to learn more about the wonderful work these organisations are doing for the community in which we operate and how they might like to personally get involved.”

Community Impact and Legacy

Beyond technical delivery, the campaign has provided direct financial support and raised awareness for these organisations, reinforcing both Fenner and Kestrel’s shared commitment to social responsibility.

Fenner Conveyors are proud to have been part of this important partnership with Kestrel Coal Resources.

Explore our four selected charities below

Emerald Neighbourhood Centre

For the Emerald Neighbourhood Centre, we painted this conveyor a brilliant royal purple. Emerald is a mining town like no other, with 15,000 people calling it home, Emerald has grown to be one of Queensland’s largest rural centres, with cafes, restaurants, schools, golf courses and all the conveniences of the big city, including an airport with multiple daily flights to Brisbane.

To support this small but vibrant community, the Emerald Neighbourhood Centre offers a variety of services, including emergency relief, temporary housing, domestic violence support, day to day living support for those experiencing mental health challenges, community connect programs, and funded courses for young people looking to enter the job market.

Breast and Prostate Cancer Awareness

For Breast and Prostate Cancer Awareness, vivid sky blue lit up this conveyor. The Breast and Prostate Cancer Association of Queensland provide care, treatment and support services for those in rural QLD suffering from breast and prostate cancer, as well counselling and support for their families.

They also provide education to the public, to assist in the prevention of breast and prostate cancer, a critical task as these are the most common kinds of cancer.

Headspace

Headspace Emerald work tirelessly to support the mental and physical wellbeing of the people of Emerald, as well as their overall ongoing development. Offering free or low-cost services, they support those aged between 12-25 by liaising closely with General Practitioners, Sexual Health Services, Vocational Education Services and Alcohol and Other Drug Services so they can offer to support tailored support to all who come to them for assistance.

Men’s Shed

ACE has now completed the fourth and final conveyor, an orange community conveyor dedicated to supporting the incredible work of the Men’s Shed in Emerald.

Men’s Sheds are a place where men can be open with one another, share their feelings and feel supported. They also serve as a place where men can enjoy some old-fashioned camaraderie over shared projects, which in the case of Emerald, focus on woodworking. These spaces can be vital for supporting men who may otherwise feel isolated outside of the workplace.

This final Maingate conveyor encompasses the full scope of design, manufacture, installation, and commissioning and will be retrofitted into the existing onsite infrastructure, completing the community-focused conveyor series.