Engineering Solutions: Low-Level Module Idlers in action at Maxwell
Posted at February 02, 2026
Fenner Conveyors was selected to deliver a 9-kilometre overland conveyor system for the Maxwell Underground Project. This project has proven to be a complex, collaborative effort, coordinated across Fenner’s portfolio of leading conveyor brands.
System design, engineering, manufacturing, and on-site construction are being led by ACE, while Fenner Conveyors provides the belting. For idlers, rollers, and pulleys, CPS has been brought into the project, showcasing our expertise by deploying Low-Level Modules (LLM) as the optimal solution for the site’s requirements.
This 9 km, 1400 BW overland conveyor system for Malabar Resources will play a critical role in the largest underground metallurgical coal mine in NSW, linking underground operations to the coal processing facility. To meet the project’s unique needs, several iterations and improvements were required to the typical LLM system, a challenge our engineers were well-equipped to meet.
What Does the Next Generation of Low-Level Modules Look Like?
CPS has led industry innovation for many years, and the LLM design for Maxwell is no exception. We’ve evolved the design of the LLM beyond the limitations of traditional LLM designs seen in the past with a number of improvements:
- Integrated Return Idler Brackets with H-Frame Module Structure
Reduces overall steel members and complexity. - Consolidated Banking Design Variations
Significantly simplifying engineering, fabrication, and installation. - Compliance with Australian Structural Standards
Including AS4100 and AS1170.2, validated through scaled wind tunnel testing. - In-Depth Fatigue Analysis of Critical Components
Ensures structural integrity for the plant’s required design life.
These enhancements not only improve efficiency but also reduce complexity across the entire project lifecycle, from design and fabrication to installation. Deployment at Malabar and other large-scale projects across Australia will provide performance data and insights, enabling CPS to further refine LLM designs for unmatched efficiency and performance.
Setting the Benchmark for Idler Manufacturing
CPS continues to set the standard for idler manufacturing, with proven capability to meet the volume and tolerance demands of major overland conveyor (OLC) projects. Our track record includes supplying frames for projects such as:
- South Flank (26 km) – BHP
- Western Ranges & West Angelas – RTIO
- Biggi, Queens, Canyon-G – Fortescue
…and other key projects internationally.
We look forward to continuing to iterate on our LLM’s and all our innovative offerings, to ensure we continue to provide the mining sector the very best in roller, pulley, and idler performance.
