FLUID SYSTEMS SPECIALIST
The leadership team at Cooper Fluid Systems, an industry leader in the Australian hydraulic and lubrication market, update us on the company’s significant investment in a new Mackay facility, hydraulic test bench, and more
Writer: Jack Salter | Project Manager: Eddie Clinton
During these times, there’s a continued focus on improving efficiency and productivity. More and more, we’re required to offer solutions that improve the cost per tonne, especially as some clients start to sweat their assets more, so reliability and maintenance become all the more important.”
Giving his updated take on the Australian mining industry is Brody Sewell, General Manager of Cooper Fluid Systems (Coopers), whom we
last interviewed in February 2025.
On this occasion, he is joined by Peter Doolan, Northern Regional Manager; Geoff Cane, Branch Manager – Mackay; and Daniel Doolan, Project Manager – Mackay.
Brody notes the industry has had relatively robust commodity prices in iron ore, coal, and particularly copper over the past year.
However, currency fluctuation –especially the strengthening of the Australian dollar – has increased costs for producers.
There have also been local challenges in Queensland (QLD), where some major coal mining companies have been impacted by significant government royalties.
Across all major Australian states, including QLD, where the company is in close proximity to the Bowen Basin, Coopers has a network of 15 branches geographically positioned nearby its customers.
Out of these branches, the company runs fully maintained workshops that allow it to provide
both on-site and in-house service repairs.
“We also have an engineering department which provides us the capabilities to fully design solutions, both bespoke, one-off projects and also repeatable products which are required within the client’s operations,” Brody tells us.
“We’re heavily focused towards the mining industry; it makes up between 65 and 70 percent of our customer base nationally, and the business was built on those foundations.”
“WE REMAIN FOCUSED ON HOW WE CAN IMPROVE OUR ABILITY TO SERVICE OUR CUSTOMERS AND ADD NEW TECHNOLOGICAL SOLUTIONS TO DRIVE EFFICIENCIES AND POSITIVE OUTCOMES”
–
BRODY SEWELL, GENERAL MANAGER, COOPER FLUID SYSTEMS
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With just over 300 employees, Coopers specialises in the design, manufacture, installation, supply, and repair of hydraulic, lubrication, refuelling, fluid dispensing, fire suppression, automation, and high-force tooling systems and components.
CUSTOM-BUILT FACILITY
For Coopers, the past 12 to 18 months have been quite demanding, having upgraded its enterprise resource planning (ERP) system and relocated its founding branch in Mackay, QLD to a custom-built facility.
The company had long outgrown the branch and spent a number of years trying to find a facility in Mackay that suited its needs.
“It was a struggle; availability of commercial land is a problem,” acknowledges Geoff.
“Having something reasonably economical to take on was the next challenge. Then, out of the blue, we were lucky enough to strike up a conversation with another well-known business owner. Discussion started, and that’s where the idea he could build a shed for us started.”
The concept for the 4,000 square metre (sqm) shed on an 11,000 sqm block was drawn up, with Coopers’ engineering team involved in the layout from the very start.
“We got to common ground, agreed costs everyone was happy with, then went away and built the shed,” Geoff outlines.
“We now have enough hardstand for all our gear and five cranes, whereas previously we only had one. It’s like a brand-new business!” he excites.
“WE NOW HAVE ENOUGH HARDSTAND FOR ALL OUR GEAR AND FIVE CRANES, WHEREAS PREVIOUSLY WE ONLY HAD ONE. IT’S LIKE A BRANDNEW BUSINESS!”
– GEOFF CANE, BRANCH MANAGER –MACKAY, COOPER FLUID SYSTEMS
HYDRAULIC TEST BENCH
Alongside the branch relocation, Coopers has made over AUD$1 million in investments in a 240-kilowatt (kW) hydraulic test bench and other hydraulic repair equipment.
What began as a dream on a wish list has streamlined everything the company does in hydraulics and enables it to test things at full capacity, which it didn’t have the ability to do previously.
“It’s our understanding that it will be the highest-capacity test bench on the eastern seaboard of Australia,” Daniel acclaims.
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The test bench is equipped with a 22-inch touchscreen and can be programmed by Coopers to perform repetitive work.
It can also be run remotely, has all diagnostic equipment built in, and includes a calibration function.
A thermal imaging camera, meanwhile, allows customers to log in and watch pump tests happen in real time.
“We’ve never had the capability to do that, so it just brings in a new era of testing. I believe it’s the way forward,” affirms Daniel.
PEOPLE DEVELOPMENT
Both the custom-built facility and hydraulic test bench have allowed Coopers to expand the business and take on extra work.
This in turn is going to enable the company to expand its workforce and bring on more apprentices.
COOPERS’ PRODUCTS AND SERVICES
• Lubrication
• Fluid power
• Hoses and fittings
• Fluid dispensing
• Refuelling
• Fire suppression
• Automation
• Pneumatic
• Engineering design
• Projects
• Workshop repairs
• Site services
• Mobile audit and calibration
• Shutdown maintenance
• Installation and commissioning
“Apprentices have been how the branch has grown over the years. We like to put money back into bringing young people through the business,” emphasises Peter.
There’s no better example of this than Peter himself, who started with
“APPRENTICES HAVE BEEN HOW THE BRANCH HAS GROWN OVER THE YEARS. WE LIKE TO PUT MONEY BACK INTO BRINGING YOUNG PEOPLE THROUGH THE BUSINESS”
– PETER DOOLAN, NORTHERN REGIONAL MANAGER, COOPER FLUID SYSTEMS
Coopers as an apprentice and has now been with the company for 32 years, having joined in 1994.
“I would say we’ve got at least another eight people within the business that were apprentices and come through as well,” he informs us.
INDUSTRIAL FLOW METERS
For Mining Applications
In 2026, the Australian mining sector has shifted its focus from “volume at any cost” to disciplined, calculative growth. With fluctuating input costs for fuel and reagents, the ability to account for every litre of fluid has transitioned from a utility to a front-line strategic advantage.
The Sovereign Supply Chain Advantage
A defining trend this year is the prioritization of Australian Designed and Made infrastructure. To de-risk operations, Tier 1 and mid-tier miners are partnering with local METS providers. Choosing Australian-made ensures that equipment is engineered for the 45°C extremes of the Pilbara, backed by local technical support and immediate parts availability.
Accuracy Beyond the Slurry
While slurry handling gets the headlines, a significant “efficiency leak” exists in high-value fluid transfer. Lubricants, diesel, and chemical dosing agents represent massive OPEX. Traditional meters often struggle with shifting viscosities, leading to data drift.
The industry is correcting this through Positive Displacement (PD) Oval Gear technology, which physically captures fixed volumes to eliminate guesswork.
Operators are now deploying a two-pronged approach:
· Mechanical Resilience: Standalone mechanical counters for remote fuel pods, providing fail-safe accuracy without external power.
· Digital Integration: Digital outputs feeding realtime pulse data into AI dashboards to instantly identify leaks or “shrinkage.”
The Calculative Bottom Line
Precision is the new benchmark for operational excellence. By implementing meters with 0.5% accuracy, engineers can move into predictive costmodeling. When you know the exact fuel burn per tonne moved, you can tighten the screws on waste. In 2026, the most profitable mines aren’t just those moving the most earth—they are the ones managing their fluids with the highest degree of precision.
Mechanical Flow meters
1” MECHANICAL FLOW METER WITH STANDARD MECHANICAL DISPLAY
F025-1S3
• Cast Aluminium construction
• FKM (Viton) seals
• Maximum flow rate 120 L/min
• Accuracy of ±1.00% of reading
• Exceptional repeatability of ±0.03%
• Temperature up to 80°C / 176°F
• Available from size 1/4 to 4 inch
Digital Flow meters
1” DIGITAL FLOW METER WITH PR (LCD 12MM DISPLAY)
MX25F-1SD
• Aluminium (6061) construction
• FKM (Viton) seals
• Maximum flow rate 160 L/min
• Accuracy of ±0.5% of reading
• Exceptional repeatability of ±0.03%
• Temperature up to 80°C / 176°F
• Available from size 1/4 to 4 inch
Coopers invests in the development of its people and has always tried to offer them as much flexibility as possible.
For instance, it constantly looks at roster changes that align more with lifestyle requirements and supports higher learning, including one recent staff member’s postgraduate diploma in project management.
“We continue to look at offering other individuals development opportunities where they desire it,” Brody assures.
ELW PROJECT
Coopers has continued to differentiate itself from the competition by providing turnkey solutions with engineered products.
For example, it recently took on a project for the elimination of live works (ELW), keeping operators out
of harm’s way.
“It’s about being able to operate machines without physically moving the wheels, knobs, or whatever else. This project was coming up with a solution to engineer out the operator and be able to move a bucket
“IT’S OUR UNDERSTANDING THAT IT WILL BE THE HIGHEST-CAPACITY TEST BENCH ON THE EASTERN SEABOARD OF AUSTRALIA”
– DANIEL DOOLAN, PROJECT MANAGER – MACKAY, COOPER FLUID SYSTEMS
remotely. We built a prototype and was able to showcase it at the Mackay facility,” outlines Daniel.
“We went through probably seven variations. We went to have a look at how they were doing it and get some real-life experience. Whilst we
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From critical bolting applications to field-ready maintenance solutions, Enerpac products are engineered to enhance safety, precision, and operational e ciency in the most demanding environments.
Designed for use across mining operations, plant shutdowns, infrastructure projects, and heavy industry, these solutions help minimize downtime and maximize performance where it matters most.
MRO Tool Boxes
(Wheeled & Non-Wheeled)
• Heavy-duty build designed for harsh environments
• Wide tooling range for diverse MRO tasks
• Built for service teams, shutdown crews & field operations
• Available in 3 options: 5 ton, 10 ton & 20 ton
• High-precision torquing for critical bolting
• Cordless mobility for improved productivity
• Faster setup in remote & confined spaces
• Wide torque range (160 – 8,130 Nm) across 5 models (BTW500 – BTW6000)
S-Series Square Drive Torque Wrenches
• Industry-proven bolting solutions
• High accuracy and repeatability
• Durable design for demanding conditions
• Range starts from S1500PX up to S25000PX
Powering Performance Where It Matters Most
were out there, we 3D-scanned the machine, put our brains trust together, and tried to come up with different concepts on how we could attack it.
“The first two designs were a complete failure, and the customer was almost ready to walk away, but we got them over the line with the third concept we put together,” he adds.
As a full system integrator, Coopers adds value to its suppliers and provides a growth platform for them by expanding their market penetration and reach.
Further to that, the company continually looks at expanding its supplier base, assesses gaps in its existing portfolio, and identifies where new partnerships make sense.
HEALTH AND SAFETY
In 2021, Recognised Standard 23 (RS23) was implemented in QLD to establish minimum health and safety standards for fluid power systems in coal mines.
COOPERS’ SOLUTIONS
ENGINEERED SOLUTIONS – Coopers designs and delivers engineered solutions across hydraulic, lubrication, refuelling, pneumatic, fluid dispensing, and ELW systems, including automation and integrated solutions. Working closely with site teams, the company solves complex operational challenges with practical, fit-for-purpose outcomes that improve safety, efficiency, and equipment reliability.
ASSET OPTIMISATION – The company’s asset optimisation solutions improve the performance, reliability, and lifespan of mobile and fixed plants. Through filtration, thermal management, and system upgrades, Coopers helps maintain cleaner fluids, improve temperature control, extend maintenance intervals, and maximise uptime.
SYSTEMS INTEGRATION – As a trusted systems integrator, Coopers combines engineering expertise with a global supplier network to deliver high-quality, fully integrated systems. From design through to commissioning, it selects and integrates the right components to deliver durable, reliable, and high-performance solutions that support efficient operations.
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Bridging the gap with innovation
These minimum standards meet legislated objectives for risks to be as low as reasonably achievable and result in a further reduction in the incidence of fluid power system incidents.
The implementation of RS23 assists in protecting workers and other people against harm to their health and safety through the elimination or reduction of lifecycle risks associated with fluid power systems in mines.
“With RS23 comes a lot of hose asset management. You need to be able to manage when a hose was manufactured, when it was built, if it was tested to two times the working pressure – it’s a whole process of manufacturing hoses and being able to serialise numbers so every hose is individual and you can track them through any system,” Daniel explains.
For almost two years, Coopers has been working on a hose asset management system, which is now
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in place and has been a significant investment.
This system allows the company to print QR codes and test all the hoses it manufactures.
“We’ve got off-site and in-workshop capabilities, so we can do it in situ, and we’ve completed several machines where one machine is 870 hose assemblies –approximately 8.5 kilometres of hose, just to put it into perspective,” notes Daniel.
PROFITABLE GROWTH
Coopers continues to look at profitably growing the business whilst managing some industry headwinds.
“We remain focused on how we can improve our ability to service customers and add new technological solutions to drive efficiencies and positive outcomes,” Brody sets out.
In the coming years, Coopers seeks to partner with more forward-thinking
clients who require solutions to difficult challenges in the automation, fluid dispensing, fluid power, and lubrication spaces.
“There’s no challenge too big or too small for us,” he closes confidently.
Tel: 1300 026 673
cfssalessupport@cfs.cgl.com.au www.cooperfluidsystems.com.au
Tel:
cfssalessupport@cfs.cgl.com.au www.cooperfluidsystems.com.au