Since 1997, National Plastics & Rubber has been a trusted leader in manufacturing and supplying high-quality polyurethane, rubber, and industrial plastic products to heavy industrial operations and the mining industry in Australia and worldwide.
Our commitment to quality and reliability has fostered long-standing partnerships with organisations across Australia, North America, South America, Canada, Europe and South Africa.
As we continue to grow, we are excited to expand our reach into new markets where we are developing innovative solutions to meet the evolving needs of heavy industrial operations and the mining sector.
Case Study: Enhancing Safety and efficiency with Lightweight Minechocks
Problem
An international mining company faced significant challenges with their existing wheel chocks used on heavy-duty vehicles. The chocks were either too heavy to be handled safely, causing frequent employee injuries, or they had a high failure rate, compromising safety. Each failure led to the destruction of essential safety devices, putting workers at serious risk. While some chocks were able to handle the required load, their excessive weight resulted in back injuries among the staff responsible for their handling.
Challenge
The customer approached National Plastics & Rubber with a set of critical, non-negotiable goals:
- The chock must support the world’s largest mining truck on a 10% gradient.
- Its design must prevent expulsion when subjected to load.
- The materials used must withstand harsh and demanding mining environments.
- The solution must be cost-effective.
- The product's weight had to be reduced by 40% to ensure safer handling.
Solution
Our team conducted a comprehensive analysis of the customer’s requirements and the challenging operating environments.
After extensive field testing of multiple materials and designs, we identified a material that met all safety and performance criteria. Rigorous design testing followed to ensure full compliance with safety standards.
Once functionality and safety were confirmed, we optimised production methods to manufacture the MineChocks efficiently and cost-effectively.
Outcome
Our lightweight MineChocks now set the industry standard for safety, durability, affordability, and reduced weight.
They are widely adopted across the mining industry, both locally and internationally, helping companies improve worker safety and operational efficiency.
Case Study: Delivering Reliable, High quality products with agile manufacturing solutions
Problem
An Australian manufacturer faced critical challenges after their Polyurethane supplier relocated production overseas. The quality of the custom-made product declined significantly, leading to frequent product failures.
Additionally, the manufacturer dealt with long lead times due to shipping and customs delays. Communication with the overseas supplier became increasingly difficult, with slower response times.
As a result, the manufacturer experienced a sharp decline in sales of their best-selling product and suffered damage to their reputation.
Challenge
National Plastics & Rubber was tasked with developing a premium-quality product using top-tier materials. Given the unpredictable demand for the product, our manufacturing process had to be highly responsive and adaptable. At the same time, the new product needed to remain competitive in price with the imported version.
Solution
We engineered an efficient manufacturing system that minimised labour costs, allowing us to offer a competitive alternative to the imported product. Our system was designed to quickly scale up production on short notice, ensuring we could meet sudden spikes in demand. Additionally, we implemented stringent quality control and testing procedures to guarantee the reliability and durability of the new product.
Outcome
Our customer now benefits from a consistent, high-quality product at competitive prices. Our flexible production process seamlessly accommodates fluctuations in demand, ensuring timely delivery without compromising quality.
Leveraging our expertise in Polyurethane and industrial applications, we have also supported the customer in developing additional products, further strengthening their market position.
Case Study: Revolutionising Roller systems with modular, cost effective solutions
Problem
Through our regular machinery inspections and maintenance consultations with customers, we discovered a recurring set of issues related to their roller systems. These challenges included:
- High purchase and repair costs
- Labour-intensive installation and maintenance
- Short service life
- Expensive equipment needed for servicing
- Increased injury risks due to the weight of components
- High shipping costs for off-site repairs
Challenge
The industry needed a simplified, efficient system that addressed these costly and time-consuming issues.
Solution
National Plastics & Rubber embarked on extensive trials, testing a variety of systems and materials to develop a comprehensive solution. Our approach led to the creation of a modular system where the wear components are designed to be easily disposable.
This eliminated the need for expensive shipping and off-site repairs, as only the worn parts needed replacing. The new design also made the system significantly lighter and easier to handle, reducing the need for cranes during maintenance and improving overall safety.
Outcome
Our innovative solution was embraced by the industry, with major mining companies widely adopting the new design. Even original equipment manufacturers began incorporating our system into new machinery.
The modular roller system now offers easier, safer installation, enhanced service capabilities, extended service life, and significantly lower maintenance costs, setting a new standard in the industry.
Our Capabilities
Discover how our expertise and innovation bring your vision to life, guiding you through every step of the manufacturing process with precision and excellence.