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.
COOPER FLUID SYSTEMS
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.”
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 brand-new 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.
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.
“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
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.
“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 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.
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.
“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
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 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 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.
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 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.
“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
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.
COOPER FLUID SYSTEMS PARTNER
This company profile was produced by the editorial team at APAC Outlook, a publication within the Outlook Publishing global network of B2B industry magazines.
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