Case Studies
Safety Control System for Underlay Production Machine
Industry: Manufacturing & Processing
Project: Electrical Control Panel Build, PLC Programming, and Machine Safety Integration
A UK-based flooring manufacturer purchased an underlay production machine from overseas. The equipment, comprising a foam shredder and a log moulder, was non-compliant with UK safety regulations. The machine lacked a valid UKCA mark, and its CE marking was invalid due to inadequate safety measures.
Despite the customer installing perimeter fencing and access gates, the machine’s control system did not meet PUWER (Provision and Use of Work Equipment Regulations) requirements. A comprehensive machine risk assessment identified critical safety hazards, requiring a safety-related control system to mitigate risks and achieve compliance with ISO 13849-2 standards.
Maquina Technical Services Ltd was appointed to design, build, and integrate a bespoke safety control system to ensure the machine met the necessary legal and safety requirements. Key focus areas included:
- Designing a safe control system to manage machine hazards
- Installing safety devices, including interlocking gate handles and "key in pocket" systems, to prevent unauthorised access to hazardous areas
- Building and integrating an electrical control panel with a programmable safety controller (PLC) to ensure controlled, safe operation of the machine’s motors, pumps, and hydraulics
Our solution involved implementing Euchner MGB2 interlocking door handles and Euchner CKS 2 "key in pocket" systems to control access through the machine’s gates.
Operators wishing to enter the machine perimeter must:
- Remove a CKS key, keeping it on their person
- Press an entry request button on the gate
- The system verifies that the machine is in a safe state—monitoring conditions such as heat, steam, and hydraulic activity—before unlocking the gates
Once maintenance or operational tasks are complete, operators must perform a full area sweep before exiting. This involves pressing four strategically placed reset buttons, ensuring all zones are clear of personnel. The gates can only be fully reset when the CKS key is returned to its terminal, ensuring no one remains inside the cell.
We delivered a complete, end-to-end solution, including:
- Design and build of a bespoke safety-related electrical control panel
- Installation of a Euchner MSC programmable safety controller to handle motor control, pump shutdowns, and safety device monitoring
- Integration of safety devices, including Euchner MGB2 door handle interlocks and Euchner CKS 2 key systems
- Full integration with the existing electrical system, ensuring that motors, pumps, and other key components shut down during entry procedures
- Development of a comprehensive SISTEMA report, electrical drawings, and Safe Operating Procedures (SOPs) to provide the client with a complete technical file for compliance
Maquina Technical Services Ltd focused on achieving compliance with:
- UKCA marking requirements for machinery used in the UK
- PUWER (Provision and Use of Work Equipment Regulations) for safe machine operation
- ISO 13849-2 for safety-related parts of control systems
Our machine risk assessment and SISTEMA calculations ensured that the control system met the highest functional safety standards.
Following the integration of the new safety control system, the client now benefits from:
- A machine that is UKCA compliant and PUWER ready
- A safe working environment for operators and maintenance staff
- Controlled entry and exit procedures that reduce the risk of accidents
- Full shutdown functionality, ensuring motors, pumps, and other hazardous equipment are powered down before access is granted
- Comprehensive documentation, including SISTEMA reports and technical files, for ongoing compliance
The system improves overall operational safety while maintaining production efficiency. The client can now confidently operate their underlay production line, knowing that it meets the highest machine safety standards required in the UK manufacturing sector.
At Maquina Technical Services Ltd, we specialise in delivering tailored control system solutions that ensure your machines meet UKCA marking, PUWER compliance, and functional safety standards.
Our services include:
- Electrical Control Panel Design and Build
- PLC Programming and Integration
- Machine Safety System Design
- Machine Risk Assessments
- SISTEMA Reporting
We help businesses in the UK manufacturing sector achieve safe and compliant production environments, ensuring your equipment is fit for purpose and legal to operate.
Bespoke Control System for Improved Safety and Efficiency
Maquina Technical Services delivered a bespoke control system to eliminate a manual handling task within a client’s machinery process. The original lever’s were heavy and prior to this upgrade, one lever had sprung back under tension and hit an operator in the face. This required a hospital visit.
The project began with a comprehensive survey of the client’s manual mechanical process. Maquina Technical Services then designed a tailored solution, which was reviewed and approved by the client before implementation.
The solution involved the integration of synchronised DC-powered linear actuators to lift a heavy machine component as part of its regular operation. This replaced the previous manual system, which required operators to use heavy levers to perform the task.
At Maquina’s facilities, the control panel was precisely built to the agreed specifications, ensuring both quality and reliability. Upon completion, the system was installed on-site. The new actuators were integrated into the machine’s existing framework, making the operation faster, safer and the alignment of the loader was much better.
Throughout the project, Maquina adhered to all relevant industry standards, ensuring the highest levels of safety and compliance. These included:
- IEC 60204-1 (Safety of Machinery – Electrical Equipment of Machines)
- Low Voltage Directive (2014/35/EU)
- EMC Directive (2014/30/EU)
- ISO 13849-2 (Safety of Machinery – Safety-Related Parts of Control Systems)
The tailored solution was highly praised by both the client and their operators. By replacing manual heavy levers with synchronised actuators, the system improved operational safety and ease of use.
The bespoke control system significantly enhanced the safety of the machinery, reducing the risk of injury associated with manual handling tasks. Additionally, the automated process improved operational efficiency, leading to a streamlined workflow and reduced operator fatigue.
The client expressed satisfaction with the solution, noting its positive impact on both operator safety and machine performance. The operators particularly appreciated the simplified and safer operation of the machine, underscoring the effectiveness of the tailored solution provided by Maquina Technical Services.
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