Boiler manufacturer relies on resilient safety interlocks

– Castell’s products withstand demanding operating conditions at Ideal Heating –

Leading domestic and industrial boiler manufacturer Ideal Heating has upgraded safety procedures at its Hull site with the introduction of interlocking systems from Castell. The heating specialist has installed safety switches and access interlocks on ten machines in its foundry blowing area.


The blowing area turns out sand-based moulds for casting heat exchangers used in the company’s boilers. Waste sand from the production process tended to clog up the previous safety system, but Castell’s heavy-duty KSE20 multi-key electrical switches and AI access interlocks have been unaffected by the demanding environment.

“We had a problem with the old system,” admitted Jason Waltham, senior maintenance technician, “and thanks to Castell’s robust products we have addressed it. Their customer service has also been first class.”

Ideal Heating produces a range of domestic and commercial boilers for distribution in the UK and Eire. Improvement projects, like the installation of Castell’s safety interlocks, have had a positive impact and contributed to the goal of an accident-free culture. The company’s lost time frequency, reportable injury and accident severity rates currently stand at an all-time low.

When maintenance of a mould-making machine is required, the operative removes the primary key from the electrical switch. This action changes the status of the electrical supply to the machine to a safe condition and enables the release of two secondary keys. These keys are then used to unlock the interlocks on the machine’s access doors. The guards can only be opened when the electrical supply has been switched to a safe condition.

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