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Leading food-to-go manufacturer Uniq Prepared Foods has virtually eliminated downtime from the bacon-slicing process at its facility in Northampton, thanks to a trapped key interlocking system from Castell.

As part of its continuous improvement programme, Uniq replaced the electrical safety switches on its bacon slicer with a panel-mounted KSSE20 multi-key solenoid-controlled switch and four AI access interlocks. The safety switches had been prone to misalignment, with each incident requiring the intervention of an engineer and typical downtime of half an hour. Not only have Castell’s heavy-duty interlocks resolved this issue, but their stainless steel construction makes them much more suited to the daily hosing down given to the machine.

“Castell’s interlocks have completely solved the problem,” said Mark Caulfield, engineering manager at Northampton. “The trapped key system has worked really well and been welcomed by staff.”

Uniq is Marks & Spencer’s largest sandwich supplier, producing over half of the sandwiches sold in M&S stores across the UK. The company’s Northampton site turns out 2.1 million sandwiches in an average week.

When access to the bacon slicer is required, the machine must first finish its cycle so that a signal is received by the solenoid. The push button is depressed, which energises the solenoid and illuminates the LED, confirming that the primary key may be removed. Removal of the primary key changes the condition of the electrical supply to the machine to a safe condition. The primary and three secondary keys can then be used to unlock the interlocks on the access doors. The guards can only be opened once the electrical supply has been switched to a safe condition.

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- Shanghai steel plant safeguarding electrostatic plating process -

Baosteel, the largest steel manufacturer in China and the second largest in the world, is entrusting the safety of personnel at its Shanghai plant to trapped key interlocking systems from Castell.

Many steel plants in China still rely on warning signs to remind employees of recommended operating procedures. However, this method is prone to abuse, with potentially disastrous consequences.

Castell’s products are being used to ensure that Baosteel’s electrostatic plating process is carried out safely. The three interlocking systems completely remove the possibility that personnel who ignore safety procedures could put themselves at risk, by forcing operatives to strictly follow a predetermined series of steps based on the transmission of keys.

Under normal working conditions, when maintenance is required, operatives must first turn and remove the key from the electrical switch; this action isolates the power supply to the electrostatic spray room. The key is inserted into a key exchange unit, releasing four access keys. Each access key opens a specific door into the electrostatic spray room. Electrostatic plating cannot begin again until each access key has been returned to the key exchange unit, and the initial key reinserted into the electrical switch.

David Hughes, Castell’s sales director, commented: “Winning such high profile business is very rewarding, and we are very pleased to be creating long-term partnerships with such important customers. The Castell system Baosteel has implemented will ensure its employees can work in a safe and efficient environment.”

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Castell, a provider of industrial safety components for over 90 years, has redesigned the electrical isolator to prevent component failure leading to malfunction. The KSD+ is a new trapped key interlock power isolator, suitable for 3-phase currents from 32 amps to 250 amps, which dramatically increases safety protection over conventional designs, preventing fail-to-danger.

Designed to the latest standard BS EN 60947-3:2009, the new KSD+ has been created with a non-direct drive interlocking mechanism. The key that controls the operation of the isolator does not bear the load of switching the contacts, traditionally a potential point of failure. Switching is now achieved with an extending handle that increases the ease of use, as well as device reliability. The key traps the handle in place and prevents operation when the key is removed.

To further enhance the safety of the KSD+, the ability to switch the device on while the case is open has been removed through the use of a coded sensor. This is an issue for current designs of isolator, even where protection has been built in, as such protective measures can easily be overcome. The KSD+ coded sensor ensures the case is secure before allowing operation, meaning that the user is protected to a much higher degree.

The KSD+ features a stainless steel enclosure that can be placed in harsh environments – this is important for food, chemical and heavy industry applications.

The new unit is fully compatible with previous FS lock types and can therefore be used in existing interlocking systems.

Keith Allingham, Castell’s operations director, commented: “The new KSD+ is a further example of how Castell’s understanding of customer requirements has led to the development of a product with superior features and benefits. The KSD+ also utilises end coding technology and is available off the shelf. Products can be shipped to the customer and coded to their requirements within 48 hours”.

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- Driveaway-prevention system to be installed at 24 DCs in total -

Tesco is to install Castell’s driveaway-prevention system, Salvo, at all of its distribution centres in the UK. The installation will be carried out by Rowland Door Services.

Trailers secured by Salvo at Tesco DC in Hinckley, Leicestershire

The supermarket chain has decided to entrust the well-being of its warehouse personnel to Salvo following a successful three-month trial of the safety system at its distribution centre in Hinckley, Leicestershire. Salvo was installed on 46 loading bays in the goods out area.

Joe Carthy, Tesco Distributions Health & Safety Manager, explained the reasons for his company’s adoption of Salvo: “It’s an established, proven product, and it will always fail-to-safe. With Salvo, you cannot open the warehouse door unless the trailer is immobilised on the bay outside. More importantly, you cannot remove a trailer whilst the loading bay door is open. This removes the risk of bay drive-offs.”

The Salvo system links the articulated trailer to the loading bay door during the loading procedure. The Salvo Susie lock is fitted to the emergency air brake line coupling when the trailer has been reversed into position at the loading bay. After successful fitment, a uniquely-coded key is released from the Salvo, locking the unit firmly onto the coupling. The key can only be released once the Salvo has been fitted to the brake coupling. The key is then taken to the corresponding loading bay and used to switch the power on to the door. Without a locked trailer, there can be no power to open the door.
Once the loading bay door is opened, the key cannot be removed to release the trailer until the door is closed.

The Salvo system hinges on the fact that only a single key exists for each bay, ensuring that the door can only be opened after the trailer has been secured in place. To guarantee the integrity of the system, each bay is assigned a different code.

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- Fully welded design reduces potential food traps -

Castell Safety International has developed a new X-type key exchange unit featuring an extremely robust design that minimises potential food traps.

The exchange unit has been designed to be both ergonomic and durable. The enclosure is now fully welded, offering increased rigidity. Newly designed locks, relocated to be rear mounted, mean that the unit has no visible fixing holes and therefore opportunities for dirt or food to be trapped are significantly reduced. This makes the unit suitable for environments such as the chemical or food and beverage industries, where dirt and food traps are a major issue.

When designing the exchange unit, Castell’s engineers reviewed the enclosure colour. The new colour selected was chosen to match the standard colour for electrical enclosures.

The new unit is fully compatible with previous FS lock types and has identical dimensions to Castell’s X-type exchange unit, allowing it to be retrofitted to existing interlocking systems.

Exchange units are typically used when a control key, having isolated the electrical supply, needs to release multiple keys to allow access to a number of areas. The new exchange unit is available in multiple configurations, according to customer requirements.

David Hughes, Castell’s sales director, commented: “The new exchange unit demonstrates Castell’s commitment to continuous innovation and addressing market requirements. The unit supersedes the old X-type and is available immediately”.

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Castell Safety International’s channel partners, which include distributors and agents across Europe, will be joining Castell on the 30th November and 1st December for the first European Channel Partner Forum, which will be held in London, England. The purpose of the forum is to share knowledge between participants on applications and industry trends and examine how to build on the significant success Castell has had in European markets.

The forum will also allow Castell to formally introduce to its channel partners four recently launched new products: the Salus access lock, the Salus20 isolation switch, the new key exchange box and the KSD+ switch disconnector. The latter will be launched exclusively through Castell’s channel partners.

The forum’s first day will take place at Castell Safety International headquarters in Kingsbury, north-west London, while the following day’s programme will be held a few miles away at the Crown Moran Hotel in Cricklewood.

Symon Winch, Castell’s European distribution manager, is looking forward to the event: “This is a great opportunity to get all of our distributors together and share knowledge and ideas. I am very excited about introducing Castell’s four new products to the network. I am sure these products are going to have a very big impact in our European markets.”

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- 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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Castell Safety International has launched an improved and more efficient padlock differ recording database for its Iso-Lok range of lockout tagout (LOTO) products.

Castell's Iso-Lok range of Lockout Tagout key differed padlocks has upgraded their differ database to increase efficiency

The Iso-Lok padlock range is designed to uphold the integrity of the user’s LOTO safety system by guaranteeing that each padlock on any one site is unique – that each one ‘differs’ from the others so that it can only be unlocked by the specific key meant for it. This is achieved by supplying each padlock with a distinct barrel which has a differ (key) number associated with that barrel.

Every differ number is stored on the Iso-Lok database, referenced against the customer and the site it was delivered to. This enables the company to very simply and reliably identify differs previously supplied in the past, and therefore prevent any padlock differ duplication.

Iso-Lok is the only company to automatically record differs on a site or company-wide basis rather than just per order, ensuring the validity of and enhancing their customers’ safety systems over time. The newly developed database allows the company to process orders more efficiently, trace differs per site more easily, and gather more data more quickly – further improving on the already uniquely beneficial system.

Neal Partridge, Castell’s Head of Quality, commented: “The main advantage of this system is that it records the actual operatives and the entries they make into the database, which provides a greater level of verification and validation, and minimises errors. The integrity of this new system has helped to further improve our Quality Assurance process for Iso-Lok padlocks.”

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Castell Safety International has appointed TSA as its new and exclusive distributor for the Netherlands and Belgium.

TSA now has access to the full Castell product range, including trapped key interlocks, warehouse loading-bay safety system Salvo and the Iso-Lok lock-out / tag-out range.

TSA focuses on the safety market in the Netherlands and Belgium, and currently provides training, consultancy, safety monitoring and shutdown coordination from its four offices across the region. The company’s knowledge of customers and the safety market makes it a logical partner for Castell’s safety solutions.

TSA will supply the trapped key interlock and Iso-Lok lock out / tag out product ranges from stock, ensuring that customer needs are matched by local service and support.

Tim Whelan, Castell’s managing director, commented: “The Netherlands and Belgium are key market areas for Castell. Appointing TSA as our distributor for these territories will increase the level of support we are able to provide our customers. With TSA’s customer knowledge and experience of the safety market, and Castell’s history of providing safety solutions, I am sure this will prove a successful relationship for our customers, TSA and Castell.”

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- IP66 rating makes Salus20 suitable for the food industry and harsh environments -

Castell Safety International has developed the Salus20, a new trapped key isolator switch capable of switching 20 amps.

Salus20 stainless steel switch

The switch is designed for use in trapped key interlocking systems and is a new addition to the Salus family, which also includes the recently launched Salus access interlock.

The Salus20 maintains the design theme of the Salus access interlock, combining an integrated flush-mounted lock with sliding lock cover in a stainless steel IP66 sealed enclosure. The cable can enter the enclosure from any direction, depending on the orientation of the base when fitted.

Using an entirely new stainless steel housing with an ergonomic design that has no areas for dirt to collect and trap, the Salus20 is suitable for wash-down environments such as those found in the food and beverage industry. The switch is also fitted with stainless steel cable glands that further enhance its suitability for food and harsh environments.

The Salus20 is mounted using a clip-in fixed mounting. This makes it easy to install since the switch does not need to be fixed in place to be wired. The switch is available with either two normally open and two normally closed contacts with an optional auxiliary set of contacts, or four normally open or normally closed contacts with optional auxiliaries.

The Salus20 also benefits from Castell’s new end coding system that enables the switch to be stocked and rapidly delivered to customers regardless of the key code required. The flexibility offered by both end coding and the enclosure’s ability to be mounted in any orientation means that the Salus20 is particularly suitable for distribution. The switch is applicable to a wider range of applications than similar Castell products and reduces the requirement for stock holding.

The Salus20 is fully compatible with previous FS lock types and can therefore be used in existing interlocking systems.

David Hughes, Castell’s sales director, commented: “The new Salus20 is a very exciting development for Castell and builds on the success of the Salus access interlock, launched late last year.

“The design team have done a great job of focusing on the needs of our market and have delivered an excellent product. Thanks to its stainless steel construction and IP66 rating, the Salus20 will be particularly attractive to our customers in both the food and beverage and heavy industrial sectors.”

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