Castell USA News - a Halma PR news blog

Centrally control all aspects of lockout safety
Erlanger, Kentucky (November 7, 2008) – The Iso-Lok Doc Combo from Castell combines the features of a lockable document holder with those of a safety lockout station and group lockout box.  Securely keeping both the permit to work documents and lockout equipment in the same unit, all aspects of lockout safety can now be controlled and monitored from one central location.

Up to five Permit to Work documents can be safety stored in the strong, clear Perspex cover sleeve, and ten more in a compartment behind the unit. The strong, lightweight aluminum box backboard is designed to securely hold keys, padlocks and multi-clasps (up to 15 total).

Once a Permit to Work has been completed, it can be displayed in the cover sleeve. After the necessary padlock(s) for the job have been removed, the sleeve is then locked closed by up to seven supervisor’s padlocks. Once the intended isolation is in place, the padlock keys are dropped into the slot on top of the box. They will be securely held there until the work is complete – the supervisor then opens the Doc Combo again, and the lock-out can be safely removed.

The Doc Combo also comes with a pad of 10 Permit to Work documents, and can be arranged for left- or right-handed operation. The aluminum box is finished in a durable powder coating, has a tray for the dropped-in keys, and uses removable hooks to hold the padlocks inside.

The Doc Combo, and related lockout/tagout accessories, can be quickly and securely ordered from the Iso-Lok section of www.castell.com, or by calling 859-341-3075. 

New system creates flexible safety zone around dangerous process equipment

Erlanger, Kentucky (August 13, 2008) – Traditional mechanical and barrier methods to machine guarding are only as safe as the people using them. With Castell’s new QuadCam system, sophisticated 3-dimensional imaging technology eliminates the potential for human error and tampering.

QuadCam’s 3D detection technology is able to identify objects and people moving in and around machinery, distinguishing between one, two or more persons with real-time tracking of all people within its field of view. Machinery can not be restarted until the entire detection zone is clear of unauthorized objects and people. The highly accurate detection system ignores background objects, avoiding nuisance alarms.

The flexible system allows users to define warning and shutdown zones. When the warning zone is breached, QuadCam quickly provides visual and audible warnings to workers, and can also provide a signal to slow machinery. If the person or object continues and enters the shutdown zone, the system sends a signal to halt the machinery. Warning and shutdown signals are sent within milliseconds of an intrusion, a fast response time that prevents accidents and equipment damage.

A single QuadCam imager is capable of protecting up to an eight foot by ten foot zone, when the imager is mounted at 11 feet. Up to ten imagers, creating ten protection zones, can be managed by a single QuadCam controller, monitoring up to 800 square feet.

The entire QuadCam system is designed for user flexibility. During initial installation, plug and go harnesses enable simple imager installation, wiring, and even relocation of imagers when necessary. Reconfiguring the system is simple via a windows based PC interface, and warning and shutdown zones can be quickly redrawn with the click and drag of a mouse.

Mounted high above the machinery, the imagers can view multiple potentially dangerous areas of human and machine interaction and are tamper-resistant. When maintenance is needed, the QuadCam provides fast machine access to minimize process downtime.

MillerEdge completes loading dock portfolio with Castell’s Salvo drive-away prevention
Erlanger, Kentucky (July 11, 2008) – To increase customer support across North America, Castell has formed a new OEM partnership with MillerEdge to carry the company’s Salvo dock safety system. 

MillerEdge has 70 years manufacturing experience in commercial and industrial emergency stopping devices for motor driven doors and gates, as well as safeguarding products for perimeter, area, and machine guarding.  The company’s unique understanding of industrial door and dock safety challenges, coupled with its engineering capabilities, will bring experienced local contacts to Castell’s Salvo customers. 

MillerEdge will provide complete sales and service support for the Salvo product, which prevents injury and damage to loading platforms by making it impossible for trucks to drive away during loading or unloading.  Once the Salvo’s Glad Hand lock is attached to the truck’s brake line, ensuring that brakes are applied and trailer movement has stopped, a uniquely coded key is released.  The key is then used in either the automatic or manual door lock, which traps the key, and allows workers inside the plant to unbolt the lock and begin loading or unloading the trailer.  When work on the trailer is complete, the door interlock is bolted and the key needed to open the Salvo Glad Hand brake lock is released, making it possible for the driver to depart.

From its facilities in Jennersville, Pa. and Tempe, Az., MillerEdge’s engineering staff will provide on-site assessments and design engineering assistance to Salvo customers in the United States and Canada.  To contact MillerEdge, visit the company’s website www.MillerEdge.com, or phone (800) 220-3343.

New end-coding technology cuts order lead times
Erlanger, Kentucky (June 19, 2008) – Castell will be exhibiting safety interlocking products at the Air Pollution Control (APC) Roundtable and Exposition, July 14-15, 2008 at the Hyatt Regency Savannah (Savannah, Ga.).  Castell’s range of heavy-duty interlocks promote worker safety by preventing access to live electrostatic precipitators.

With precipitators carrying charges of over 50,000 volts, stringent safety procedures during routine maintenance are vital to prevent operator access prior to isolation of the LV/HV transformer.  Castell’s trapped key interlocks force workers to adhere to a step-by-step process every time internal access to a precipitator is needed.  Each step releases a key which in turn permits activation of the next stage in the process.  This system ensures that access to live precipitators is impossible.

The company’s new end-coding system facilitates faster, more accurate delivery of interlocks.  When an order is placed, locks can be quickly keyed with the customer requested three-digit alphanumeric code for fast order turnaround.

The durable Castell lock mechanism with sealing key and cap resists plugging for consistent performance, even in a precipitator’s high fly-ash environment.  This design, coupled with Castell’s robust, large handled key, guards against failures.  The key is capable of transmitting much more torque to the lock than a standard pin tumbler key for ease of operation.

In addition to the company’s product exhibit at booth 5, Castell will be co-sponsoring Family Fun Night Tuesday, July 15, 6:30 - 9:30 p.m.  For more details on the event, jointly hosted with GE Energy’s Precipitator and Fabric Filter Divisions, CoorsTek and Stein Industries Inc., visit Castell’s booth at the show.

For live demonstrations of Castell’s lock systems, visit Castell’s exhibit at the APC Expo. 

3D imaging safety joins traditional interlock range to safeguard paper processing equipment
Erlanger, Kentucky (May 20, 2008) – Castell will be debuting a new safety system during the Pulp and Paper Safety Association (PPSA) Conference, June 8 - 10, 2008 at the Sheraton Society Hill (Philadelphia, Pa.).  Castell’s new QuadCam uses 3-dimensional imaging technology to provide fast, accurate machine safety for pulp and paper mills, black liquor systems and other processing equipment.

QuadCam’s 3-dimensional detection technology is able to identify objects and people moving in and around machinery, sending warning and shutdown signals within milliseconds of an intrusion.  The flexible system is configured via PC user interface, allowing users to define warning and shutdown zones, and reconfigure them when processes change.  A single QuadCam imager is capable of protecting up to an eight foot by ten foot zone, regardless of shape.  Mounted high above the machinery, the imagers are tamper-resistant. By eliminating the obstruction of traditional mechanical access and barrier safety methods, the QuadCam provides fast machine access when needed.

For safety on mill loading docks, Castell’s Salvo system prevents unscheduled truck departures.  The brake line interlocking system makes it impossible for a driver to depart during loading or unloading, reducing the possibility of worker injury and property damage. A new product design, on display at the show, and a complete kit purchase option have increased the ease of installation and shortened order lead times.

Also on display at the show will be Castell’s trapped key interlocks, which enforce safety with a step-by-step process every time internal access to machinery is needed.  In black liquor systems, trapped key interlocks can be used to physically lock ports after liquor guns are removed.  To satisfy the OSHA 1910.147 compliance issues, Castell’s Iso-lok lockout/tagout products can secure circuit breakers, valves, live electrical installations and other hazardous equipment. 

Visit Castell’s exhibit at the PPSA show for live demonstrations of the new QuadCam and other lock systems. 

Motion monitoring, drive away prevention, static discharge and integrated systems
Erlanger, Kentucky (April 8, 2008) – Castell will be showcasing safety systems for the industrial processing and bulk solids handling markets at the International Powder and Bulk Solids Show, May 6-8, 2008 at the Donald E. Stephens Convention Center (Rosemont, Ill.).  Castell’s BEMF, Salvo, Earth-Line and integrated systems, on display at booth 2343, ensure that workers adhere to step-by-step safety procedures. 

Castell’s BEMF motion-monitoring device guarantees that motor-driven equipment such as mixers, hammer mills and pellet mills has completely stopped before access is granted.  Entrance to the equipment is immediate after reaching zero speed, unlike fixed time delay systems which can overcompensate run-down times for lighter loads.
To promote safety at the loading dock, the Salvo system prevents trucks from driving away during loading or unloading.  A unique brake line interlocking system makes it impossible for a driver to depart during loading or unloading.  A new product design, on display at the show, and a complete kit purchase option have increased the ease of installation and shortened order lead times.

To prevent explosions due to static charge when handling flammable solids, powders, liquids or gases, the Earth-Line electrostatic discharge system monitors resistance to earth, triggering an alarm sequence and automatically shutting down operation when a preset limit is exceeded. 
For complex production lines, Castell is able to design custom integrated systems that work together to form a complete machine to dock safety package.  For example, in high dust environments, Salvo and Earth-Line systems can be combined to protect against both potential explosion hazards and unscheduled truck departures in the loading area.

For demonstrations of Castell’s safety products, and to discuss application-specific needs, visit booth 2343 at the International Powder and Bulk Solids Show.

Drive-away prevention system protects workers at UK bakery
Erlanger, Kentucky (March 13, 2008) – Pork Farms, one of the UK’s leading bakeries, has eliminated the risk of unscheduled truck departures with an investment in Castell’s Salvo safety system, protecting its workers from injury and its property from damage.  The systems have been installed on all four loading docks at Pork Farm’s Palethorpes site in Shropshire, which handles hundreds of vehicles a month.

The Salvo is a simple way to promote loading dock safety by preventing trucks from mistakenly pulling away during trailer loading and unloading.  At Pork Farms, drivers pull into a loading dock and retrieve a lock from the office.  The driver applies the lock to the trailer’s emergency brake line-effectively immobilizing the trailer- which releases a uniquely coded key.  Drivers then insert the key into the control box next to the dock.  This turns the traffic lights from green to red, allowing the motorized door to be raised and the dock leveller positioned.  The key remains trapped in the control box until the door is fully closed.

When loading / unloading has finished, the door is closed, and the key is released from the control box.  The driver is then able to remove the lock from the trailer’s emergency brake line and depart.

“Salvo is easy to control and cost-effective,” commented Dave Bradley, Logistics Support Manager, about Pork Farm’s decision to adopt the interlocking system.  “We did look at wheel-locking devices but felt that Salvo was simpler and more manageable within our site processes.”  Additionally, interlocking systems have been endorsed as a safe system of work to combat unscheduled truck departure.

The Salvo system is available from Castell USA, with short lead times from its Erlanger, Ky. offices.  For information on the company’s full range of products, go to www.castell.com, or call 859-341-3075. 

Since the inception of the industrial safety industry, Castell, a member of the global Halma group, has been a leader in trapped key interlocking technology, developing products that keep pace with the needs of emerging markets and applications in all business sectors.  Their products go beyond meeting legislation to create the safest working environments possible. 

Drive-away prevention system and more on display for logistics industry
Erlanger, Kentucky (February 19, 2008) – Castell will be showcasing safety solutions for attendees of the Material Handling Industry of America’s NA 2008 annual show and conference, April 21-24, 2008 at the I-X Center (Cleveland, OH).  Castell’s dock safety, motion monitoring and interlock products safeguard personnel and equipment in material handling warehouses.

To promote safety at the loading dock, the Salvo system prevents trucks from driving away during loading or unloading.  The Salvo gladhand lock attaches to a trailer’s brake line, releasing a uniquely coded key.  In an automatic system, the key is then used in an exterior control panel, which disengages the automatic door interlock so that workers may begin safely loading or unloading.  Until the automatic door interlock is bolted again, the control panel will not release the key needed to open the Salvo gladhand lock, making it impossible for a driver to depart.  A new product design and complete kit purchase option have increased the ease of installation and shortened the order lead times.

In addition to the Salvo, Castell offers a range of trapped key interlocks and systems that ensure workers adhere to a step-by-step process every time access to dangerous equipment is needed.  The BEMF motion-monitoring device guarantees that motor-driven equipment with variable run-down times, such as mixers, blenders, hammer mills and pellet mills, has completely stopped before access is granted.  Entrance to the equipment is immediate after reaching zero speed.  The equipment cannot be restarted until personnel has safely withdrawn, then closed and locked the guard hatch.  Castell also offers a wide range of lockout tagout products to satisfy OSHA regulations.

For live demonstrations of Castell’s Salvo and BEMF safety systems, visit booth 710 at NA 2008. 

Drive-away prevention system eliminates unscheduled truck departures
Erlanger, Kentucky (December 20, 2007) – Unscheduled truck departures increase risk to workers and the potential for damage to loading docks and equipment.  The Salvo loading dock safety system from international safety expert Castell ensures that a particular sequence of events happens before a truck is able to pull away from the dock.  A new product design and complete kit purchase option have increased ease of installation and shortened order lead times.

The key to the Salvo system is the Salvo gladhand lock.  Once the gladhand lock is attached to the truck’s brake line, ensuring that brakes are applied and trailer movement has stopped, a uniquely coded key is released.  The key is then used in either the automatic or manual door lock, which traps the key, and allows workers inside the plant to unbolt the lock and begin loading or unloading the trailer.  When work on the trailer is complete, the door interlock is bolted and the key needed to open the Salvo gladhand brake lock is released, making it possible for the driver to depart.

Castell is now packaging the safety system as a complete kit, with all system components and control panel wiring included.  A one-size-fits-all design for the Salvo bollard, brackets and barrier chain set, and modular mounting rack model have lowered customer cost and made installation easier.  Castell has also increased durability with a new temperature resistant gladhand lock design, and weatherproof stainless steel storage box.  The entire kit is stocked and shipped from Erlanger, Kentucky with short lead times.

New logo unites all safety product lines under one brand

Erlanger, Kentucky (November 27, 2007) – Castell (www.castell.com), a worldwide leader in industrial safety solutions, has adopted a new corporate brand identity.  The new logo reflects the company’s evolving business direction and unites its varied product lines and global offices with a single, strong brand identity. 

Since the inception of the industrial safety industry, Castell has been a leader in trapped key interlocking technology, developing products that keep pace with the needs of emerging markets and applications in all business sectors.  The company’s Salvo loading dock safety system, QuadCam 3D machine safety system, Iso-lok lockout tagout products and trapped key interlocks are all known for excellence within their respective application areas.  With the new logo and brand identity, all of these product lines will be recognized under the universal Castell identity.

“We expect the recent investments we have made into diversifying our technology and applications to bring significant growth,” said Thomas Schluep, President of Castell USA. “Our new logo is a visual representation of the essential traits which drive this evolution: uniqueness, innovation, reliability and quality.  Customers will now see one Castell and know that they will get the same great product and service, regardless of which product line best suits their needs.”

Castell products go beyond meeting legislation to create the safest working environments possible.  The company’s expertise ranges from simple single key access interlocks to integrated systems with motion monitoring and static discharge capabilities.  A member of the global Halma group, Castell USA is headquartered in Erlanger, Kentucky, with global Castell offices in the UK, Germany and China.