New manufacturing approach dramatically reduces lead times
Erlanger, Kentucky (March 11, 2010) – Industrial safety specialist Castell has adopted a manufacturing process to improve efficiency and benefit the end-users, machine builders and distributors who use its safety interlocks. The company is the first in the interlocking sector to implement end coding, which allows standard products to be coded at the final, rather than initial, stage of production.

With Castell’s new end coding manufacturing process, stock safety interlocks can be fitted quickly, with the coded tablet (marked CAS) added as a final system design step.

End coding enables the company’s interlocks to be fitted uncoded to machinery and remain there until they are commissioned. The coding scheme can be changed right up until commissioning is accepted, when an authorized coding engineer codes the system. As a result, standard products can now be held as stock with distributors and machine builders, speeding up the supply chain.

The system relies on a coded tablet that is inserted into the lock. Once inserted, the tablet cannot be removed or recoded, which guarantees the integrity and safety of the system. Tablets can be provided within 24 hours of being defined and requested.

Since trapped key interlocks were first designed, the production of any system could not start until each code within the system had been defined. This created a number of potential issues. There was no flexibility during the commissioning phase for alterations once the locks had been fitted. Similarly, as each unit was individually coded at the start of the manufacturing process, replacement stock required a full set of duplicates to be kept as spares. Machine builders could not stock items and orders could only be placed once end-users had confirmed codes. The product was not readily available as a stock item either at distribution outlets or from the manufacturer. Essentially, each component was a special order and as such came with an extended lead time, no matter how frequently that product was used. Castell’s new end coding system changes all this with flexible and fast safety interlocking.

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Erlanger, Kentucky (August 18, 2009) – Equipment from industrial safety specialist Castell has been added to Tapeswitch Corporation’s product line up.  Castell’s portfolio of trapped key interlocks and loading dock guarding systems will now be available in the United States through Tapeswitch.

Castell’s trapped key interlocks ensure that personnel follow a predetermined sequence of tasks to control process risks and equipment hazards.  Valves, actuators, switches, doors and processes are physically locked in a state until the right key is used. By using a trapped-key system, the next step in any process can only be unlocked and started once the previous step has been completed and the appropriate key released, guaranteeing the correct sequence of events.

Trapped key interlocking can be used in a wide variety of applications, such as machine guarding, machine control, switch gear, valve interlocking, process control and most importantly, personnel safety. For instance: in a robot cell where the robot needs to be disabled for safe personnel entry, Castell’s trapped key products ensure that a key is only released once the robot has completed a full cycle. Once the key is removed, the robot is disarmed and the key is then used in the access interlock to obtain entry to the now safe hazard zone.

To promote safety at the loading dock, Castell’s 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. 

Castell’s products complement Tapeswitch’s line of electrical and photo-electric safety equipment which features a wide range of switching and sensing products, such as safety mats, sensing edges and bumpers, touchpads, and safety controllers.

For more information on Tapeswitch’s new line of trapped key interlocks and extensive line of safety products, call 631-630-0442 or email blipsman@tapeswitch.com.
 
About Castell
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.  Their products go beyond meeting legislation to create the safest working environments possible.  A member of the global Halma group, Castell has its US offices in Erlanger, Kentucky. 

About Tapeswitch
For the last 50 years, Tapeswitch (www.tapeswitch.com) has been a major player in the development and manufacture of sensors for safety applications, and currently has the widest range of safety mat, sensing edge, and sensing bumper products available anywhere in the marketplace.  In addition to Castell’s interlocking products, the company also offers complementary electronic devices such as safety controllers and light curtain safety systems.

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Cocktail reception planned for Tuesday, July 14
Erlanger, Kentucky (July 1, 2009) – Castell will be exhibiting safety interlocking products at the Air Pollution Control (APC) Roundtable and Exposition, July 13-14, 2009 at the Woodlands Resort & Conference Center (Houston, TX).  Castell’s range of heavy-duty interlocks promotes worker safety by preventing access to live electrostatic precipitators.

Strict safety procedures are essential when working with electrostatic precipitators.  Failing to isolate the LV/HV transformer prior to maintenance operator access can expose workers to charges of over 50,000 volts.  Each time internal access to a precipitator is needed, workers must follow the step-by-step process imposed by Castell’s trapped key interlocks.  Each step releases a key which in turn permits activation of the next stage in the process, making access to live precipitators impossible.

The company’s new end-coding system facilitates faster, more accurate delivery of interlocks.  When an order is placed, locks can be quickly coded with the customer requested three-digit alphanumeric symbol. A large robust key with a neoprene seal or a stainless steel dust cap resists the plugging common in the high fly-ash environment of a precipitator guard against mechanical lock 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 37, Castell will be co-sponsoring a cocktail reception on Tuesday, July 14.  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 and end-coding process, visit Castell’s exhibit at the APC Expo. 

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Control equipment specialists have installed Castell on dozens of jobs over past two decades
Erlanger, Kentucky (May 20, 2009) – When it comes to choosing safety interlocking devices for its air pollution and thermal control equipment installations, Hamon Research-Cottrell trusts Castell Interlocks to deliver to deliver the quality, reliability and service required.  As one of Hamon’s carefully selected preferred suppliers, Castell interlocks have protected operators on Hamon’s equipment from extreme temperatures, high voltage and fall hazards for over twenty years. 

Hamon’s state of the art technology for electrostatic precipitators, fabric filters, dry desulfurization and wet gas scrubbing systems, like all equipment of its kind, require strict adherence to safety and maintenance procedures to safeguard personnel and equipment from human error.  Hamon selects Castell’s trapped key interlocks to force workers to adhere to a step-by-step process every time internal access to equipment is needed.  Each step releases a key which in turn permits activation of the next stage in the access process.  This system prevents access to live precipitators and other machinery that may be hazardous if accessed during operation.

“Castell is known industry-wide as a quality organization that designs and manufactures a superior product,” explained Hamon Project Manager Glenn Ostfeld.  “For this reason, Castell products are often specified by Hamon, who insist on only the best from its quality approved suppliers.”

Castell has earned its reputation by producing durable products that perform well in challenging locations.  Typical light duty locking devices, such as pin tumblers, are prone to plugging and performing poorly in “dirty” environments, such as precipitators with high amounts of fly-ash.  Castell’s lock mechanism avoids this problem with a sealing key and cap to keep out dust and debris.  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 and longevity of the interlocks.

In addition to producing products that meet Hamon’s requirements for reliable, tamper-proof safety systems, Castell has also delivered outstanding service over the course of their long standing relationship. 

“For example, on a recent project, the supply of key interlocks became a part of the project critical path.  Castell understood the importance of agreed deadlines and took immediate action to ensure on time delivery to the job site, which meant that Castell has certainly proved itself capable of meeting the high standards we demand and value,” said Ostfeld.

About Castell
Since the inception of the industrial safety industry, Castell (www.castell.com) 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.  Its products go beyond meeting legislation to create the safest working environments possible.  A Halma company, Castell has its US offices in Erlanger, Kentucky. 

About Hamon Research-Cottrell
With over 100 years experience in the air pollution control field, Hamon Research-Cottrell (www.hamon-researchcottrell.com) provides innovative state of the art air pollution and thermal control equipment to a wide array of industries.  The company is a worldwide market leading supplier of: dry and wet electrostatic precipitators; fabric filters; dry flue gas desulfurization systems; wet gas scrubbers; DeNOx, and urea to ammonia on-site generation equipment.  Hamon provides tailor made pollution control technologies to meet ever more stringent regulations, earning renown for the quality of its design, engineering, installation and after sales support.

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Trapped key interlocks prevent unauthorized access to hazardous areas
Erlanger, Kentucky (March 4, 2009) – Trapped key interlocks from Castell were chosen by China’s Qinshan Nuclear Power Plant to safeguard two new areas of the plant during a recent expansion project. 

Castell Safety Interlocks at China's Qinshan Nuclear Power Plant

Built in 1984, the Qinshan plant was China’s first domestically designed and constructed nuclear power plant.  Expansion of the plant began in 2006, and the second phase is expected to be complete in 2011.  When the project is finished, the total generating capacity of the plant will reach 2.6 million KW with an annual output of 18-20 billion KW/H.

When dealing with energy levels of this magnitude, safety is a top priority.  Castell supplied trapped key interlocking systems for the Number 3 and Number 4 units in the second phase of the project.  The interlocks were fit to the middle voltage switchboard and to the transformer system to create a reliable busbar and transformer interlocking safety system.

Castell’s trapped key interlocks force workers to adhere to a step-by-step safety process each time access to dangerous equipment is needed.  Each step releases a key which in turn permits activation of the next stage in the process.  This system ensures that contact with live transformers is impossible.

Castell’s trapped key interlocking systems are used globally in coal-fired power plants as a safeguard for lockout tagout procedures on and around electrostatic precipitators.

The durable Castell lock mechanism with sealing key and cap resists clogging for consistent performance.  Its 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 and durability.

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.

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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.

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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. 

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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. 

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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.

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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. 

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