Castell USA News - a Halma PR news blog

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. 

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. 

Customers to benefit from new imaging systems for machine safety

Erlanger, Kentucky and Seattle, Washington (November 5, 2007) – Castell and Newton Research Labs, Inc. have partnered to develop the next generation of machine guarding systems.  By incorporating a sophisticated three dimensional imaging technology and redundant system components, the new systems will provide a far more efficient and cost-effective means of protecting personnel and property than traditional machine guarding methods.

Castell has been a leader in industrial safety solutions since 1922, with a portfolio of unique and reliable products designed to eliminate human error in a wide variety of industries.  Newton Research Labs is a manufacturer of machine vision, robotics and optical automation whose products allow the quality, efficiency and cost-effectiveness of computer technology to replace the human element in virtually every industry. Combining time-tested experience and new vision technology, Castell and Newton Labs are working together to finalize a high quality imaging system that is both a budget-friendly and fail-safe solution to machine guarding.

“Castell was founded on what are today considered to be simple mechanical interlocks,” said Castell President Thomas Schluep.  ”At the time, however, they were cutting edge technology.  Over the years we have continued to stay at the forefront of innovation in the machine guarding and safety industries.  Aligning with Newton Labs brings us the latest imaging technology and expertise to continue meeting changing industry demands.”

“We are very pleased to be able to work with such an experienced, successful company as Castell,” said John W. Bramblet, President and CEO of Newton Labs. “This is an opportunity for Castell to answer the demand from its worldwide customer base for this specific solution.”

 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 U.S. offices in Erlanger, Kentucky. For information on the company’s full range of products, go to www.castell.com, or call 859-341-3075. 

About Newton
Seattle-based Newton Research Labs, Inc. is a privately held manufacturer of machine vision, robotics and optical automation.  A spin-off of MIT, the company has for more than 15 years developed and marketed high-performance, computer-driven automation for industrial processes.  Newton’s products are designed to allow the quality, efficiency and cost effectiveness of computer technology to replace the human element in virtually every industry.  Newton Labs has deployed more that 15,000 machine vision, robotic and automation systems worldwide.  Additional information about Newton and its products may be found at www.newtonlabs.com.

Castell prevents explosions and drive-aways in Class 1, Division 2 Facility

Erlanger, Kentucky (October 31, 2007) – When a large flooring manufacturer recently upgraded its laminate milling area, the company took proactive steps to assure the continued safety of its facility with the addition of equipment from Castell.  The unique combination arrangement of a Castell Earth-Line static discharge unit and Salvo trailer interlocking safety system protects against both potential explosion hazards from dust generated in the milling process and unscheduled truck departures in the loading area.

At the company’s wood flooring facility, dust collected from the milling process is made into fuel pellets with an on-site pellet mill.  With the new configuration in place, this “wood flour” can go from the milling line to one of three places: directly to the pellet mill, a storage silo, or a waiting tractor trailer.  Diverter valves and conveyors direct the flour to where it is needed, based on the availability and capacity of the pellet mill, the silo, or a waiting trailer. 

As a Class 1 Division 2 facility, the company had to manage the explosion proof requirements of its classification while working with contract truckers.  The wood flour creates a potentially unsafe environment where static discharge from a truck being driven away at the wrong time could create an explosion.  Even without the static discharge danger, unscheduled truck departures pose a threat to workers and potential for damage to loading docks and equipment.  To ensure that trucks could not be filled with product or moved without proper safety precautions, the company worked with Castell and its distributor to design a combination Earth-Line grounding and Salvo interlocking system.

When a trailer is parked at the hopper and ready to receive a load of wood flour, the Salvo gladhand lock is attached to its brake line, securing the device in place and releasing a uniquely coded key.  That key is then inserted into the Earth-Line and is trapped.  Plant personnel then manually make a ground connection to the trailer, sending an electrical interlock signal to the enable the conveyer’s motors.  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. 

Once the grounding connection is made, a second uniquely coded key is released from the Earth-Line unit.  This key is used to open the lock on one of two diverters to direct the flour away from the pellet mill, to either the silo or trailer.  This key is trapped in the diverter until the pellet mill is back in use and ready to receive flour again from the milling line.  A proximity sensor detects the valve position and sends an enable signal to the motor controller that the trailer is grounded and ready to receive a load of dust from the hopper.  When the trailer is full and ready to be moved, the process is reversed.  Until the flour is routed back to the pellet mill, the diverter will not release its key.  Without this key, the Earth-Line will not release the first key, which opens the Salvo gladhand lock, making it impossible for a truck to depart.

“This facility presented a real challenge to tie the trailer in place and safely handle its explosion proof requirements.  The addition of contract truckers who may not know, or follow, proper safety procedures brought further variables to consider,” explained Mike Pille of Southern Sales, a Castell distributor.  “The combination of Castell’s Earth-Line and Salvo was the perfect answer to minimize the possibility of human error and maximize safety.  After two and a half years in operation, the processing lines have run smoothly, without any static discharge or drive-away incidents.” 

Remodel doubles square footage

Castell is preparing for anticipated future growth with a full facility expansion and upgrade.  A two month remodel project has doubled the square footage to create a working environment befitting the company’s aggressive growth goals.

 
Castell has taken over new space in the same location at Kenton Lands Road in Erlanger (shared with fellow Halma group companies Aquionics, Crowcon, Fortress Interlocks, Palintest, and Smith Flow Control), increasing the square footage from 800 to 1600.  In addition to more space, the new facilities have better natural light and a more collaborative feel.  Two walls of windows enclose the previously windowless office space and cubical walls have come down to create a more open workspace.  The new environment was designed to promote creativity, facilitate working together, and create a sense of company pride. 

The company now has a professional looking space in which to work with customers and the room to grow their team.  Being able to keep up with growing demand with added personnel will allow Castell to maintain a consistently high level of customer service.

“I am very confident about the future of Castell,” said Thomas Schluep, President of Castell. “Our strategy is to first operate in markets which are constantly growing due to increased safety demands.  Second, we are diversifying in technology and applications, bringing new high-tech products into our portfolio of traditional lock mechanisms.  And third, our new infrastructure has created a foundation which will enable us to implement this strategy and be one step ahead of the competition in both innovation and technology.”