Castell Salvo Protects Loading Docks

Drive-away prevention system mitigates human error
Chicago, Illinois (April 4 , 2014) – Castell’s Salvo™ Loading Dock Safety System drive-away prevention products promote safety on automatic and manual loading dock doors. The brake line interlocking system minimizes the possibility of human error to protect workers from injury and property from damage.

Castell's Salvo

Castell’s Salvo brake line interlocking system prevents premature loading dock drive-aways.

Fast, safe access is an important issue in loading docks. The Salvo system prevents injury and damage to loading platforms by making it impossible for trucks to drive away during loading or unloading. Salvo’s Glad Hand Lock attaches to the truck’s emergency brake line, ensuring brakes are applied. This provides worker safety and ensures compliance with OSHA 29 CFR 1910.178 and FMCSA 49 CFR 393.41 vehicle loading requirements.

Once the Gland Hand Lock is applied, the uniquely coded key is released. This key is then used to open the dock door to begin loading or unloading the trailer. Only after work is completed and the door closed is the key needed to unlock the Salvo Glad Hand Brake Lock released, making it impossible for the driver to depart prematurely.

A number of custom Salvo configurations are available. The range includes manual and automatic door systems, brake line locking options, accessories and a new efficiency enhancing software program, DockMonitor. The software captures operational data such as loading time, number of operations, idle time and available time, measuring performance while still guaranteeing safety.

To see a video demonstration of the Salvo in use, visit http://www.castell.com/us/salvo/.

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New Vehicle Restraint Prevents Drive Aways

Salvo™ Chock quick and easy to use
Chicago, Illinois (March 1, 2013) – Industrial safety specialist Castell’s interlocking wheel chock, Salvo™ Chock is specifically designed for restraint of straight trucks and other vehicles that cannot be locked out with a Salvo glad hand lock. Ideal for demanding loading yard conditions, the chock is light, strong, easy to use and fast to maneuver.

Salvo™ Chock is specifically designed for restraint of straight trucks and other vehicles that cannot be locked out with a Salvo glad hand lock.

Salvo™ Chock is specifically designed for restraint of straight trucks and other vehicles that cannot be locked out with a Salvo glad hand lock.

The Salvo system restrains vehicles at loading docks during loading or unloading. Its technology uses safety interlocking to eliminate human error and enforce safety procedures. If the Salvo Chock is not properly fitted, the loading dock door cannot be opened.

Drivers position the chock and clamp the two halves together around the wheel using a convenient foot pedal, releasing the trapped key. The key is then transferred to the loading dock control panel, allowing the loader inside the warehouse to open the door and begin safely loading or unloading.

To remove Salvo Chock, the loader must first close the loading dock door. The driver can then remove the key from the control panel and return it to the chock. Inserting the key unlocks the chock and traps the key until it is again properly fitted on a tire.

Launched eight years ago to prevent drive aways in the logistics industry, the Salvo range has grown to address key market needs. It includes manual and automatic door systems, brake line locking options, accessories and a new efficiency enhancing software program. DockMonitor software captures operational data such as loading time, number of operations, idle time and available time measure performance while still guaranteeing safety.

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Maximize Loading Dock Efficiency with Salvo™ DockMonitor

Dock management system displays real-time site performance and individual dock statistics
Chicago, Illinois (October 9, 2012) – Industrial safety specialist Castell Interlocks Inc. has developed a data-gathering and analysis product to maximize loading dock efficiency. Salvo™ DockMonitor integrates with the company’s Salvo™ Loading Dock Safety System to display live graphic information running on a PC interface for assessment of overall site performance and individual dock statistics.

Salvo DockMonitor tracks loading dock activity for reporting and analysis.

Salvo DockMonitor tracks loading dock activity for reporting and analysis.

Effective safety systems help prevent accidents, keeping workers safe and complying with OSHA standards. Combining the Salvo DockMonitor with Salvo Loading Dock Safety System can meet safely goals while also maximizing efficiency, optimizing use of resources, and assisting in cost reduction analysis.

Salvo Dock Monitor enables loading operations to run more efficiently by providing crucial information in real time. Dock personnel and activity benchmarking includes:

  • Tracking efficiency and frequency of use of each dock
  • Monitoring load and unload times
  • Comparing shift performances
  • Logging carrier information to a specific dock
  • Scheduling dock maintenance based on dock usage
  • Measuring maintenance down time

The system’s report function generates reports on these criteria which can then be exported to a range of standard file formats for further review and analysis. With this data costs can be cut by potentially reducing the number of loading docks required in a facility or suggesting increased activity for company growth, ensuring assets are used as efficiently and economically as possible.

The Salvo Loading Dock System eliminates risk of unscheduled truck departures from loading docks. The brake line interlocking system minimizes the possibility of human error to protect workers from injury and property from damage. Pairing this proven safety technology with the new Salvo DockMonitor feature ensures that loading remains safe, even while speed and efficiency are increased.

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Castell’s Multi-voltage Solenoid-controlled interlock for UPS System Safety

KSUPS+ improves delivery times and safety rating
Chicago, Illinois (April 27, 2012) – Industrial safety specialist Castell has launched a new multi-voltage interlock primarily for use with uninterruptible power supply (UPS) systems. The KSUPS+ is a solenoid-controlled trapped key interlock that only permits access to a UPS system once the system has been put into a safe condition.

The KSUPS+, Castell’s multi-voltage interlock for uninterruptible power supply (UPS) systems.

The KSUPS+, Castell’s multi-voltage interlock for uninterruptible power supply (UPS) systems.

The KSUPS+ features a number of design improvements, including multi-voltage input. Having a wide voltage input range means that a single device now replaces eight previous devices; the input voltage for the KSUPS+ ranges from 24 V AC or DC to 220 V AC or DC.

As a safety device, the integrity of the KSUPS+ is vital. A monitored solenoid increases the safety performance rating of the KSUPS+, ensuring a higher level of protection for personnel while working on UPS systems.

Castell has also reviewed improved the operational efficiency of the KSUPS+, with clear indication of where the safety component is located on a switchgear panel. The KSUPS+ retains the same mounting dimensions as the previous unit for easy retrofitting.

Inserting and turning the key operates four pole switch contacts and allows the system to run. The key remains trapped and can only be released when a signal is received by the device and the solenoid is energized. Removing the key switches the contacts to the ‘off’ state, and the key can then be used to open the access interlock.

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Salvo™ Drive-Away Prevention System for Loading Dock Safety

New Salvo Control Panel+ improves operational performance and installation time
Chicago, Illinois (February 14, 2012) – Castell’s Salvo range of drive-away prevention products promote safety on automatic and manual loading dock doors. Its new Salvo Control Panel+ (SCP+) is easier both to use and install.

Castell's Salvo Glad Hand Lock and SCP+

Castell's Salvo Glad Hand Lock and SCP+

Fast, safe access is an important issue in loading docks. The Salvo system prevents injury and damage to loading platforms by making it impossible for trucks to drive away during loading or unloading. Salvo’s Glad Hand lock attaches to the truck’s emergency brake line, ensuring brakes are applied. This provides worker safety and ensures OSHA 29 CFR 1910.178 and FMCSA 49 CFR 393.41 vehicle loading requirements compliance.

Once the Gland Hand Lock is applied, the uniquely coded key is released. This key is then used to open the dock door to begin loading or unloading the trailer. Only after work is completed and the door closed is the key needed to unlock the Salvo Glad Hand brake lock released, making it impossible for the driver to depart prematurely.

A number of custom Salvo configurations are available for powered and manual doors, tanker unloading applications and even loading areas without doors. Sites with numerous doors often choose to install the Salvo Control Panel to improve loading efficiency and ease of install. The control panel delivers operating efficiencies by visually indicating loading dock availability, reducing needless wait time and confirming the presence of trucks ready for loading or unloading.

The new SCP+ further increases productivity with an illuminated lock ideal for use 24/7 operating environments. Entirely visual operating instructions eliminate language barriers and shorten the learning curve.

SCP+ has also been designed for simpler installation. A new ergonomic enclosure allows for fast access to the electrical terminals and reduces wiring time. The multi-voltage panel is suitable for 24V AC, 24V DC, 110V AC or 230V AC supply.

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Castell Introduces New Key Exchange Unit

Fully welded design reduces potential dirt and food traps
Chicago, Illinois (April 5, 2011) – Key exchange units from industrial safety specialist Castell form part of an integrated safety system linking machine control and access interlocks. Its new X-type key exchange unit has an extremely robust design for reliable use in a wide variety of environments.

Castell’s new X-type key exchange unit reduces potential dirt and food traps.

Castell’s new X-type key exchange unit reduces potential dirt and food traps.

The key exchange is configured to trap and release keys in a pre-determined sequence, depending on the operating requirements of the safety interlocking system. The X box can have multiple keys entering and/or withdrawing. It can be supplied in numerous key configurations: one key to release three or six keys to release four, or any combination to suit the operating sequence of the machine.

Both ergonomic and durable, the unit’s enclosure is fully welded for increased rigidity. Newly designed locks, relocated to be rear mounted, have no visible fixing holes, reducing opportunities for dirt or food to be trapped and interfere with operation. 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.

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

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New Castell Iso-Lok Doc Combo Board Launched

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.

Doc Combo

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. 

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QUADCAM ADDS DIMENSION TO MACHINE GUARDING WITH 3D IMAGING

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

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.

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CASTELL PACKAGES SALVO LOADING DOCK SAFETY IN CONVENIENT KIT

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.

 salvo

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.

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CASTELL SALVO SAFEGUARDS MILLENNIUM INORGANIC CHEMICALS SITE

Drive-away prevention system in place at Maryland distribution facility
Erlanger, Kentucky (June 18, 2007) – When a truck pulled away prematurely from his plant, causing a dock plate to fall, warehouse Distribution Superintendent Chris Gagliardi was convinced of the need to physically restrain trucks during loading and unloading.  The incident could have caused serious injury to a worker at Millennium Inorganic Chemicals’ Baltimore, Maryland distribution facility.  Millennium selected Castell’s Salvo trailer interlocking safety system to prevent unscheduled truck departures, reducing risk to workers and potential damage to loading docks and equipment.

CASTELL SALVO SAFEGUARDS MILLENNIUM 

In choosing a safety solution, Millennium evaluated both traditional bar systems and the Salvo system. Salvo’s error proof design and cost-effectiveness were driving factors in its selection.  Eight Salvo Automatic Interlock Systems were installed at the plant.  Each system consists of a Salvo gladhand lock, control panel, automatic door interlock and barrier chain.

Upon arriving at the plant’s loading docks, drivers attach the Salvo gladhand lock to their brake line, securing the device in place and releasing a uniquely coded key.  The lock ensures that brakes are applied and trailer movement has stopped, in compliance with FMSCA’s braking requirement. The driver then turns that key in the exterior control panel, which traps the key, disengages the automatic door interlock and alerts workers inside the plant that it is safe to unbolt the lock, remove the barrier chain and begin loading or unloading.  Until the barrier chain is replaced and the automatic door interlock is bolted, the control panel will not release the key needed to open the Salvo gladhand lock, making it impossible for a driver to depart.

“Since installing the systems over a year ago, we haven’t had a single incident of a truck pulling away.  Our workers have fully embraced the Salvo’s error proof design and the peace of mind it gives them,” said Gagliardi.

“The Salvo system avoids the pitfalls of procedures that rely on drivers to avoid accidents,” Gagliardi continued.  “One of these methods is requiring drivers’ keys while loading and unloading; we still have a set of keys from months ago.  Clearly the driver did not give us the keys to his trailer.  Without the Salvo system, he could have easily made an unscheduled and unsafe departure.”

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