Project Overview

ESA were engaged to assess and improve the safety of a loading mechanism used to transfer sling/stillage onto a slow-moving buffered production line.

The Challenge

A new loading mechanism had been introduced, replacing an existing pneumatic system with a motorised solution.This change created new potential hazards, including:

• Automatic movements within the loading area
• Increased risk during start-up operations
• Uncertainty around whether existing safety measures were still adequate

The system required a full safety review to ensure compliance with current standards and safe operation.

Key Improvements Implemented

Following the assessment, we recommended and implemented a range of safety enhancements:

• Audible warnings for automatic start-up operations
• Additional guarding around moving components
• Floor safety monitoring using scanner systems
• Clearly defined safety zones
• Additional emergency stop points
• Improved hazard signage in key areas

These measures reduced operator risk and improved overall system safety.

System Classification & Validation

Using industry-standard tools such as SISTEMA, we verified that all safety-related control systems met the required performance levels.

This ensured:

• Compliance with safety standards
• Reliable long-term operation
• A system designed for a 20-year lifecycle

The Outcome

• Improved safety for operators working around the loading area
• Full compliance with current machinery safety standards
• A clearly defined and validated risk reduction strategy
• Greater confidence in the system’s long-term performance