Upgrading Old Machinery: 4 Critical Safety Improvements Every Manufacturer Needs
As industrial machinery ages, breakdowns increase, safety diminishes, and compliance with regulations such as PUWER becomes challenging. Thankfully, manufacturers can significantly enhance safety, reduce downtime, and stay compliant by addressing four critical upgrades.
1. Emergency Stop (E-Stop) Upgrades
Reliable E-Stops are legally required and vital for operator safety. Older systems often suffer from worn contacts, poor positioning, or slow responses. To upgrade:
- Install modern twist-to-release or mushroom-head E-Stops.
- Position according to ISO 13850 guidelines for optimal accessibility.
- Regularly test and maintain to ensure functionality.
2. Retrofitting Modern Safety Guards
Many older machines have inadequate guarding, risking operator safety and compliance. Modern guards, like clear polycarbonate with interlocking features, stop machines instantly when opened:
- Choose quick-install guard kits for rapid upgrades.
- Ensure interlocked guards meet PUWER Regulation 11.
3. Updating Control Panels (EN 60204-1 Compliance)
Old control panels pose risks due to deteriorating wiring and outdated safety features. To comply with UK standards:
- Install modern circuit breakers and safety relays.
- Clearly label wiring and maintain updated diagrams.
- Incorporate safety-rated components such as safety PLCs with PLC programming.
4. Adding Remote Monitoring & Safety Interlocks
Remote monitoring boosts safety and productivity by providing real-time machine alerts and remote lock-out/tag-out:
- Implement IoT gateways or PLC extensions for remote alerts.
- Install safety interlocks to halt machinery under unsafe conditions.
- Set up affordable monitoring systems quickly and efficiently.
Conclusion
Implementing these upgrades will greatly improve safety, ensure regulatory compliance, and reduce downtime. Start today by downloading our free PUWER Checklist or contacting us directly for a no-obligation safety consultation. Let's ensure your machinery remains safe, compliant, and reliable.