Industrial Safety System Upgrade

Project Overview

We delivered a comprehensive safety PLC upgrade across 13 tuft and carpet manufacturing machines for a global carpet tile manufacturer.

The existing safety systems required modernisation to meet current machine safety regulations and improve functional reliability. The objective was to ensure full compliance while enhancing machine control and operational performance.

The upgrade introduced a failsafe PLC platform with integrated programmable safety functions, giving the client greater control, improved diagnostics and long-term scalability.

Scope of Work

All work was completed within a one-week installation and commissioning window, minimising disruption to production.

The upgrade included:

• Rapid fault detection and correction to reduce downtime
• 7” HMI operator touch panel for intuitive control
• Siemens Failsafe PLC integration improving both safety and productivity
• Installation of multiple safety light curtains
• Alarm logging and detailed fault history for faster diagnostics
• Real-time overview of machine safety function status