Safety Control System Upgrades for Three Cupper Presses in a Packaging Facility
Sector:
Packaging
Type:
New Build - Control System, Safety
Platform:
Allen Bradley
Certification:
CE / UKCA
Summary
DelaControl designed, built, and installed dedicated safety control panels for three cupper presses at a UK packaging facility, upgrading the safety guarding circuits to Performance Level e (PLe) in accordance with ISO 13849-1. The project covered all three press lines, each receiving a bolt-on enclosure housing new safety components, lockable guard switches, and a standstill monitor, with on-site installation carried out by DelaControl engineers.
Challenge
A UK packaging manufacturer operating three cupper presses (two of the same type and one of a different type) identified a need to reduce the risk of human interaction with the power press mechanisms. The existing machines lacked guarding provisions capable of meeting modern safety standards.
The customer required the safety guarding circuits across all three lines to be upgraded to Performance Level e (PLe) in preparation for the future addition of servo infeed units, and requested full design, supply, build, documentation, certification, and on-site installation as a single turnkey scope.
Solution
DelaControl designed a dedicated bolt-on safety enclosure for each press, housing the new safety components alongside the existing control panel rather than modifying the original panel internals — an approach chosen to preserve existing aged cabling and work within available panel space. Safety contactors were fitted in-line with the main press motor supply within the existing drive panel. Each enclosure was built around a Rittal steel enclosure (RAL 7035) with Allen Bradley safety contactors, Allen Bradley guard locking switches rated to PLe, and a Pilz standstill monitor forming part of the safety circuit. Guard release push buttons and an emergency stop were mounted on the front face of each new enclosure. Volt-free contacts were provided for interfacing with the Perfecto servo infeed units' STO signals.
The complete documentation package included electrical schematics produced in AutoCAD Electrical or Eplan, general arrangement drawings in AutoCAD Inventor, a SISTEMA report confirming the achieved PLe rating against ISO 13849-1, thermal calculations using Rittal Therm software, a Factory Acceptance Test (FAT) schedule and signed certificate, and a Declaration of Conformity covering the Low Voltage Directive and EMC Directive. The customer was invited to a FAT at DelaControl's Bristol facility prior to delivery.
On-site installation was carried out by DelaControl industrial electricians, with two engineers allocated per machine for up to three days each. Line A and Line B required four lockable guard switches each; Line C required three.
Key Facts
Three cupper press lines upgraded — two identical type and one variant
Safety performance level: PLe (ISO 13849-1), verified by SISTEMA report
Allen Bradley 440G TLS-GD2 lockable guard locking switches — 4 per Line A and B, 3 per Line C
Allen Bradley 100S-E 190 A safety contactors (qty 2) fitted in-line with main press motor supplies
Pilz standstill monitor and dual-channel Pilz safety relays incorporated in each safety circuit
Rittal AX steel enclosures, RAL 7035, used for all three bolt-on safety panels
Murrelektronik MICO Pro electronic circuit breaker module used for 24 V DC distribution
Full documentation package: schematics, GA drawings, SISTEMA report, thermal calculations, FAT schedule and certificate, Declaration of Conformity
On-site installation