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​Machinery Safety Experts: Risk Assessment, Design, and Compliance Solutions

At DelaControl, safety isn’t just a tick-box exercise, it’s the foundation of every machine we design and build. Our team of certified machinery safety experts ensures your systems comply with international standards, are fully documented, and ready for audits. From initial risk assessments to final validation, we deliver machinery that’s not only safe but also reliable and efficient, minimising downtime and boosting productivity.

​Risk Assessment: Identifying and Managing Hazards

Safety begins with a thorough understanding of potential risks. Our certified experts conduct comprehensive ISO 12100 risk assessments to identify hazards, evaluate risks, and recommend targeted reduction measures. We also verify compliance with essential standards such as IEC 13850 for emergency stop functions, tailoring our approach to fit your specific industry and application 

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This phase lays the groundwork with key deliverables, including:

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  • Safety Requirement Specifications (SRS): Detailed guidelines outlining required safety features.

  • Functional Hazard Analyses: In-depth reviews to spot potential dangers in operation.

  • Failure Modes and Effects Analyses (FMEAs): Systematic evaluations to predict and prevent failures.

 

For example, in a recent project for an automotive parts manufacturer, our ISO 12100 assessment uncovered hidden risks in conveyor systems, leading to redesigned guards that reduced accident potential while maintaining production speed.

Example Risk Assessment Page 4

​Design: Building Safety into Every System

Siemens Safety PLC

Using insights from the risk assessment, we engineer safety directly into your machinery. Our designs prioritise compliance without sacrificing performance, ensuring seamless integration with your operations. We favour flexible programmable safety controllers, such as Siemens F-CPUs (fail-safe central processing units), for their advanced diagnostics, reliability, and easy compatibility with existing automation setups.

Our machinery safety design services include:

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  • Hardware and Software Architecture: Developing robust, standards-compliant structures.

  • Emergency Stop and Guard Interlock Integration: Implementing secure systems to halt operations instantly when needed.

  • Redundancy and Fault Detection: Adding back-up mechanisms to catch and address issues early.

  • Safe States and Fail-Safe Responses: Designing automatic shutdowns or reduced-speed modes for emergencies.

 

In one case, we helped a packaging facility integrate Siemens F-CPUs into their assembly line, achieving full compliance with ISO 13849 while improving uptime by 25% through smarter fault handling.

Substantiation: Verifying and Documenting Safety

Building a safe system is one thing — proving it works is another. We rigorously verify designs against ISO 13849, delivering auditable proof of the achieved Performance Level (PL), which measures safety function reliability. This ensures your machinery performs safely under real-world conditions.

Our substantiation process involves:

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  • Performance Level (PL) Calculations and Verification: Quantifying safety metrics to confirm compliance.

  • Safety Function Testing: Hands-on validation against initial requirements.

  • Design Substantiation Reports: Comprehensive, traceable documentation for audits.

  • Independent Reviews: Conducted by third-party certified safety professionals for unbiased assurance.

 

A food processing client, for instance, benefited from our PL-d verification on high-speed mixers, providing documented evidence that satisfied regulatory inspections and prevented costly recalls.

Safety Logic

Why Choose DelaControl for Machinery Safety?

Certified Experts: Our team holds industry-recognised certifications in machinery safety.

Standards Compliance: Proven expertise in ISO 12100, IEC 13850, ISO 13849, and more.

Complete Documentation: From SRS to full substantiation reports, we handle it all.

Practical Solutions: We focus on real-world efficiency, ensuring safety enhances, not hinders,  your operations.

Proven Track Record: Years of experience across industries, delivering compliant, high-performance systems.

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