The challenge
What needed to change.
Existing guards allowed access to hazardous areas, machine movement could continue after access, and emergency-stop circuits were not integrated to the required standard.
Machine safety · Life sciences & chemical
Production-line safety upgrade
A coordinated mechanical and electrical upgrade that brings an established capping line up to modern safety standards.
ClientThermo Fisher ScientificSectorLife sciences & chemicalPrimary disciplineMachine safety
Adbro’s approach
How the solution was engineered.
Adbro designed the new guarding, access controls and safety circuitry together, treating the existing production line as one connected system.
The outcome
What the project delivered.
The upgrade improves operator protection, supports safer intervention and provides a compliant control strategy without replacing productive machinery.
Technical delivery
Inside the engineered solution.
The detail below shows how the main equipment, software and interfaces were brought together—not just what the project achieved.
System scope
- Extruded-aluminium and polycarbonate guarding
- Pneumatic safety dump valves
- Line-wide master safety panel
- Pilz Multi safety control with distributed I/O
- Coded guard locking and replacement guard switches
- Integrated emergency-stop system
- Diagnostic HMI and periodic global-stop test
Line-level safety architecture
A new master panel coordinates safety across the connected machines. Its isolating contactor can remove power from the line when a global emergency stop is demanded.
Guarding and hazardous energy
Additional guards close identified access points. Pneumatic dump valves remove stored pressure where actuator movement could present a hazard during intervention.
Monitored access
Coded magnetic devices replace unsuitable switches, with locking used where machine rundown must complete before a door can be released.
Diagnostics and proof testing
The HMI shows the state of safety devices, records faults and guides a scheduled global emergency-stop test so problems can be identified before they are needed in an event.
Verification & handover
The safety functions were documented and tested across the complete line. A SISTEMA report supported verification of the control-system performance, with functional validation covering guards, locks, emergency stops, pneumatic isolation, reset behaviour and diagnostics.
Project highlights
GuardingSafety interlocksEmergency stopsValidation
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