Slicer Safety Modifications Becoming New standards of Safety for Client

Skelmerdale, Septermber 2024

The challenge

A Long-Standing client, within the Food and Drink industry, approached Elmleigh’s Mechanical team to Design, Manufacture and Install a solution to Integrate Free Issue equipment which was required for updated hardware within their production line. Concerns arose due to the operators having the ability to open the machine whilst in progress, adversely the machine would not cease to function, consequently leading to a higher risk of injury, as the machine would still be operational. Upon site surveillance, it was further noted that the process of quality control of the product harboured potential risks to the operator, leading to an increase in the Complexity of the modifications.

The Teams

- Mechanical Design

- Fabrication Team

- Mechanical Installation

The solution

The issue at hand was complex to solve. Due to the location of the slicers being embedded within the production line, the team had to utilise 3D Scanning Technology to get an accurate display of the scope of OEM they were Upgrading. This benefited the design process; our team of mechanical designers were able to Efficiently Design and Fabricate a solution to an accurate model of the process equipment. Reducing Time spent on the design process, fabrication and installation of the solution, leading to a quick turnaround on the project.

The outcome

As this project’s focus was enhancing the safety of the machine, the team designed multiple systems intending to reduce risk for the operators. Sensor Bracketry, Alignment Spigots, Identification Plates and locking Mechanisms were fabricated to ensure the new OEM equipment integrated using the current SOP’s, negating the ability to reach inside the machine during operation. Further Tear-drop Pin Locks were welded on, along with sensor brackets and flags, enacting as an e-stop system, shutting off the slicer upon the opening of the machine. A sample tray guard was fabricated to ensure that the product could still be tested at regular intervals. With an opening of 20 mm to conform to safety standards raised during PUWER, operators were able to safely check product quality using approved equipment. In addition, 2 further stainless steel Estop buttons were welded in place between the slicer operator station. 2 7-core LAPP robust cables were installed from the Pre-Panel to the slicer platform for each of the new estop push buttons. The rest of the supporting upgrades were also welded in situ, ensuring the new systems in place could not be removed or tampered with. An additional letter box was incorporated into the existing guards to allow the operators to insert the removed sample for QA purposes back into the production line. The new mechanical equipment designed by Elmleigh considered the Ergonomics required as well as the existing operator processes and safety requirements for an area which has a high ratio of manual interaction.

As this slicer was part of the client’s other production lines, the work that Elmleigh’s team did was Requested as Repeat Works at their other Sites across multiple lines, becoming a new standard of design for the client keeping their employees safe. Upon further inspection it was found that each line had Variations with their designs, each line was subsequently scanned to allow the standard design to be updated for each line and ensure smooth installation would be achieved the first time.

Find out how Elmleigh can help

Here at Elmleigh, we pride ourselves on producing solutions to hazards, ensuring that our client’s operators are not put at risk whilst undertaking their vital role. If you are finding yourselves to question the safety of your production lines, we will support you with engineering the solution.

Enquire now by filling out the form on our Contact page. Alternatively, contact us on 01455 847045. We are open to all queries you might have about our services and how we can help you.

[21807]

Value £280,577
Client Leading Crisp Snack Food Manufacturer
Location Multiple sites within the Midlands
Time On going Project

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