When a company with over a century of experience in the chemical sector they are contacting us with a clear concern —“we want our machines to be safer for those who use them every day”—, we know this is an important project. Because behind every machine, there are people. And behind every adaptation, there is an opportunity for caring for those who make production possible.
On this occasion, we are travelling to Tres Cantos, Madrid, to intervene on a fragrance bottling line. The objective was clear: improve the security of a machine which formed part of the production process, adjusting it to the requirements of RD1215/1997.
The key Combine protection, accessibility, and continuity in operations.
Risk assessment of chemical bottling machinery
During the initial visit, the first thing the team conveyed to us was their concern about a specific area of the facility. During certain stages of the process, the operators had to insert plugs manually while the machine was still running.
This direct intervention generated a Constant sense of danger, something that cannot be allowed in a healthy work environment. And furthermore, it did not comply with current industrial safety regulations. It was time to act.
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Installation of polycarbonate cages for suitability according to RD1215
We proposed a simple yet effective technical solution: Install a custom-made polycarbonate cage, who would completely cover the machine. This structure not only protected personnel but also offered full process visibility thanks to the use of transparent materials.
But the real added value was in the sensor doors. When integrating them with Magnetic sensors, it was guaranteed that the machine only works with all accesses properly closed. This allowed the team to carry out tasks of maintenance, cleaning or inspection with complete safety.
How to balance safety and production without stopping the machine
We know that, in some cases, there are processes that require the Operator interaction while the machine is running. How to ensure protection without hindering production?
The answer was design a door without a sensor, but with physical protections What they keep dangerous moving parts isolated. This way, the operator can work safely, even with the machine running.
These types of solutions allow combining automation with manual intervention, complying with the technical requirements of RD1215 and maintaining operational efficiency.
Benefits of adapting industrial machinery with caging solutions
The installation of the cage brought with it immediate benefits:
Full compliance with RD1215, avoiding sanctions.
Risk reductionThe dangerous points were completely isolated.
Improving the working climateThe team feels more secure and supported.
Effective retrofitThe machine was modernised without being replaced.
Furthermore, the cage allows to see the process without compromising protection, and the Magnetic sensors provide an extra layer of security without affecting production.
Machinery suitability: an investment in safety and people
This project reminds us that safety should not be understood as a legal obligation, but as a daily commitment to those on the shop floor.
When a company decides to adapt its machinery, it is saying: “you matter to us”. You are betting on environments secure, sustainable and humane. And we, as part of that journey, we place all our experience and closeness so that each solution is effective and realistic.
