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Client: Leading Metals Manufacturer
Client Type: End User
Industry: Metals Production & Processing
Location: UK
Scope: Multi-phase safety integration programme connecting new robotic cells with legacy machinery and site-wide control systems.
Enhanced safety and regulatory compliance
Achieved Performance Level “d” (PL’d) across integrated systems
Seamless communication between multiple PLC platforms
Collision risk eliminated through automated prevention logic
Safe and scalable integration of new and legacy machinery
Minimal operational disruption across all project phases
With the installation of two new industrial robot cells, our client required a robust safety solution capable of unifying both modern and legacy infrastructure.
Existing safety guarding around the ingot handling area—specifically the ingot gates—was not performance-rated and failed to satisfy machine risk assessment requirements. In addition, the plant relied on multiple PLCs controlling independent parts of the process, including the gate, hoist, knives, ingot system and robot cell.
This complex control landscape posed significant challenges:
Safety compliance issues across outdated guarding systems
Lack of coordinated PLC-to-PLC communication
Increased risk of operational hazards and mechanical collisions
Need for a scalable, phased safety architecture aligned with future expansion
Our client required a centralised, compliant and future-proof safety solution to ensure operators could work safely while maintaining high levels of productivity.
iconsys designed and delivered a fully integrated safety automation architecture achieving the required Performance Level “d” (PL’d) across both new and legacy equipment, while ensuring safe, synchronised operation.
Implemented a new Siemens S7 Safety PLC as the overarching gate access controller
Integrated new guarding and access systems to separate ingot hoist and robot areas
Installed a Fortress interlocked gate solution using Profisafe-enabled POE devices
Retrofitted manual gates to meet safety compliance
Installed and fully integrated new automatically actuated gates for safe robot-cell operation
Introduced point-to-point Ethernet communication between all relevant PLCs, including:
Gate, Hoist, Knives, Ingot and Robot PLCs
Added a new communication processor and managed network infrastructure for real-time data exchange
Updated existing SCADA HMI pages to provide full system visibility and operator clarity
Integrated new position-feedback devices within the hoist system
Developed new PLC logic to prevent hoist entry into unsafe zones based on real-time gate status
Successfully eliminated mechanical conflict across all interconnected systems
All engineering, software development, documentation and commissioning were delivered in accordance with UKCA/CE safety directives and relevant industry standards.
iconsys’ integrated safety solution has transformed operations at our client’s business, delivering:
Fully compliant safety infrastructure meeting PL’d requirements
Effective integration of both new robotic cells and long-established systems
Significant risk reduction, including complete elimination of collision hazards
Improved operator safety through coordinated access control and automated gate logic
Operational continuity with minimal production downtime
Future-ready scalability, supporting additional phases and system expansions
iconsys brings deep expertise in safety automation, system integration and industrial digitalisation. Our multidisciplinary engineering teams specialise in bridging old and new technologies—helping customers modernise safely, efficiently and with minimal disruption.
We provide:
Certified safety engineering competence
Proven experience integrating multi-vendor PLC environments
Turnkey project delivery from design and software through to commissioning
Long-term support, documentation and lifecycle services
Our commitment is to deliver safe, compliant and high-performance automation solutions tailored to the unique needs of complex industrial environments.
At iconsys, safety is a central part of every project we deliver. Our approach is consistent with the principles described in the Machine Safety section of our website, where we focus on protecting people, maintaining uptime and supporting full compliance with current safety standards.
Our TÜV-certified engineers follow our structured SHIELD methodology, which supports all stages of the functional safety lifecycle. This includes hazard surveys, defining safety requirements, system design and engineering, performance verification, validation in real operating conditions and continued compliance throughout the system’s service life. The process provides clear traceability and aligns with standards such as ISO 12100, EN ISO 13849-1:2023 and BS EN 60204-1.
We work with technology from a wide range of industry-leading suppliers including Siemens, ABB, Rockwell Automation and Schneider Electric. This ensures each safety solution is matched to the plant, process and operational objectives of the customer, whether it is a leading metals manufacturer or an organisation within another sector.
For a full overview of our safety capabilities, our SHIELD process and our wider engineering expertise, please visit the Machine Safety section of our website.
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