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Pulp and Paper Machine Builder Creates Safety System That Streamlines Machine Design and Protects Workers


Manufacturing engineers use integrated safety system to reduce waste and cut costs.


Manufacturer of roofing shingles for residential construction.


The manufacturer faced an issue with their current light curtains being obsolete. The equipment was so old they could no longer find a source for what was installed. They needed competitive pricing to what they had been purchasing as well as someone that could review their applications, wiring and devise a solution. They could no longer find a source to sell them their light curtains because they were obsolete. This caused a large problem for them because it interfered with operating their production lines safely and effectively.


Previously, the systems consisted of several machines linked together that automatically cleaned the remaining paper off the cardboard cylinders and transported them to a core joiner. The joiner would remove the damaged ends, join the good portions of consecutive cores and cut the new cylinders to the correct lengths. Each system is customized to customers’ specific needs and seamlessly integrated into their process. The process consists of the crane that hoists the used cylinder from the previous machine and positions it in the automatic core cleaner, the roll loader, buffer crane and core joiner. There are many moving parts and pieces to consider and manage.

To easily connect multiple machines in a control’s solution that integrated safety, motion, discrete and drive control was needed.


There were many challenges that were faced with this solution because of the size of the system. Traditional hardwired safety circuits were too cumbersome and complicated to troubleshoot future upgrades and maintenance. The Machine Builder, McNaughton-McKay and Rockwell Automation worked together to design and implement a safety-control system that would help to eliminate these issues. The new system relies on EtherNet/IP which allows for the safety system to reside on the same network and share data between the safety and standard applications. This helped to eliminate an entire system shutdown when a safety event happened in only one section of the system. With the use of an Allen-Bradley PanelView Plus HMI, plant personnel can respond quickly and return machines to full operation should an event occur.

The new core cleaning and joining system was upgraded with an Allen-Bradley PowerFlex® 755 AC drives with a safe-off function. Additionally, an Allen-Bradley Kinetix® 6000 or 6500 drive can be used to manage all the machines’ motion axes. With the Kinetix drive on the same network as the EtherNet/IP and PowerFlex 755 AC drive, the machine design is simplified. Engineers can configure, program and control both drives using the same embedded instructions for standardized operation.


Reduced Engineering Hours and Costs for Machine Builder

  • Hardwiring efforts are reduced by 75% because of the new integrated safety system
  • Factory acceptance testing is done in hours instead of days or weeks
  • It is estimated that engineering hours for programing and software design are cut in half

Enhanced Sustainability for End Users

  • Scrap reduced by 80%
  • Millions of dollars a year are saved because less paper needs to be recycled.


  • Allen-Bradley GuardLogix
  • Allen-Bradley Kinetix 6500
  • Allen-Bradley POINT Guard I/O
  • Allen-Bradley PowerFlex 755 AC
  • Rockwell Automation machine safety consulting