When a Midwest pharmaceutical manufacturer identified unsafe operating conditions on a pneumatic stamping press, they partnered with Feyen Zylstra to bring the machine up to current safety standards and provide reliable protection for operators. The existing press presented risks during certain machine sequences and needed an upgrade to address both immediate safety concerns and long-term operational reliability.

Feyen Zylstra delivered a fully integrated safety and controls solution through a design-build approach, starting with a review of the press to identify hazards and develop a mitigation plan. Our team replaced the main pneumatic cylinder and process control valves and programmed a Keyence safety controller to protect operators reaching into the machine. Additional electrical upgrades migrated controls from 120V to 24V, separated remaining 120V wiring into its own enclosure, and consolidated several add-on panels into a single, improved control panel.

The primary challenge was defining the machine's mechanical requirements and specifying the correct replacement components. Feyen Zylstra worked closely with the component supplier and performed multiple calculations to verify the design and component selections before implementation. This collaborative, detail-driven approach ensured that every upgrade met the customer's safety and operational requirements.

Since implementation, the upgrades have delivered a safer, more reliable machine. After the upgrades, the system automatically removes hazardous energy during service and secures the load in position. The project's success was driven by collaboration between Feyen Zylstra's engineering, panel shop, and electrical service teams, delivering lasting value and supporting the customer's commitment to operator safety and reliable production.