Client
Sector
BONNER Provided
Project Overview
A Dublin-based pharmaceutical manufacturer engaged BONNER to design and install a hardwired safety system across two Clean-in-Place (CIP) wash rooms.The objective was to improve machinery safety by ensuring wash cycles could not operate with access doors open and that doors remained secured during active cleaning cycles.
Working alongside the site’s existing control system integrator, BONNER delivered the hardwired safety design, equipment installation, commissioning and functional testing within a live, validated pharmaceutical facility.
The Challenge
The manufacturer required consistent safety functionality across both CIP rooms, ensuring:
- Wash cycles could not start with a door open or emergency stop activated.
- Doors remained locked during active wash cycles.
- Emergency stops brought the process to a safe stop before allowing access.
- New safety functions integrated with the existing automation system.
The hardwired safety functions were designed and verified in accordance with ISO 13849-1, with minimal disruption to ongoing site operations.
BONNER designed, supplied and installed a dedicated hardwired safety system for both rooms.
Each installation included:
- Safety door position sensors.
- Wall-mounted emergency stop buttons.
- Automatically resetting safety relays.
- Electrical connections and control panel integration.
The safety relays monitor the door sensors and emergency stops, removing power from the relevant output circuits when activated. BONNER worked alongside the control system integrator, who delivered the associated software interlocks, HMI updates, alarms and event logging.
This coordinated approach allowed the new safety system to integrate with the existing control infrastructure without requiring wholesale replacement.
Following a site survey in June 2026, BONNER provided installation specifications, cable schedules and sensor mounting details ahead of the works.Installation, commissioning and functional testing took place on 17 and 18 August 2026, with follow-up work completed in September.The project included pre-installation functional checks, safety system verification, electrical documentation and functional test records for both CIP rooms.
The Results
- Improved machinery safety and controlled access during wash cycles.
- Independent hardwired emergency stop and door safety functions.
- Improved operator visibility through HMI status, alarms and event logging.
- Documented functional testing to support site records and future maintenance.
- Integration with existing pharmaceutical plant automation infrastructure.
This project demonstrates BONNER’s expertise in machinery safety, electrical engineering and industrial automation within complex manufacturing environments.From hardwired safety system design and safety relay installation to commissioning and functional verification, BONNER works alongside manufacturers and system integrators to deliver practical safety upgrades that integrate with existing plant infrastructure.
Planning a machinery safety upgrade or automation project? Contact the BONNER team at www.bonner.ie to discuss your requirements.
