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Plant conversion with optimal workplace safety

Case Study

Executive summary

    A large, global paper manufacturer achieved a high workplace safety level before the start of operations in a new recycled cardboard production facility. Brady Corporation provided an action plan based on safety expertise and its wide range of safety identification solutions.


A global paper manufacturer acquired and transformed a large paper mill into a recycled cardboard production facility for product packaging. New machinery was installed and the internal layout of the plant was changed to optimally fit its new purpose.

The complete conversion of the plant also created a need for new safety and identification solutions:

  • The new machinery was powered and supplied via new cabling and pipes and these energy and material flows needed to be identified
  • New tools were needed to safely perform maintenance on the installed machinery in compliance with the company’s safety procedures
  • The new layout of the plant required new safety signalisation to properly inform, warn and guide coworkers


Pipe markers

Brady offered pipe markers pre-printed to specifications to identify the contents of pipes throughout the facility. Identified pipe contents inform coworkers, 3rd party contractors and first responders about potentially dangerous pipe contents and help to achieve adapted behaviour around these pipes. Brady also presented the BBP37 Multicolour & Cut Sign & Label Printer so the customer could create his own pipe markers on-site in order to respond quickly to future needs.


Together with the customer, Brady designed a Lockout/ Tagout plan for the entire plant to achieve a high level of machine maintenance safety. With Lockout/Tagout, machine energy can be neutralised during maintenance to avoid accidents. Brady scoped and documented the project and identified optimal lockout devices, padlock types, padlock engraving and padlock key types before implementing the project in the workplace.


Brady also suggested and implemented safety signs at selected locations in the plant. Safety signs help to inform or warn coworkers about risks, mandatory personal protection and prohibited behaviour.


During the safety identification project, Brady also provided zero halogen sleeves to identify a large number of new electrical cables in the plant. Identified cables provide better insight for maintenance planning and troubleshooting.


With these solutions in place, the paper manufacturer was able to achieve a high level of workplace safety for an efficient start of operations in the newly converted plant.