Introduction: Safety as a Strategic Asset in Insulation Manufacturing
In the insulation industry, where high-temperature ovens, fiberized materials, and automated conveying lines pose constant risk, machine safety is not a regulatory checkbox, but it is a business-critical investment. Global insulation leaders Knauf and Johns Manville operate high-speed, high-throughput facilities producing fiberglass, mineral wool, and other thermal/acoustic insulation products. While these environments demand efficiency, they also come with elevated machine safety risks.
Recognizing the need for a comprehensive, flexible, and OSHA-compliant safety strategy, both companies partnered with PowerSafe Automation to deploy tailored custom machine guarding solutions that would:
- Reduce risk of injury from hazardous motion
- Improve operational uptime.
- Increase maintenance efficiency.
- Comply with OSHA 1910 Subpart O, ANSI B11, and ISO 13857 safety standards.
This case study outlines the challenges, custom-engineered solutions, and measurable results from implementing PowerSafe’s guarding systems at Knauf and Johns Manville insulation plants.
Learn more about PowerSafe’s tailored machine guarding at: https://powersafeautomation.com/tailored-custom-machine-guarding
The Manufacturing Challenge: Complex Hazards in Insulation Production
Insulation production facilities are among the most physically and thermally demanding industrial environments. The process includes:
- Melting and curing of raw materials in large, heated ovens
- Conveying of fiberized materials through cutting, rolling, and packaging systems
- Airflow management using high-speed fans and ducting systems.
- Frequent accumulation of fibrous debris, requiring scheduled cleanouts
Each of these steps introduces mechanical motion, thermal exposure, and ergonomic hazards for operators and maintenance teams.
Common Safety Risks at Knauf & Johns Manville:
| Hazard Type | Example Risk Points |
| Thermal | Curing ovens, melt tanks, heated conveyors |
| Mechanical Motion | Rollers, belts, infeed/outfeed systems |
| Ergonomic | Awkward access for maintenance, high-reach guarding |
| Debris Accumulation | Dust and fibers blocking sensors, jamming conveyors |
| Compliance | Need for machine-specific documentation, functional safety validation |
Traditional guarding methods often failed in these environments due to:
- Poor fit with complex machinery
- Inaccessibility for cleaning or repairs
- Use of non-durable materials not suited for heat or debris.
Knauf and Johns Manville needed a machine-specific, modular, and maintainable guarding strategy built around their unique operational needs.
The PowerSafe Approach: Engineered Risk Reduction Through Custom Guarding
PowerSafe Automation was brought in to audit the machinery, assess risk levels, and provide engineered solutions that go beyond off-the-shelf guarding.
Step 1: Machine Safety Risk Assessment
PowerSafe’s engineering team conducted a Task-Based Risk Assessment (TBRA) and applied its proprietary RRPP™ framework (Recognize, Rank, Prioritize, Plan) to evaluate:
- Severity of potential injuries
- Frequency of operator interaction
- Exposure time and access conditions
- Existing protection levels (if any)
This allowed for precise categorization of risks as required by ANSI B11.0 and ISO 12100.
Step 2: Custom Guarding Design for Key Zones
Based on the findings, PowerSafe designed modular aluminum-framed guarding systems using T-slot extrusion, high-heat polycarbonate, and powder-coated steel panels where needed. These were tailored to each machine’s geometry and operator workflow.
Tailored Guarding Solutions Included:
| Machine Zone | Custom Features |
| Curing Ovens | High heat shielding, removable access panels, visual inspection windows |
| Fiber Conveyors | Interlocked guards with Category 3 safety relays, debris-shedding materials |
| Cutting & Packaging | Sliding doors with mechanical latches, E-stop integration, tool-free removal |
| Maintenance Access Points | Hinged or lift-off panels, maintenance override key systems |
| Electrical Panels | Locked enclosures with clear signage and visual status indicators |
Step 3: Installation, Validation & Training
All guarding solutions were installed by PowerSafe’s in-house field team with minimal disruption to plant operations. Post-installation, PowerSafe provided:
- Validation of functional safety circuits to ISO 13849-1
- Lockout/tagout verification procedures
- Onsite maintenance and operator training
- A full safety package including CAD drawings, interlock schematics, and OSHA compliance checklists.
Notable Implementation Highlights
Johns Manville: Curing Oven Guarding Overhaul
Johns Manville’s facility required guarding on multiple high temperature curing ovens with daily operator observation needs.
Challenge: Traditional metal mesh guards restricted visual inspection and required tools for removal, delaying maintenance.
PowerSafe’s Solution:
- Polycarbonate inspection panels rated for heat exposure.
- Integrated LED lighting for clearer visibility
- Quick-latch system for tool-less access
- Lockable swing gates with tongue interlocks
Result: 40% reduction in average inspection time and improved maintenance scheduling.
Knauf Insulation: Full-Line Guarding for Fiberglass Conveying
Knauf’s challenge was guarding long, elevated conveyor lines transporting loose fiberglass, with multiple infeed points and motorized rollers.
Challenge: Previous guarding created airflow restriction and debris build-up.
PowerSafe’s Solution:
- Ventilated guarding panels to maintain airflow.
- Dust-resistant T-slot aluminum framing.
- Interlock switches with safety relays for each motor zone.
- Color-coded maintenance access doors
Result: Improved airflow control and quicker LOTO access for line isolation. Maintenance crews reported a 30% faster restart after cleanout.
Outcomes: Measurable Gains in Safety and Operations
Both insulation manufacturers reported immediate and ongoing improvements after implementation.
Key Results:
| Metric | Result |
| Operator Exposure Reduction | >75% risk reduction in high-motion zones |
| Maintenance Downtime | Reduced by 30–40% through tool-less and hinged panels |
| Compliance Readiness | Passed internal audits with zero guarding violations |
| Production Efficiency | No unplanned shutdowns due to guarding interference |
| Employee Confidence | Positive feedback from operators and technicians |
“PowerSafe’s guarding systems have made our facility safer without slowing us down. The design team clearly understood our workflow and built around it.” — Maintenance Supervisor, Knauf Insulation
Why PowerSafe’s Tailored Guarding Works in High-Demand Industries
1. Built for Harsh Environments
Whether it is heat, dust, or complex equipment layout, PowerSafe’s modular guarding adapts to real-world plant conditions—not just ideal ones.
2. Engineered by Safety Professionals
All solutions are designed by engineers trained in machine safety, functional safety validation, and OSHA/ANSI compliance.
3. Designed for Maintenance
Tool-less access, quick-release panels, and intelligent interlock placement make PowerSafe’s guards friendlier for PMs and shift changeovers.
4. Backed by Documentation
Each system includes full safety documentation, CAD drawings, electrical prints, and LOTO procedures to streamline future audits or upgrades.
5. Scalable Across Facilities
The solutions used at Knauf and Johns Manville are scalable and replicable across sister facilities or new lines, creating long-term ROI.
Conclusion: A Safer, Smarter Insulation Manufacturing Line
For Knauf and Johns Manville, tailored machine guarding was more than a compliance upgrade it was a strategic improvement in operational safety, reliability, and efficiency.
In high-risk industries like insulation manufacturing, standardized guarding often falls short. But PowerSafe’s engineered, field-tested, and standards-compliant solutions ensure every machine is protected — and every operator is confident.
Want to make your insulation line safer and smarter? Visit the Tailored Custom Machine Guarding page at https://powersafeautomation.com/tailored-custom-machine-guarding or contact PowerSafe at sales@powersafeautomation.com to schedule a free consultation and risk audit.
