Introduction: Speed and Safety in Modern Manufacturing
In today’s high-paced manufacturing environment, downtime is costly—and safety is non-negotiable. Graphic Packaging, a global leader in sustainable packaging solutions, needed a rapid, custom-engineered machine guarding solution for one of its facilities. With only 72 hours from concept to delivery, PowerSafe Automation was tapped to deliver a turnkey, ready-to-ship guarding kit using t-slotted aluminum extrusion and wire mesh. This case study details the challenge, the engineered solution, and the outcomes, showing how PowerSafe’s streamlined process and expert team made it possible to deliver both speed and safety.
The Challenge: Custom Machine Guarding with a 3-Day Deadline
Graphic Packaging’s team identified a new hazard area around an automated packaging system and needed to quickly implement machine guarding to comply with internal safety protocols and OSHA 1910.212. The complication? Production downtime had to be avoided, and their in-house team required a kit that could be assembled and installed immediately upon arrival—without any onsite fabrication or design troubleshooting.
Key requirements included:
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Custom footprint based on a hand-drawn sketch with rough measurements
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Non-penetrating, floor-mounted guarding structure
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Durable wire mesh for visibility and protection
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Integrated access points with swing doors
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Complete bill of materials and instructions included
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Shipped within 3 days to meet internal safety deadlines
This situation was a true test of PowerSafe Automation’s promise of engineered speed, flexibility, and safety-first design.
The Solution: PowerSafe’s 3-Day Sketch-to-Ship Process
Day 1 – Engineering the Concept
Upon receiving a quick sketch with site photos and measurements from the safety manager at Graphic Packaging, PowerSafe’s applications engineering team translated the concept into a real-time CAD model using Bosch Rexroth’s FramePro plugin in SOLIDWORKS.
A custom layout was created, incorporating:
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1.5" x 1.5" t-slotted extrusion for structural integrity
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Black PVC coated wire mesh panels for safety and visibility
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Integrated panel mounting for pre-assembled door hardware
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Modular corner gussets and fasteners for ease of assembly
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Anchoring footplates designed for bolt-in or non-penetrating options
By the end of Day 1, the design was finalized and approved by the customer. A complete cut list and part drawing set were created, and the job was released to PowerSafe’s internal extrusion warehouse.
Day 2 – Manufacturing and Kitting
PowerSafe’s in-house team immediately cut, labeled, and packaged over 50 custom-cut extrusion bars and mesh panels. Each kit was carefully organized into sections:
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Structural frame assemblies (pre-labeled)
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Fastener kits in clearly marked bags
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Swing gate panels with pre-attached hardware
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Detailed, color-coded assembly drawings and reference BOM
Quality control performed a complete dry-fit mockup to ensure accuracy and ease of installation on the customer’s floor.
Day 3 – Packaging and Shipping
Each kit was boxed in PowerSafe’s modular shipping crates with reinforced foam edges and anti-scratch packaging materials. The job was shipped via overnight freight and delivered on time to Graphic Packaging’s facility with detailed tracking and documentation.
Results: Safety Compliance Without Downtime
Delivered Results:
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From concept sketch to ready-to-ship kit in 72 hours
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Zero rework or on-site fabrication required
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Assembled in under 2 hours by Graphic Packaging’s in-house team
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Project cost came in under budget compared to local fabrication estimates
Graphic Packaging’s maintenance lead commented, “This kit saved us a full week of downtime. We gave PowerSafe a sketch on Monday and were guarding our equipment by Friday morning.”
Why This Worked: The PowerSafe Advantage
1. Engineered Speed
PowerSafe’s team of mechanical designers and extrusion experts specialize in rapid deployment kits. With real-time engineering support and FramePro-powered CAD libraries, they translated basic concepts into deliverable solutions in hours—not weeks.
2. In-House Inventory
By stocking thousands of feet of Bosch Rexroth extrusion and mesh paneling, PowerSafe eliminated common vendor lead time issues and maintained full control over the cut-to-length process.
3. Modular Kit Packaging
Pre-assembled sub-kits, labeled components, and print-ready documentation allowed the customer to install the system like a well-organized LEGO set—minimizing errors and maximizing speed.
4. Turnkey Support
The customer didn’t need to source components from five vendors. PowerSafe provided:
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Design
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Material sourcing
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Assembly instructions
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Logistics
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Ongoing support
This single-source approach reduced internal burden and kept Graphic Packaging’s team focused on production, not engineering.
Technical Specifications of the Project
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System Footprint: 20 ft x 8 ft guarding perimeter
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Extrusion Profile: Bosch Rexroth fractional / English t-slotted aluminum
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Paneling: 1” x 1” black pvc coated steel wire mesh
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Access Points: 3 swing doors with keyed latch hardware
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Anchoring: Floor-mount footplates with optional vibration-isolated pads
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Documentation: Assembly drawings and tagged BOM
Customer Testimonial
“PowerSafe treated this like a mission-critical job from the first phone call. We had rough drawings, and they had a finished product on our dock in three days. It was the easiest guarding installation we’ve done—and the safest.”
– Maintenance Supervisor, Graphic Packaging
Conclusion: Rapid Guarding Kits Built for Today’s Manufacturing Demands
This case study is a powerful example of how PowerSafe Automation turns urgent customer needs into fast, compliant, and reliable solutions. For companies like Graphic Packaging—where uptime, safety, and scalability intersect—PowerSafe’s engineered kits provide unmatched value.
Whether you're dealing with a new hazard, upgrading outdated fencing, or responding to a surprise safety audit, PowerSafe’s team can take your sketch and turn it into a turnkey guarding solution—fast.
