Introduction: Tailored Machine Guarding for Wire & Cable Manufacturing
Wire and cable manufacturers like Southwire and Atkore operate in fast-paced, high-output environments filled with specialized, large-scale equipment. These machines often present significant risks: rotating shafts, cable winders, pinch points, and automated gantries can all pose serious hazards if not properly safeguarded. For manufacturers striving to meet OSHA 1910.212, ANSI B11, and ISO 13849 standards, off-the-shelf solutions rarely meet the unique demands of their operations.
That is where PowerSafe Automation comes in. As a leading provider of turnkey machine safety and guarding solutions, PowerSafe Automation partners with companies across North America to engineer custom machine guarding systems that do not just protect workers—they enhance workflow and support production uptime.
This case study explores how Southwire and Atkore have both benefitted from PowerSafe Automation’s tailored guarding systems, helping them mitigate risk, streamline operations, and unify safety standards across facilities.
Southwire: Tailored Guarding for Forklift-Friendly Cable Winder Access
The Challenge Southwire, one of the largest wire and cable manufacturers in North America, needed to safeguard a high-volume cable winding operation that involved continuous forklift traffic. Operators were frequently loading and unloading massive cable spools using forklifts, making traditional fixed fencing or interlocked doors impractical. They needed a guarding system that could:
- Protect operators and bystanders from moving parts and spooling equipment.
- Maintain visibility into the process.
- Allow forklifts to pass through quickly and safely.
- Remain compliant with OSHA 1910.212 and ANSI B11.19
The Solution PowerSafe Automation developed a modular, forklift-friendly guarding solution using a combination of T-slotted aluminum framing, wire mesh panels, and double-hinged gate systems. These custom gates allowed full forklift access while also integrating locking mechanisms to restrict entry during machine operation.
Key design features included:
- Hinged bi-parting gates with interlocks to prevent access during machine run cycles.
- Integrated light curtains to detect personnel presence and stop equipment when triggered.
- Modular T-slot panels for fast future modification or relocation
- Clear visibility into guarded zones for operational awareness
The Result Southwire’s team saw immediate improvements in both safety compliance and workflow efficiency:
- Forklift traffic continued uninterrupted thanks to rapid-access custom gates.
- OSHA and ANSI compliance was achieved with the integrated interlocks and safety devices.
- The modular design allowed Southwire to make future layout changes without needing a complete redesign.
By addressing their unique material handling needs, PowerSafe Automation delivered a solution that supported both throughput and risk reduction—a hallmark of tailored guarding success.
Atkore: Comprehensive Machine Guarding for Wire Forming Equipment
The Challenge Atkore manufactures a variety of electrical conduit and wire products using complex, automated machinery with multiple hazard zones. These included rotating arbors, automated gantries, cable tensioning systems, and fast-moving conveyors. The goal was to:
- Reduce exposure to mechanical hazards during operation and maintenance.
- Create standardized guarding across multiple lines.
- Integrate machine safety devices to stop the process if a guard was opened or bypassed.
- Ensure the system could be installed with minimal disruption to production.
The Solution PowerSafe Automation performed a complete machine safety assessment, then designed a suite of custom guarding systems tailored to each machine and hazard zone. Key components included:
- Vertical sliding safety doors with safety-rated interlocks for quick operator access
- Fixed perimeter guarding made from T-slot extrusion and polycarbonate panels.
- Integration of presence-sensing devices like safety light curtains and radar scanners
- Centralized safety relays to monitor all safety devices and control stop commands.
To support continuous improvement, PowerSafe’s design also included maintenance access zones with removable panels and tamper-resistant fasteners, balancing security with serviceability.
The Result Atkore experienced measurable gains in safety compliance and operational consistency:
- Audit readiness improved significantly across all lines equipped with PowerSafe systems.
- Operators reported a better sense of safety without sacrificing visibility or accessibility.
- Maintenance teams appreciated the modularity and clarity of the guarding layouts.
The success of this deployment led to Atkore expanding PowerSafe’s solutions to additional facilities, aligning with their corporate safety initiatives.
Common Benefits Across Southwire and Atkore
Though each project was unique, both Southwire and Atkore experienced overlapping advantages that highlight the value of PowerSafe’s tailored guarding approach:
1. Improved OSHA & ANSI Compliance Every PowerSafe solution is engineered in compliance with OSHA 1910.212, ANSI B11.19, and ISO 13849-1. That gives plant managers peace of mind during safety audits and helps eliminate exposure to costly violations.
2. Modular, Scalable Designs Using T-slotted aluminum extrusion allows rapid design, easy reconfiguration, and minimal downtime during installation. Both companies leveraged this flexibility for future layout changes.
3. Functional Access for Operations & Maintenance PowerSafe does not believe in one-size-fits-all guarding. Custom doors, lift panels, and sensor-integrated zones maintain productivity while reducing risk.
4. Integrated Safety Controls Smart guarding includes safety interlocks, light curtains, and scanners that connect directly to machine safety circuits. Guards do not just block access—they communicate with the equipment to stop motion when a hazard is detected.
5. Full Turnkey Execution From risk assessments to design, fabrication, and field installation, PowerSafe delivered complete turnkey service. That meant fewer vendors to manage and a unified safety system across locations.
Tailored Guarding: Not Just Safer—Smarter
Industrial customers in the wire & cable sector face specific safety challenges that cannot be solved with off-the-shelf fencing. Forklift traffic, oversized parts, rotating reels, and heavy-duty motion demand custom-fit guarding systems that understand both risk and operations.
PowerSafe Automation specializes in engineering solutions that do just that. With decades of experience, deep compliance knowledge, and in-house design and installation capabilities, PowerSafe ensures every guarding solution is safe, smart, and scalable.
Ready to Tailor Your Guarding?
If you are a safety manager, plant engineer, or EHS leader in the wire and cable manufacturing sector, you do not have to settle for cookie-cutter guarding systems. PowerSafe Automation can design a solution that fits your machines, your processes, and your people.
Visit our Tailored Custom Machine Guarding page to learn more: https://powersafeautomation.com/tailored-custom-machine-guarding
Or contact our applications engineering team directly to schedule a site visit or virtual consult.
About PowerSafe Automation
PowerSafe Automation provides turnkey machine guarding, safety controls integration, and custom risk-reduction solutions for manufacturers across North America. From robotic cells to legacy machines, we help clients move from reactive compliance to proactive safety engineering. Explore more at: www.powersafeautomation.com
