Protecting industrial safety systems in harsh environments

Whether exposed to intensive washdown procedures, condensation, salt spray, freezing temperatures or outdoor weather conditions, safeguarding devices must continue to deliver reliable performance while protecting both personnel and productivity.

In these applications, protecting the safety device itself can be just as important as selecting the right safety technology.

Environmental protection matters

Safety light curtains are widely used to protect operators from hazardous machinery and automated processes. While modern devices offer high detection accuracy and rapid response times, their long-term effectiveness can be compromised by environmental factors.

Frequent cleaning cycles, high-pressure water jets, humidity, steam, mechanical impacts and rapid temperature fluctuations all have the potential to affect reliability, increase maintenance requirements and reduce operational availability.

As a result, environmental protection is increasingly becoming an integral part of machine safety design rather than an afterthought.

Designed for challenging conditions

To meet these demands, ReeR Safety has developed its WT (WaterTight) enclosure range, enabling safety light curtains to operate reliably in harsh industrial environments where moisture, dust and aggressive cleaning procedures are routine.

WT enclosures provide IP67 and IP69K protection, offering resistance to dust ingress and high-pressure water jets of up to 100 bar at temperatures reaching 80degC. The enclosure also protects the sensor from accidental impacts and mechanical abrasion, helping extend service life in demanding applications.

An integrated GORE vent prevents internal condensation from forming inside the enclosure, maintaining the clarity of the PMMA housing and ensuring consistent optical performance throughout the product's lifetime.

Application-specific solutions

Recognising that industrial environments present different challenges, ReeR has developed specialist versions of the WT enclosure range.

The WT Heated (WTH) model is designed for outdoor installations, cold stores and refrigerated warehouses. A thermostatically controlled heating system enables operation at temperatures down to -25degC, preventing frost and condensation that could obstruct the sensing field.

For food and beverage applications, the WT Food (WTF) version uses AISI 316L stainless steel, Delrin and PMMA materials selected for their resistance to aggressive detergents and disinfectants. The design supports intensive washdown procedures while meeting the hygiene requirements typical of food processing environments.

Outdoor automation at the Port of Brisbane

A good example of safety technology operating in challenging conditions can be found at the AutoStrad Terminal at the Port of Brisbane, Australia.

The facility uses automated container handling systems that include overhead cranes, quay cranes and autonomous guided vehicles (AGVs). While automation improves operational efficiency and reduces human exposure to hazardous areas, it also requires highly reliable perimeter protection.

Safety devices at the terminal are continuously exposed to rain, salt-laden air, UV radiation, condensation and significant temperature changes. These conditions can rapidly affect conventional installations.

To address these challenges, ReeR supplied Admiral WTH UV Dual Beam safety light curtains installed within heated WT enclosures. The system combines long-range detection of up to 50 metres with Dual Beam technology, helping to reduce nuisance trips caused by birds or wind-blown debris.

The heated enclosure prevents condensation, while corrosion-resistant stainless steel mounting accessories provide additional durability in the harsh marine environment. The result is a perimeter protection solution capable of maintaining reliable safety performance while minimising maintenance requirements.

Hygienic safety for food processing

Food manufacturing presents a different set of challenges, where machine safety must be combined with strict hygiene standards.

Italian machine builder Elcat develops automated systems for handling, dosing and packaging products including sliced cheese, cooked meats, hamburgers and olives. These systems are constructed using stainless steel and food-grade materials designed to withstand frequent cleaning with detergents and disinfectants.

Because safeguarding devices are exposed to the same cleaning procedures as the production equipment, they must resist water, steam and chemical cleaning agents without compromising detection performance.

For these applications, Elcat selected ReeR EOS4 safety light curtains fitted with WTF enclosures. The solution provides IP69K protection, allowing it to withstand high-pressure washdowns and temperatures up to 80degC.

For refrigerated areas, the heated WTHF version incorporates thermostatically controlled heating to prevent condensation forming on the enclosure surface. This ensures uninterrupted visibility of the protected area, even in environments operating at temperatures down to -25degC.

By combining hygienic design, environmental protection and reliable detection performance, the system helps food processors maintain both operational continuity and compliance with demanding industry standards.

A growing requirement for modern industry

As industrial environments become increasingly demanding, environmental protection is playing a larger role in safety system design. Whether safeguarding outdoor automated operations or supporting hygienic food production, specialised enclosure systems can significantly improve the reliability and longevity of safety installations.

By protecting the safety device from environmental hazards, manufacturers can reduce maintenance requirements, minimise downtime and maintain consistent safety performance. In an era of ever-increasing automation, designing safety systems that can withstand harsh operating conditions is becoming essential for ensuring both productivity and workforce protection.