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Castell Iso-Lok
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Castell Safety International Ltd has seventy six years of experience in the design of safety systems, manufacturing the world’s widest range of industrial trapped key interlocks.   Designed to protect personnel working with dangerous machinery or in hazardous environments, the company’s products are robust, durable, and suitable for the heaviest of applications.  Available in a range of materials, including stainless steel, they are proven even in dusty, corrosive and aggressive operating environments

Castell also manufactures simple but effective locking-off equipment which prevents the inadvertent use of hazardous plant and equipment. These are sold under the Iso-Lok brand, one of the first companies in the world to produce locking-off safety products.  Central to the range is the Multi-Clasp, which effectively locks-off energy sources and allows multiple personalised padlocks to be attached. Access can only be restored once all padlocks are removed from the clasp.

As a single source for interlocking and locking-off equipment, Castell can design safety systems to meet specific needs.  The company works in partnership with customers, helping with risk assessments and advising on the best and most cost-effective combination of its products to ensure safe methods of work on a particular site. Castell is also able to install and commission safety systems for customers, and provide operator and maintenance training.

One company that has been using Castell and Castell Iso-Lok safety products for many years is Iggesund Paperboard, based in Cumbria.  A manufacturer of folding boxboard, the company has the largest mill of its type in the country, and exports fifty percent of its production. The company produces folding boxboard for converters and merchants, for end-use in the packaging, tobacco, graphics and pharmaceutical industries.

Iggesund Paperboard has a significant inventory of Castell and Castell Iso-Lok products on site.   Alan Brown, the company’s Projects Department Manager says “The mill has used Castell key systems for many years and our experience is that they are reliable and robust products.”

As a result of the paper mill implementing the HSE initiative ‘Making Paper Safely’, the company has introduced many new safety procedures.  Recently, Castell supplied the company with several Powersafe KSS 20 solenoid released interlock switches, plus key exchange boxes and a large number of access locks with corresponding colour-coded and numbered keys.  These have been installed on the gates of the two board machine dryers and safeguard production operators and engineers who require entry into this hazardous area.




The products provide protection by ensuring that the dryers have stopped before keys are released to allow gates to be unlocked.  When a dryer is turned off the solenoid energises, allowing the trapped key to be removed from the Powersafe. This puts the machine into jog mode, allowing only controlled movement and, until the key is returned, the dryer cannot enter any other mode. This key releases the colour-coded keys from the key exchange box that allow access on the gates. It cannot be removed from the key exchange box and returned to the Powersafe until all the access keys are returned to the key exchange unit.

The installation of the Castell products was as cost-effective as installing tongue switches, and provides greater reliability in this harsh environment. The interlocks are mechanical so, although the unit cost is initially higher, installation does not require extensive electrical wiring and is therefore less complicated. This mechanical feature also means that they are more durable and dependable than tongue switches under heavy-duty use.

Iggesund is also using Castell Iso-Lok products for all procedures that involve single point isolation.  The company uses the padlocks and Multi-Clasps as part of the standard Personal Protective Equipment when either machine or power isolations are carried out under Permit To Work conditions.

An important feature of locking-off is that it should involve personalised safety padlocks to prevent one person from opening another person’s padlock. If duplicate keys are in circulation in a workplace, the possibility arises that one will be used to remove a padlock protecting a worker during a maintenance or cleaning procedure.

To combat this, the padlocks are issued from a central ‘key-differ’ database held by Castell Iso-Lok.  Castell Iso-Lok holds every single key number ever produced on computer record and every customer has their own ‘key-differ log’.  This ensures that duplicate keys cannot come into circulation, maintaining the integrity of the safety system.

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