At the facility of one of our steel structure manufacturing partners, a hydraulic press machine plays a critical role — one that was manufactured back in 1994. This machine is used to process special workpieces, meaning any downtime directly threatens continuous production.

When it was built, the press was equipped with protective devices that met the safety standards of the time, designed to protect operators from injury. Safety was ensured by a SICK LVS type, rotating-mirror prism, retroreflective light curtain. Since the press also produces parts that, due to their size, necessarily extend outside the machine’s working area, the factory-installed protection was supplemented with a special prismatic “blanking” (masking) system.

The press remained in excellent mechanical condition over the decades — but its safety system had been overtaken by time.

The challenge

After more than 30 years of reliable service, the day finally came this year when the light curtain failed. As a result, the machine immediately became inoperable — operating such machines without a functioning safety device is strictly prohibited and poses a serious risk of injury.

The situation was made more difficult by the following factors:

• Irreparable components: This old SICK LVS light curtain type is no longer repairable, and the manufacturer no longer offers a directly compatible replacement product.
• Critical downtime: The stoppage of the press caused an immediate bottleneck in our partner’s production processes, making a fast solution essential.
• Preserving the existing control system: A solution was needed that would allow the machine to retain its original functionality without requiring a complete redesign of the control system.

The factory management came to us with this problem after being referred to the ODRADE team through a professional recommendation. Since several of our colleagues previously worked at SICK, we have substantial hands-on experience in modernising equipment of this age.

The solution

For situations like this, we have developed a proven, reliable replacement process. The technical centrepiece of the solution was the integration of a safety intermediary controller between the new-type light curtain and the machine’s original factory control system. This unit receives the signals from the modern light curtain while precisely emulating the outputs and functions of the system from thirty years ago toward the old machine controller.

The practical implementation involved the following steps:

• Equipment replacement: The old SICK LVS unit was replaced with a modern SICK C4000 light curtain pair, with the intermediary control entrusted to the SICK Flexi Soft central system.
• Engineering design: The process required the design and manufacture of a compact control cabinet, as well as the development of the associated safety software.
• On-site execution: After the required special components arrived, the on-site field assembly and electrical integration work was carried out remarkably quickly.

The result

At Odrade, tasks like this don’t end with a simple component swap. We designed the system to be technically stable, safety-compliant by current standards, and formally transferable — all adapted to the technological constraints and production requirements of the facility.

• Rapid restart: Just one week after the components arrived, the press was operating again just as it did in its prime, now meeting current safety requirements, without significant investment or a full machine replacement.
• Standards-compliant operation: Alongside the physical modifications, we carried out the mandatory safety measurements, during which we determined the precise protective distances. Based on the measurement results, a minor correction to the safety distance was required to ensure full compliance with applicable standards in every detail. The thirty-year-old press passed the structural inspection with excellent results.
• Documentation and accountability: Upon completion of the work, we handed over a complete documentation package that certifies safe operation. With this, we formally assume responsibility for the modification carried out — meaning our partner can continue operating the equipment with documented, certified safety.

Long-term safety without replacing the machine

This project is a clear example of how a failure in an older piece of equipment does not automatically signal the end of that machine’s lifecycle. When the mechanical foundations are solid and the technological value of the equipment is beyond question, professional modernisation of the safety systems represents the most sustainable path forward.

The key is a responsible engineering approach: at Odrade, we don’t simply swap components — we take a comprehensive look at how the machine operates, the regulatory environment it sits in, and the production requirements it must meet. With a thoroughly designed and documented modification, proven and valuable machines can continue to serve safe and efficient production reliably for many years to come.

Do you have a machine in your facility whose safety system is already outdated? Don’t wait for the unexpected breakdown. Get in touch with us — we’ll help you replace the old system with modern equipment.