Intelligent safety: how ReeR Safety redefined scalable intralogistics

Through a strategic technology partnership with ReeR Safety, Metalprogetti has moved beyond traditional safety components to implement a fully integrated, programmable safety architecture. The centrepiece of this collaboration is the Trident - a sophisticated multi-level automated warehouse that demonstrates how safety logic can become a powerful lever for machine efficiency.

Founded in 1980, Metalprogetti is a global leader in the design of automated systems for handling and storing hanging garments, folded goods, and light-duty items. With hundreds of systems commissioned annually worldwide, the company has built its reputation on modularity and mechanical reliability.

For Metalprogetti, safety is not a 'bolt-on' compliance requirement but a core design principle. This philosophy is most evident in the Trident system, where ReeR Safety's solutions were integrated from the initial prototyping phase to manage the complexities of a highly dynamic environment.

Distributed safety for multi-level storage

The Trident is a modular, horizontal carousel system designed for simultaneous picking and replenishment. Its architecture consists of stacked carousels equipped with storage baskets that operate independently at each level.

While this design maximises throughput, it presents a significant safety challenge. The system features multiple independent operating zones, various access points for personnel, and continuous motion. A 'one-size-fits-all' emergency stop was not an option; the machine required a nuanced approach to safety that could distinguish between a local maintenance intervention and a critical system-wide emergency. To manage this, the Trident integrates a diverse array of safety devices:

Physical Guarding & Monitoring: Transparent sliding doors allow access to carousels, monitored by magnetic safety sensors that trigger stops only on the specific carousel being accessed.

Zonal Protection: Metal access doors between modules use safety switches with separate actuators to trigger a safe stop of all carousels facing that specific corridor.

Peripheral Safety: Perimeter safety ropes monitor for falling products or positioning anomalies.

Global Shutdown: Strategically placed Emergency Stop buttons for immediate, total system isolation.

To manage this variety of inputs without the bulk and rigidity of traditional safety relays, Metalprogetti adopted the ReeR Mosaic platform - a modular, programmable safety controller.

The architecture is built around two Mosaic M1 controllers housed in the main electrical panel. Operating independently, each controller manages half of the machine. Rather than using miles of individual hard-wiring, the system utilises the MCT bus to collect safety signals from remote peripherals, significantly reducing the cable footprint and cabinet space. Key modules used in the Trident include:

MCT2 Interface: Connects remote input modules via the bus, simplifying distributed wiring.

MOR4 Modules: Specifically manages Safe Torque Off (STO) signals for the motor drives.

MBEP Module: Provides PROFINET communication with the primary PLC, allowing for real-time diagnostics and pinpointing the exact location of any safety trip.

Above each workstation, a dedicated junction box houses remote I/O modules (including the MI12T8 for short-circuit monitoring), allowing safety signals to be processed locally before being transmitted back to the central controller.

From commissioning to maintenance

The transition to a programmable, distributed safety architecture has delivered measurable gains across the machine's lifecycle:

Reduced Footprint & Costs: By decentralising the I/O, Metalprogetti reduced the size of the electrical cabinets and slashed the time required for onsite wiring and assembly.

Rapid Diagnostics: Through the PROFINET link, operators can immediately identify whether a stop was caused by a deliberate door opening or a fault, drastically reducing downtime.

Design Flexibility: The Mosaic platform's software-based logic allows Metalprogetti to adapt the Trident to different site layouts and bespoke customer requirements without needing to redesign the entire electrical safety circuit.

The collaboration between Metalprogetti and ReeR Safety proves that in the era of Industry 4.0, safety and productivity are no longer at odds. By leveraging the scalability of the Mosaic M1 system, Metalprogetti has created a high-performance warehouse solution where intelligent safety is an integral part of the machine's value proposition.

For UK manufacturers looking to scale their automation, the Trident case study serves as a blueprint: when safety is programmable, the possibilities for efficiency are endless, and PLUS Automation is keen to discuss your application.