Reduce Risk. Improve Compliance. Protect Your People.
Coral Process Solutions provides professional machine safety consultancy to help manufacturers improve workplace safety, achieve compliance with Australian Standards, and maximise production reliability. We work with manufacturers, OEMs and industrial businesses across Australia to design, upgrade and validate machine safety systems that protect personnel while maintaining productivity.
Whether you require a machine risk assessment, safety PLC programming, machinery guarding, emergency stop systems or a complete safety control system upgrade, our experienced engineers deliver practical, standards-compliant solutions and advice tailored to your equipment and operating environment.
Machine Safety Specialists
Industrial machinery presents significant hazards if not properly designed, safeguarded and maintained. Modern machine safety is about far more than emergency stop buttons—it requires a systematic approach to hazard identification, risk reduction, functional safety and ongoing validation.
Our engineers have extensive experience in:
- Machine Risk Assessments
- AS 4024 Compliance
- Safety PLC Programming
- Emergency Stop Circuit Design
- Safety Interlock Systems
- Light Curtain and Safety Scanner Integration
- Guard Locking Systems
- Functional Safety Validation
- Machinery Safety Upgrades
- Control System Modernisation
- Electrical Safety System Design
Every solution is designed to improve operator safety while minimising unnecessary downtime and maintaining efficient machine operation.
Machine Risk Assessments
A professional machine risk assessment is the foundation of every successful machine safety project.
We identify hazards associated with:
- Mechanical movement
- Crushing hazards
- Shearing hazards
- Trapping points
- Electrical hazards
- Pneumatic systems
- Hydraulic systems
- Stored energy
- Unexpected start-up
- Maintenance activities
- Cleaning operations
- Operator interaction
Each assessment evaluates the likelihood and severity of injury before recommending practical risk reduction measures consistent with Australian Standards.
Machine Safety Compliance
Many existing production machines were installed before current safety requirements were introduced.
We assist manufacturers to improve compliance with the AS 4024 series by assessing existing machinery and recommending practical improvements appropriate to the age, use and operating environment of the equipment.
Our services include:
- Existing machine safety audits
- Compliance reviews
- Safety system upgrades
- Documentation reviews
- Validation of safety functions
- Functional testing
Our objective is to help clients understand current risks and implement practical engineering controls to reduce those risks.
Safety PLC Programming
Modern machinery frequently relies on programmable safety controllers to provide advanced safety functionality.
Coral Process Solutions have experience designing and commissioning standalone safety control systems from Omron and ABB, and integrated safety PLC products from Schneider, Siemens and Rockwell.
Safety control software is developed using recognised engineering practices with clear documentation to simplify future maintenance and modification.
Machine Safety Upgrades
Many older machines remain mechanically sound but require safety improvements to meet modern operational expectations.
Typical upgrade projects include:
- Installation of safety relays
- Safety PLC upgrades
- Guard interlocking
- Emergency stop upgrades
- Light curtain installation
- Safety scanner integration
- Electrical control system replacement
- PLC migration
- HMI upgrades
- Obsolete equipment replacement
Upgrading existing machinery is often significantly more cost-effective than complete machine replacement. Details of our other automation control system services can be found at Control System Engineering
Machinery Guarding
Effective machine guarding reduces exposure to hazardous moving parts while allowing operators to perform production and maintenance activities safely.
We can assist with:
- Fixed guards
- Hinged guards
- Interlocked guards
- Guard locking systems
- Access control
- Perimeter guarding
- Safety fencing
- Operator access design
Each solution is designed to balance safety, accessibility and productivity.
Functional Safety Validation
A machine safety system is only effective if it performs as intended.
Validation confirms that installed safety functions operate correctly under normal operating conditions and fault conditions.
Validation activities may include:
- Functional testing
- Safety circuit verification
- Emergency stop testing
- Guard interlock testing
- Safety PLC verification
- Documentation review
- Commissioning support
Industries We Support
Coral Process Solutions has experience supporting a broad range of industrial sectors including:
- Manufacturing
- Food and beverage
- Packaging
- Plastics
- Water and wastewater
- Materials handling
- Process industries
- Industrial automation
- OEM machine builders
- General manufacturing
Frequently Asked Questions
What is a machine risk assessment?
A machine risk assessment identifies hazards associated with machinery, evaluates the level of risk and recommends measures to reduce that risk through engineering controls, safeguarding and safe operating procedures.
Do all machines require upgrading?
Not necessarily. Existing machinery should be assessed individually to determine whether improvements are appropriate based on its design, condition, use and applicable safety requirements.
Can existing PLC systems be upgraded?
Yes. Existing control systems can often be modernised using current PLC and safety PLC technology while minimising disruption to production.
Do you work on existing machinery?
Yes. We regularly assist clients with upgrading and improving existing production equipment as well as supporting new machine installations.
See a recent project undertaken for a testing machine Machine Rockwell PLC Upgrade and Machine Safety upgrade
Contact us today to discuss your machine safety requirements and arrange an initial consultation.
