Case Study: Enhancing Safety and Efficiency at Audubon Metals with ELOKON Proximity Devices

Heavy machinery, blind spots, and close quarters create an environment where safety is a constant concern. Audubon Metals sought a reliable solution to enhance operator awareness and minimize the risk of accidents involving both people and equipment. The answer came in the form of advanced proximity detection systems from ELOKON, provided by Carroll Technologies.

The Challenge: A High-Risk Environment

Audubon Metals operates a busy facility with five furnaces and various heavy machinery working in tandem. According to Tim J. Bills, Mobile Equipment Manager at Audubon: “We recycle products from scrapyards, separate out the aluminum, and then remelt it. Our furnaces are in close proximity, and we have many blind spots and corners.”

These characteristics create a dangerous environment where machinery and personnel can unintentionally come into close contact. Prior to installing ELOKON’s proximity devices, Audubon Metals experienced incidents of equipment collisions. While these events hadn’t resulted in major injuries, they underscored the need for a better awareness system.

Audubon Metals needed a solution that would prevent such accidents by alerting operators when they were too close to other machinery or personnel, especially in high-traffic or low-visibility areas.

The Solution: ELOKON Proximity Devices

Through their long-standing relationship with Carroll Technologies, a trusted distributor of safety equipment and solutions, Audubon Metals was introduced to ELOKON’s advanced proximity detection systems. Bills highlighted the importance of working with a partner they trusted: “I’ve worked with Carroll in the past, and I knew he would be good to work with. They’ve been very communicative and helpful throughout the process.”

ELOKON’s proximity devices offered the ideal solution. Designed to prevent collisions in environments with heavy equipment and personnel, the devices use sensors to detect when people or other vehicles come too close. When an operator enters a high-risk zone, the system sends an immediate signal, allowing the machinery operators to adjust their actions and avoid potential accidents. At Audubon Metals, three different types of devices were installed: a stationary set mounted on the furnaces, a vehicle-mounted set for forklifts, and a medium-range set for larger mobile equipment like front-end loaders.

These systems work in harmony, communicating between stationary and mobile units to ensure operators always know when they are nearing another person or piece of equipment.

Installation and Training: Seamless Integration

A key advantage of the ELOKON system was the smooth installation process. Carroll Technologies worked closely with both Audubon Metals and ELOKON to ensure minimal disruption. According to Bills: “The ELOKON and Carroll teams were onsite to show our operators and department managers how the devices worked. There wasn’t much formal training required—the system was intuitive, and the operators were able to pick it up quickly.”

With minimal downtime, Audubon Metals was able to trial the system in one section of the plant, monitoring the results before deciding on broader implementation.

ELOKON’s Impact: Improved Safety and Operational Efficiency

The results of the trial were immediate and significant. Bills pointed out that since the devices were installed, “We haven’t had any incidents where equipment made contact with each other.” Beyond preventing accidents, the proximity devices also improved communication among operators. When the system signals a potential collision, operators can quickly coordinate their actions, leading to smoother and safer workflows.

Based on the success of the initial implementation, Audubon Metals is now exploring options to expand the use of the ELOKON proximity system across the rest of the plant. “We did this as a trial in one area,” Bills explained, “but now we’re talking about moving it to the other four furnaces, and potentially, across the entire plant.” The company is optimistic that the system will continue to improve safety and efficiency on a larger scale.

Partnering for Success: The Role of Carroll Technologies

Throughout the project, Carroll Technologies played an essential role in ensuring the successful deployment of the ELOKON system. From recommending the solution to facilitating installation and providing ongoing support, Carroll demonstrated the value of having a responsive and knowledgeable distributor. Bills commended the team, noting, “If we’ve had any issues, they’ve been right there to help, and ELOKON has answered and assisted immediately when needed. So far, it’s been a great relationship.”