Clearing the way for cylinder production

54 plants are to be modernised, to upgrade Vaillant’s production of hot water storage cylinders to state-of-the-art electrical and safety technology. The safety design for cylinder production was to incorporate a barrier-free solution for two older production lines, combining safety with efficiency. The loading and unloading area presented a challenge, as it was to be free of any disruptive structures.

Safety that’s almost artistic

On the basis of the hazard assessment Pilz developed an unusual safety solution using the light curtains PSENopt II. The individual positioners are accessible from three sides and secure cylinders of various sizes, which are fed in manually and via crane. Pilz supported the modernisation process in a spirit of partnership, from the hazard assessment, safety concept and safety design through to system implementation. The solution was found during a joint workshop: the light curtains PSENopt II were tilted ninety degrees, the transmitter was embedded horizontally into the floor and the receivers were installed on the ceiling. That way it was possible tor the exchange between human and machine to be free from barriers, without compromising safety. The safe configurable small controller PNOZmulti 2 manages all the safety-related signals. Should a plant operator interrupt the light beams transmitted from the floor or step on one of the upstream pressure-sensitive mats, PNOZmulti 2 will trigger an immediate safe stop of the hazardous movement – with no barriers in sight!

The benefits at a glance

  • Allows older production lines to be operated safely and in compliance with the standards for further years to come
  • Barrier-free safety solution offers higher productivity and greater freedom of movement for operators
  • Based on the configurable small controller PNOZmulti 2, expansion modules can be used to extend the system individually


“In each phase, cooperation with Pilz was open and in a spirit of partnership. We received good, competent advice at all times. It’s not an installation that you would just come up with!”

Jörg Holzportz – Industrial Engineering at Vaillant

About Vaillant

The Vaillant Group is a global market and technology leader in heating, ventilation and air-conditioning technology. For over 140 years, Vaillant has been following a strategy designed to achieve sustainable and profitable growth. Today, the family-owned company has 10 production and development sites in six European countries and in China.

Our products in the application


Pilz New Zealand
4 Prescott Street, Penrose
Auckland 1061
New Zealand

Telephone: +64 9 6345350

Pilz New Zealand

Telephone: +64 9 6345350

Technical Support

Telephone: +64 9 6345350

Was this article helpful?