Safety System Improvements -

Safety System Improvements
& Upgrades by Crossmuller

Modernize your plant’s safety controls, emergency systems, and machine guarding to ensure full compliance, reduced risk, and a safer, more productive workplace.

Why Invest in Safety System Improvements?

Australian regulations demand strict adherence to workplace health and safety standards. Aging or inadequate safety systems put your business at risk of injury, non-compliance, production losses, and reputational harm. Proactive safety system improvements not only safeguard your team, but also boost efficiency and plant reliability—while ensuring you meet or exceed all WorkSafe and Australian Standard requirements.

Proven Technology in Action

The Crossmuller Solution

Our safety system specialists provide end-to-end solutions for:

Machine Guarding & Interlock Upgrades:
Design, fabrication, and installation of physical barriers, light curtains, emergency stops, and safe access controls to prevent hazardous exposure.
Safety PLC & Emergency System Upgrades:
Replacement or retrofit of outdated safety relays and PLCs with state-of-the-art safety controllers and fail-safe logic.
Process & Plant-wide Risk Assessment:
In-depth safety audits and risk assessments, with clear recommendations to eliminate hazards and support safe operating procedures.
Functional Safety Compliance & Validation:
System design and commissioning to AS/NZS 4024, IEC 61508, and ISO 13849 standards, with all required documentation and validation.
Lockout/Tagout (LOTO) Systems:
Implementation of procedures and hardware to support safe equipment isolation and maintenance.
Operator Training & Safety Culture Support:
Custom training programs and documentation to ensure every team member understands and implements safe work practices.

Real Results You Can Benchmark

Crossmuller was engaged to design, program and commission a multi-ingredient supply and processing system for one of Australia’s major food manufacturers. Crossmuller was responsible for the design, installation, and commissioning of the control system for the upgrade.

Project Highlights

Crossmuller was engaged to design, program and commission a multi-ingredient supply and processing system for one of Australia’s major food manufacturers
Recipe System in order to batch a number of ingredients into a cooking vessel, confirming delivery and cooking the ingredients
Full safety upgrade including programmable safety system through a distributed field safety system
Upgrade and automation of the existing equipment
Integration of a third party supplied CIP cleaning system and cooking vessel.

Benefits of Safety System Improvements

Full compliance with safety standards

Modernizing your safety systems ensures your facility meets AS/NZS, ISO, and IEC safety requirements—reducing the risk of non-compliance fines, shutdowns, or regulatory interventions. Compliance demonstrates your commitment to best practice and reassures both clients and auditors.

Reduced workplace accidents and downtime

Upgraded safety interlocks, emergency stops, light curtains, and fail-safe controls directly reduce the risk of operator injury, equipment damage, and hazardous events. Fewer incidents translate to less lost time, minimized workers’ compensation claims, and uninterrupted production.

Enhanced machine reliability and lifecycle

We source and calibrate cutting-edge Fanuc robots, ASRS systems, conveyor belts, and AGVs—implementing them with mechanical, electrical, and safety precision.

Improved confidence, safety culture

Employees who feel protected by robust safety measures are more likely to follow procedures, report hazards, and contribute to a proactive safety culture. This leads to higher morale, reduced staff turnover, and a reputation as a preferred employer.

Lower insurance costs and risk exposure

Demonstrating comprehensive safety controls can lower your insurance premiums and reduce the risk profile of your operation. Insurers look favorably on facilities that invest in modern safety automation and documented compliance.

Readiness for future regulatory changes

Investing in up-to-date, scalable safety systems makes it easier to adapt to evolving legislation, standards, and industry best practices. Your facility will be positioned to respond quickly to new requirements—protecting your operations and brand reputation

why CROSSMULLER?

Crossmuller stands out for our deep expertise in industrial safety engineering, practical experience across Australia’s most demanding industries, and a proven track record delivering upgrades that protect people, processes, and assets.

Frequently Asked Questions

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Taking the Next Step

Don’t wait for an incident to highlight system gaps.
Contact Crossmuller today for a comprehensive safety audit and find out how targeted safety system improvements can protect your people and drive better business outcomes.