Legacy Machines header

Legacy Machine Safety Upgrades

Companies using any type of industrial systems must keep on top of machinery safety and regulatory compliance obligations; it is not the responsibility of the machine supplier, however, often organisations do not have the expertise in-house to ensure automated control systems are updated and meet safety requirements.

Manufacturing process failure poses huge risks and can cause disastrous repercussions. We are here to support in ensuring this does not happen.

We are control system specialists so can offer a turnkey machine safety service, upgrading legacy control systems to give manufacturers peace of mind their systems are safe and therefore, so are their business operations and stakeholders.

If you’re unsure whether your system needs an upgrade, we can provide trusted, honest advice by working with you to find out more about your processes and current efficiencies, then recommend the most appropriate next steps.

When a legacy machine safety upgrade is required, we understand that manufacturing downtime is always a concern, so our integrated approach means we are able to carry out the upgrade as efficiently as possible without needing to involve multiple vendors. In addition, we work to your bespoke needs and will fulfil the upgrade process in your required format and schedule to minimise production disruption.

To find out if you need a safety upgrade or to book in one of our engineers, contact us on – 07359006338 / gareth@hughesautomationltd.co.uk

Safety Upgrades Chart


PUWER requires that equipment provided for use at work is:

  • suitable for the intended use
  • safe for use, maintained in a safe condition and inspected to ensure it is correctly installed and does not subsequently deteriorate
  • used only by people who have received adequate information, instruction and training
  • accompanied by suitable health and safety measures, such as protective devices and controls. These will normally include guarding, emergency stop devices, adequate means of isolation from sources of energy, clearly visible markings and warning devices


Our PUWER engineers can inspect your machinery against PUWER and provide a detailed report for each piece of work equipment. If any non-conformances are found, we would undertake a risk assessment to align with ISO 12100, which would detail suitable corrective requirements referencing the applicable standards.

Machinery risk assessment

This can help you prepare instructions that you need to supply with the machine. … identify hazards in connection with the use and operation of the machine. assess the level of injury or harm that can result from exposure to each hazard. assess what safety measures may be used and the protection that they can provide.

Our safety engineers can carry out inspections and subsequent risk assessments to align with ISO 12100 and provide a detailed report for each piece of work equipment. The report will identify non-compliant issues for attention (e.g.  inadequate safety related control circuits, inadequate machine guarding or absence/validity of CE or UKCA marking) and offer corrective measures referencing the applicable standards.

Machinery Safety Upgrades

We can implement control measures for functional safety upgrades to align with ISO 13849 or IEC 62061. We can provide detailed validation reports and plans, with supporting calculations using the Sistema or PAScal tools. Onsite testing and inspection of these installed upgrades would also be supported by the relevant documentation, to ensure that the working machinery upgrades are compliant and safe.


performance level diagram
Safety Upgrades 1
Safety Upgrades 2
Safety Upgrades 3
Safety Upgrades 4