Enhancing Safety Through Bespoke Engineering

Across modern waste processing sites, safety is just as critical as performance. With high volumes of material, constant machine movement, and multiple operatives working in close proximity, even small improvements in safety design can have a significant impact.

This was the focus behind a recent project delivered by CRJ, where bespoke safety enhancements were designed, manufactured, and installed to improve operator safety on HAAS shredders operating across multiple sites.

Understanding the Challenge

The project began with a series of initial meetings led by CRJ to better understand key health and safety considerations around the machines. While the HAAS Recycling Systems shredder itself is built to a high standard, real-world operating environments increase risks.

Busy waste sites, high traffic from loading equipment, and constant material flow mean that areas such as conveyors, magnet belts, and tracks can pose hazards to operatives working nearby. CRJ identified an opportunity to further reduce these risks through practical, engineered solutions.

From Concept to Design

Following these consultations, CRJ’s engineering team set to work developing bespoke concepts using detailed CAD designs. Each solution was tailored to the specific layout and operation of the machines, ensuring the safety enhancements would integrate seamlessly without affecting performance or usability.

The focus was on designing custom safety gates and guarding systems that would:

• Restrict access to high-risk areas
• Create clearly defined operator zones
• Maintain safe but practical access for maintenance

Every element was carefully considered to strike the right balance between safety, functionality, and efficiency.

In-House Fabrication and Installation

Once designs were finalised, CRJ moved into full production – manufacturing the custom safety gates in-house to ensure complete quality control. These were then installed onto machines supplied to Biffa across three key sites in Glasgow, St Helens, and Newcastle.

A Safer Working Environment

The addition of these bespoke safety gates has helped create a more controlled and secure working environment across all three sites. By limiting access to hazardous areas such as conveyors, mag belts, and tracks, the risk of injury is significantly reduced.

Importantly, these improvements don’t just protect operators – they also provide site managers with greater confidence in day-to-day operations, knowing that safety has been engineered directly into the machinery.

By combining technical expertise with practical on-site insight, CRJ delivers bespoke engineering solutions that add real value – improving safety, efficiency, and long-term reliability.

Final Thought

As waste processing environments continue to evolve, so too must the approach to safety. Through collaboration, innovation, and a commitment to continuous improvement, CRJ is helping customers like Biffa operate safer, smarter, and more effectively every day.