Proximity devices improve safety at Audubon Metals

Audubon Metals LLC, with locations in Henderson, Kentucky, and Corsicana, Texas, is a leading secondary aluminum smelting company that processes scrap metals into aluminum alloys. While their operations drive sustainability, the nature of the business comes with inherent risks.

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 people and equipment. The answer came in the form of advanced proximity detection systems from German company Elokon, provided by Carroll Technologies, Harlan, Kentucky.

The challenge: A high-risk environment

Audubon Metals operates a busy facility in Kentucky with five furnaces and various heavy machinery working in tandem.

“We recycle products from scrapyards, separate out the aluminum and then remelt it," says Tim J. Bills, mobile equipment manager at Audubon. "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 come into close contact unintentionally. Prior to installing proximity devices from Elokon, Audubon Metals experienced equipment collisions. While no major injuries resulted, they underscored the need for a better awareness system.

Audubon Metals needed a solution to 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: Proximity devices

Through their long-standing relationship with Carroll Technologies, a distributor of safety equipment and solutions, Audubon Metals was introduced to Elokon’s proximity detection systems.

These proximity devices are designed to prevent collisions in environments with heavy equipment and personnel and 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 operator to adjust his or her actions to 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 such as front-end loaders.

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

Installation and training

Carroll Technologies worked closely with Audubon Metals and Elokon to ensure minimal disruption to Audubon’s operations.

“The Elokon and Carroll teams were on-site to show our operators and department managers how the devices worked,” Bills says. “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 trialed the system in one section of the plant, monitoring the results before deciding on broader implementation.

Improved safety and operational efficiency

Since the devices were installed, Bills says there haven't been 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 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 proximity system across the rest of its Kentucky plant.

“We did this as a trial in one area,” Bills says. “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.