Elcat case history – Application of ReeR Safety Solutions

The company founded by brothers Gianfranco and Mauro Testa in 1996 is a Cuneo-based company with an international reach.
Thanks to the team in Sanfrè, Elcat offers solutions that in 90 percent of cases reach international markets.
The machines produced in Sanfrè are in most cases exported.

Safety solutions have been entrusted to ReeR components and technology and to date have met the requirements in terms of reliability and support.

During a meeting at their headquarters, The founders, Eng. Francesco Berrino, proudly showed us a machine intended for the U.S. market and briefed us on what solutions were used by the design team to make it safe.

The company’s specialization is the design and assembly of food processing and packaging machines.
These machines make the processing steps between the slicer and the thermoforming machine to handle, dose, overlap or roll slices of cheese, cold cuts, hams, hamburgers, and then place them in the tray or the thermoforming machine automatically.
They also make machines to pick, align, and place cheese or meat sticks; others to pick, dose by weight, and package slices of salami, cheese cubes, olives, taralli, and other foods.

Elcat designs and manufactures customized devices made specifically for the customer’s timely need, an activity that allows Elcat to differentiate itself from those who make mass-produced machines.

Mosaic system

ReeR safety light curtains are used to stop the machine in the event that a person introduces a limb into the area where the hazardous work is being carried out while still maintaining unobstructed vision and the ability to intervene, which are limited when using physical guards. 

Removable guards also often have R-SAFE Reer safety sensors with RFID technology that certify their safe location.

The machines are made mainly of stainless steel and other materials suitable for use in the food and beverage industry.
Components must also be chosen from those suitable for food contact and capable of withstanding the thorough daily cleaning cycles that are carried out on food production machines.
For safety light curtains, the choice was made in favor of our EOS4s equipped with IP69K enclosures, the EOS4 WTFs (WaterTightFood).

EOS safety light curtains with WTF and WTHF (heated) housings allow use in environments exposed to water and steam jets with pressures up to 80bar and temperatures up to 80°C and in combination with the use of detergents and disinfectants.
The materials used to make the housing, such as stainless steel, Delrin and PMMI, are suitable for use in the food industry because they are inert and because they do not generate food contaminants.

All EOS safety light curtains can be used down to -25°, and thus in refrigerated environments, but the WTHF (heated) models feature a thermostat-controlled heating system that facilitates their elimination of condensation that might form on the transparent surface of the housing.

EOS4 WTHF application

ReeR Solution


EOS safety light curtains IP69K enclosure

Food & Beverage industry approved


Cleaning plan for food and beverage industry

  • Rinsing with water 40 – 50°C
    Rinsing with low pressure.
    Rinsing from top to bottom in the direction of the drains
  • Cleaning of the drains
  • Foaming from bottom to top
    Alkaline: P3-topax 66
    Acid: P3-topax 56
    Temperature: cold up to 40 °C
    Contact time: 15 min. recommended
  • Rinsing with water 40 – 50°C
    Rinsing from top to bottom with low pressure
  • Disinfection
    P3-topactive DES 1-3% 10-30 min.


Material resistance of the tested series

EOS2 – EOS4 WTF / WTHF to the P3 product used in the test can be considered Positive

Test procedure

  • Ecolab-test F&E Nr. 40-1
  • Dipping test: complete immersion in solution/liquid
  • Test Period: 28 days
  • Temperature: room temperature (costant)
  • Analysis: Visual judgement like swelling, brittleness, discoloring compared to zero-reference factor (demineralized water)

More info

The EOS WTF and WTHF light curtains are suitable for the Food & Beverage industry

IP69K logo

IP69K protection rate

Material resistance tests, according to the cleaning procedures for food and beverage industry 

It is interesting to note how physical guards have been incorporated with the aim of reducing unintentional line breaks (for example, interrupting the barrier with an arm or gown flap). The machine works harder and avoids stops and restarts, which must always be handled safely.

The ELCAT machines consist of several semi-independent modules, each performing a dedicated procedure.
All are equipped with numerous safety sensors (light curtains, door-opening sensors, emergency STOP) connected locally to remote I/Os of a single MOSAIC Safety controller. In this way each module can be separated from the others and for safety connects with a single cable.
MOSAIC makes it possible to intelligently evaluate received signals, for example, interrupting only one module and not the complete line with a continuous exchange of information with the PLC that manages machine automation.

Highly appreciated is the remote control mode that can be achieved with the Mosaic M1S COM.
M1S COM can be connected to an Ethernet network and then fully controlled through an Internet connection. 
This allows technicians to remotely intervene on machine settings, reprogramming and/or solving customer needs quickly and easily regardless of where the machine is physically installed.

Moaic Safety controller

ReeR Solution


Mosaic M1S COM

  • Mosaic is a safety hub able to manage all safety functions of a machinery or a plant. 
    Modular and expandable, Allows cost reductions and minimal wiring
  • The Mosaic M1S COM master unit integrates 2 RJ45 network connectors for connections to the field bus and / or to the network for remote control.
  • Mosaic can manage safety sensors and signals such as:
    – Light curtains
    – photocells
    . Laser scanners
    – Emergency stops
    – Electromechanical switches
    – Guard-lock
    – Safety door switches
    – Magnetic switches
    – RFID switches
    – Safety mats and edges
    – Two-hands controls
    – Hand grip switches
    – Encoders
Mosaic Gamma

– Proximities for safety speed control
– Analogue sensors (i.e. loading cells, pressure switches,
  temperature measurement, flow and level measurement, etc.).


Compared to “traditional” electromechanical safety-relays-based safety circuitries, Mosaic has the following advantages:

  • Reducing the number of devices and wiring used and, therefore, the overall size of the project
  • Speeding-up control panel construction
  • Providing logic configuration via a quick and easy-to-use software. Machine designers are always able to change configuration logic
  • Master units Mosaic M1, Mosaic M1S and Mosaic M1S COM are configurable via the MSD (Mosaic Safety Designer) graphic interface (provided with each Master units at no extra cost)
  • Possibility of remote control with the new Mosaic M1S COM master unit
  • Simply adding or removing safety function blocks at any stage of machine design
  • Is able to check the logic configuration of the application during the designing phase through the validation function and Simulation as well as to test it during the installation through the monitor function
  • Allows tamper-proof system configurations as:
    – detection of tempering attempts through specific tests (i.e. mandatory test
      of the safety device at machine start-up)
    – protection against unauthorized changes to the project through a
      2-level password
  • All logic is configured through a graphic interface. No more laborious wiring is needed as with traditional solutions
  • A lower number of electromechanical components also means a better Performance Level and, therefore, a higher Safety Level
  • The project report provides the actual values of PFHd, DCavg and MTTFd according to EN 13849-1 and EN 62061
Mosaic Safety level

Safety in the work environment
is indispensable

ReeR’s safety devices for the protection of machines and industrial plants are designed, engineered and manufactured in Italy. Our solutions, guaranteed by the Quality System, certified by TUV Italy according to ISO 9001:2008, offer versatility and safety in the automation environment at an international level. 

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