How We Transformed Waste Grab Feedback and Safety — With a Simple, Hardwired Solution

BIA Engineering Ltd — Engineering Solutions Beyond Expectations

Waste grab cranes are absolutely critical to the operation of energy-from-waste plants.

If they don’t run reliably, the plant doesn’t run.

Yet during our work on grab crane systems, BIA Engineering Ltd was surprised — even shocked — at what we found in one major facility:

The grab had no meaningful communication back to the control room.

Operators had almost no visibility on grab status.

Basic run signals were wired to the solenoids — and that was it.

If a fault occurred, the only option was for someone to enter the bunker — a biohazard area — to manually reset the grab or investigate.

Given the importance of this equipment, and the risks involved, this was simply unacceptable.

Our Approach

At BIA Engineering Ltd, we believe that good engineering is not just about machine performance — it is about supporting the people who run and maintain those machines.

We designed and implemented a simple, robust solution: a fully hardwired feedback and fail-safe system for the grab head — requiring no additional electronics, no complex integration.

Our system included:

• Hardwired fail-safes installed in the grab head

• Pre-fault stops implemented ahead of the conditions that required manual intervention

• Feedback wiring to the control room — providing clear status indication without needing operators to enter the bunker

Specific features included:

• Hardwired stop for low hydraulic oil level

• Hardwired stop for high hydraulic oil temperature

• Visual indication of fully open grab position

• “Getting warm” warning light for early fault detection on rams

• Digital readout and indicator light for oil temp trip status

• Auto-reset functionality when oil temp reduced — allowing safe continued operation overnight

The Impact

This simple solution delivered massive practical benefits:

• Operators no longer had to enter the bunker to reset the grab — greatly reducing risk

• The grab could continue operating in a “limp mode” through the night if required — allowing night shift to maintain production

• On-call engineers were no longer constantly called out at night for avoidable grab resets

• Maintenance could be planned properly during the day — by a full team, in safe conditions

• Operator morale improved dramatically — knowing they could trust the system and didn’t need to take personal risks

• Maintenance morale also improved — no more unnecessary lone working callouts in the middle of the night

• The plant saved money by reducing on-call payments and preventing unplanned night-time interventions

Why It Matters

Too often, OEM systems lack the practical feedback and control needed for safe, efficient plant operation.

At BIA Engineering Ltd, we look beyond the “official” design — and ask:

What does this plant actually need to run well and keep its people safe?

Engineering solutions beyond expectations means understanding not just the machine — but the system, the plant, and the people.

If your plant is struggling with poor feedback, dangerous manual reset processes, or avoidable callouts — we can help you implement solutions that work.