16/06/2026
Case Study: Cost-Effective Automation Upgrade & Critical Safety Improvements
The Challenge
During a recent service visit, our specialist engineer diagnosed a terminal fault in a customer's "in-head" (housed inside the frame) swing door operator. Traditionally, replacing this obsolete style of concealed automation requires an entirely new door and frame. This standard approach would have forced the customer into a major expenditure.
The Bespoke Solution
To accommodate the customer’s limited budget, we engineered a custom alternative. Instead of replacing the structural framing, we manufactured a bespoke-sized transom to infill the void left by the old in-head operator.
This custom-fit profile created a highly stable, secure mounting location for a new, premium Record DFA 127 surface-mounted door operator. By choosing this retrofitted engineering solution over a full replacement, we saved the customer approximately £4,000 in unnecessary door and frame costs.
Critical Safety Upgrade
Beyond the mechanical installation, our attending engineer identified a safety compliance issue with the existing setup:
• The Risk: The original standard sensors only covered 30% of the door's movement.
• The Danger: This left students exposed to a crushing risk against the barrier located behind the open door.
• The Correction: We advised the customer of these critical risks. Full-coverage safety sensors were included into the new automation specification to ensure 100% compliance and user protection.
Key Outcomes
• £4,000 saved compared to a full frame and door replacement.
• Premium upgrade to a reliable Swiss manufacturer Record DFA 127 automatic door operator.
• Upgraded full coverage achieved, eliminating a crushing hazard.
• Fully complaint system provided with a 24 Month comprehensive warranty
