Our application for the ZVEI Electrifying Ideas Award 2025
Relay for sustainable safety controls: Harmonising safety and the environment
Functional safety applications protect lives - and our environment. The new SID relay and our sustainable packaging show how maximum safety and ecological responsibility can be combined. We consider the entire life cycle - from production to recycling. Find out here how ELESTA combines safety and environmental responsibility.
SID relay by ELESTA: sustainability starts with the details
Safety control systems protect human life from accidents involving machines, trains, medical devices and lifts. In them, relays with forcibly guided contacts act as switching elements that link load and logic. In the case of two-channel solutions, two relays are usually required in these control systems, which must be electrically activated continuously during operation (closed-circuit principle).
The new SID relay consists of a relay coil with two independent contact sets. It therefore replaces two conventional relays. We consider the entire life cycle in terms of sustainability. To do this, we have analysed the R strategies (Reduce, Rethink, Reuse, Recycle) from the DIN Circular Economy standardisation roadmap and the Sustainability Goals (SDGs) of the United Nations, in particular Goals 9 (Industry, Innovation & Infrastructure), 12 (Sustainable Consumption & Production) and 13 (Climate Action).
Functional principle of the SID double armature relay
The SID relay consists of two independent contact sets. This allows the two-channel function to be realised. The scenario in the video demonstrates the linking of the contacts in a contact set and the properties of the associated status detection of the counter-functional contacts using the example of the fault case opening failure, e.g. contact welding.
The SID double armature relay compared to two conventional relays with the same function: advantages in production
Energy-efficient production (Reduce)
Reduced energy consumption in production due to fewer production steps. Production energy from 100% green electricity.
UN SDG 9: Industry, Innovation & Infrastructure and SDG 13: Climate action
Less material used (Reduce)
Reduced material consumption through intelligent design and fewer individual parts - conserves valuable resources.
UN SDG 12: Sustainable Consumption & Production
Less packaging required (Reduce)
Optimised packaging sizes and sustainable packaging materials reduce the ecological footprint already during production.
UN SDG 12: Sustainable Consumption & Production
Rethink
The design with double armature and only one relay drive promotes sustainability and economy.
SID relay as a component of the switchgear: advantages in design and production
Developers of safety switching devices face numerous challenges: Lack of space on the circuit board, high number of components, complex manufacturing processes. The SID relay offers solutions to these challenges. Find out how it optimises the development process and improves sustainability at the same time.
Kompakte Bauweise (Reduce)
The SID relay saves valuable space on the circuit board as it replaces two conventional relays. This enables a more compact and resource-saving control design.
UN SDG 9: Industry, Innovation & Infrastructure and SDG 12: Sustainable Consumption & Production
Fewer components (Reduce)
By integrating two relays in one, the SID reduces the number of drill holes, conductor tracks and control components for the protective circuit.
UN SDG 12: Sustainable Consumption & Production
Press-fit technology (Rethink)
The press-fit contacts of the SID relay are efficient and environmentally friendly, as they eliminate a second soldering process if no other THT components are required.
UN SDG 12: Sustainable Consumption & Production
Advantages of operating the safety controller
The SID relay not only offers advantages in development and production, but also in the ongoing operation of the safety controller.
Low power consumption (Reduce)
Lowers energy consumption during operation and reduces heat generation as only one relay drive is energised.
UN SDG 7: Affordable & clean energy, SDG 12: Sustainable consumption & production and SDG 13: Climate action
High availability
Proven technology and robust construction of the relay in combination with a compact design of the safety controller ensure higher availability in the application.
UN SDG 9: Industry, Innovation & Infrastructure
Reliability
By integrating the functions of two relays in one housing, a PCB design with fewer connections and the reduction of peripheral electronic components, potential sources of error are minimised. This increases the reliability of the safety controller.
End of life of the relay: simple recycling
Even at the end of its long service life, the SID relay makes a contribution to sustainability.
Recyclability (Recycle)
Valuable metals can be recycled at the end of their life cycle.
UN SDG 12: Sustainable Consumption & Production
REACH & RoHS conformity
The relay fulfils high environmental standards: no substances subject to reporting or registration.
PFAS-free
The SID relay is free of perfluorinated and polyfluorinated alkyl substances (PFAS) and therefore already largely fulfils international requirements.
Rethinking packaging: Sustainability from the outside in
The SID relay sets standards in terms of sustainability – and this claim is consistently continued in the packaging. We have developed a cost-neutral packaging solution that not only optimally protects the product, but also protects our environment. We want to show how we have developed our packaging based on the R strategies (Reduce, Rethink, Reuse, Recycle) and the UN sustainability goals (SDG 12: Sustainable Consumption & Production, SDG 13: Climate Action).
Our packaging consists of three components: Blister, outer cardboard packaging and two labels.
- Blister packs: The original PET-A blister packs have been completely replaced by paper-based bioform blister packs. This means we no longer use fossil components.
- Outer packaging: The outer packaging now consists of >95% recycled paper. In addition, the corrugated cardboard tube does not have a bleached surface.
- Labelling: The printed plastic labels have been replaced by printed paper labels with PFAS-free adhesive.
Sustainable packaging in detail - a cycle
This video shows the transition from old to new packaging and illustrates the implementation of the R strategies (Rethink, Reduce, Reuse, Recycle). In a time-lapse, we show how the Bioform blister decomposes in industrial compost and how every component of the packaging – from the blister to the cardboard packaging to the labels – has been optimised for sustainability. From material selection and transport routes to reuse and recycling, we have developed a packaging solution that takes the entire life cycle into account.
Advantages in procurement
Reduced transport distance (Reduce)
The transport distance for the packaging blisters was reduced by approx. 6000 km. This means fewer emissions and a lower carbon footprint.
UN SDG 13: Climate action
Advantages of the material
Compostable option (Recycle/Rethink)
All packaging is industrially compostable. However, recycling is preferable to composting.
UN SDG 12: Sustainable Consumption & Production
Recyclable option (Recycle/Rethink)
Recyclable plastic and recyclable cardboard and paper. The bioform blister is made from biobinder, chalk, lime and cellulose.
UN SDG 12: Sustainable Consumption & Production
PFAS-free (Rethink)
The packaging is PFAS-free and free of materials subject to notification, registration or sanctions as defined by REACH. The label adhesive is PFAS-free.
UN SDG 12: Sustainable Consumption & Production
Multiple use (reuse)
The blister packaging can be reused as returnable packaging.
UN SDG 12: Sustainable Consumption & Production
Advantages during transport
Reduced packaging costs (Reduce)
In relation to two comparable conventional relays, the product and transport volume is significantly reduced.
UN SDG 12: Sustainable Consumption & Production
Lighter on the road
The transport weight of the packaging including the relay is lower than that of two comparable conventional relays.
Fewer CO₂ emissions
Lower carbon footprint during transport.
At the end of use: recycling or composting
Our sustainable packaging is not only optimised for transport, but also for a long service life and an environmentally friendly end to its life cycle.
Compostable option (Recycle)
After use, the entire packaging can be industrially composted and thus returned to the natural cycle.
UN SDG 12: Sustainable Consumption & Production
Recyclable option (Recycle)
The packaging is separable and enables high-quality recycling of the materials in paper recycling (label and cardboard) or as plastic recyclate (blister).
UN SDG 12: Sustainable Consumption & Production