Hi, not in your line of work but happen to come across this when looking for different Perspex question. I don't know if this will work, but the issue of where the spell pieces of Perspex from the cracks is the main health and safety issue. Can't you just wrap the plexiglass with some what we call in UK as cling film, I think in America you have a different name for it, flexi wrap or something. The really thin sheets of plastic you may cover a sandwich with or cover a food item one opened to prevent it from contamination. It doesn't have glue on it but it sticks to everything, especially itself and any thing you don't want it to stick to. Comes on a roll in a box, the box has a serrated edge as though it's really thin if you try to just rip it you end in a mess as it will stretch stick to itself, anything but rip unless you use the serrated edge on the box, hence why it's there. It's see through, doesn't tear without a fight, come in different lengths and thickness, you can even leave it on the food it's covering, unless you by the cheep stuff then in melts into your food, so read instructions on box first. If boiling potatoes in the microwave, you can make a couple of holes to let the steam out and the holes don't get bigger.
My point, if you put it against the food side of the plexiglass, when the plexiglass cracks it will just stick to the cling film. It's see through so you'll still be able to see when it's in place. If you see a crack in the Perspex you can remove the cling film which will contain any particles. So you know your product is not contaminated. Follow other processes and attach knew cling film.
Solution 2. I don't know if this will work, if it does it solves all your problems.
Before you fix your plexiglass in place, can't you cover all sides with a thin layer, or thick layer, intact as thick as you can and I still see through, of dry clear appoxy glue. Once dry it won't break, it will even keep the plexiglass it's touching from breaking, more the plexiglass tries to break the harder the glue fights to prevent any break. Just contact a manufacturer, tell him your plans for their product, they may be able to make you a special batch for your needs. It may cost quite a bit upfront, but once done you should never need to replace them, wasting money each time on all the costs involved and a persons time checking and photographing all the time. The outlay could be covered in a year as you can apply the appoxy to the plexiglass already damaged, so you shouldn't even have to replace the plexiglass you have. Interested if this works, make sure you get back to me if it does. Also connect the appoxy firm to me as if you think of the number of companies in your situation!!!! I'm Disabled and largely bed bound, an extension with a small hydrotherapy pool would change my life, giving my time with my wife and nine year old son. My wife had to give up her work to care for me. This isn't a begging letter, but if it works and saves your companies thousands in the long run & between you, the amount to give me a life and my family time with their dad would only cost a fraction of what it could save you, and I'm sure both the appoxy and disability aid or payment to technical advisor (Me) could be written off against tax. I would even provide evidence that I am bed bound & not conning you. Even if none of you helped me if the idea works, I still hope it solves your problem.
