Adaptation of a semi-automatic baler to “Zero Access” safety requirements and CE recertification.

In Prodengroup we have carried out a project of risk assessment and machine safety adequacy in a semi-automatic baler, in order to ensure compliance with the principles of “Zero Access” and CE recertification of the equipment, thus ensuring its compliance with current European legislation and regulations.

Initial situation

In the assessment of the initial situation (Figure 1), a risk of direct access to the baler working area was identified, which entailed non-compliance with:

• Machinery Directive 2006/42/EC.
• Royal Decree 1215/1997, on minimum health and safety provisions for the use of work equipment by workers.
• Applicable harmonized standards, such as:
  • UNE-EN ISO 12100:2012 (risk assessment and reduction).
  • UNE-EN ISO 13857:2020 (safety distances).
  • UNE-EN IEC 61496 (safety light barriers).

Adjustment made

The adaptation (Image 2) was designed and executed in accordance with regulatory requirements, guaranteeing the elimination of risks and the possibility of recertifying the equipment with CE marking.

The main measures implemented were:

• Installation of a safety light barrier (light curtain) to prevent access to the hazardous area during operation.
• Integration of the barrier in the control system, so that any interruption of the light beams causes an immediate and safe stop, in compliance with UNE-EN ISO 13849-1.
• Review and adequacy of signaling and emergency stop devices, in accordance with UNE-EN ISO 13850:2016.
• Verification of safety distances and response time, following UNE-EN ISO 13855:2010.

CE recertification

After the adaptation, the CE recertification process of the machine was carried out, ensuring compliance with the Machinery Directive 2006/42/EC and its harmonized standards. This allows the customer to have a legally compliant, safe and certified equipment for use within the European Economic Area.

Results

With this intervention, the risk of access to hazardous areas during the operating cycle was eliminated, the required safety level was achieved and CE recertification was obtained, thus guaranteeing both the protection of people and legal compliance and continuity of production.

This project reflects Prodengroup ‘s commitment to industrial safety and regulatory compliance, accompanying our clients throughout the process of evaluation, adaptation and certification of their equipment.