In PRODENGROUP we have developed an engineering project and adaptation of machinery according to ISO 12100 and RD 1215/1997 of machinery and functional validation according to ISO 13849-2 in a plant of the industrial sector located in the province of Barcelona, dedicated to the manufacture of plastic components by injection.

The project involved risk assessment, engineering and machinery adaptation phases in accordance with ISO 12100 and RD 1215. Achieving the safety and functional improvement of the injector, Cartesian robot and conveyor belt assembly, with special attention to the validation of functional safety according to ISO 13849-2.

Although this action was carried out in Barcelona, PRODENGROUP applies this same methodology throughout Catalonia, helping industrial and food companies to strengthen the safety and efficiency of their industrial facilities.

Industrial engineering applied to the partial adaptation of injection molding facilities

Technical approach to safety improvement

The project began with an initial analysis of the facility in accordance with the ISO 12100 risk assessment and reduction methodology and the suitability requirements established in RD 1215/1997.
This diagnosis made it possible to identify applicable improvements in access, protection, electrical systems and control logic, defining priorities for action according to the level of risk and the interaction of operators with the equipment.

Based on this evaluation, PRODENGROUP participated in partial adaptation actions, prioritizing:

Functional coherence between the different interconnected equipment, ensuring that the control logic and safety systems act in a coordinated manner.

Safety in areas close to mechanical movements, through solutions that reduce worker exposure and improve the quality of protection.

Improvement of access and daily operation, incorporating ergonomics, maintainability and safe use criteria.

Risk reduction in critical areas, with special attention to entrapment points, hot spots, stored energy and foreseeable operation failures.

This approach ensured an efficient intervention that was compatible with the client’s production rhythm.

Technical suitability and engineering improvements in mechanical, electrical and robotic systems

Adequacy of safeguards and mechanical improvements

Standards applied to the mechanical part

Safeguards were reviewed and optimized by applying reference to the standards:

• UNE-EN ISO 14120 – Requirements for guards.
• UNE-EN ISO 13857 – Safety distances.
• RD 1215/1997 – Minimum conditions for work equipment.

This reinforced security in sensitive areas without affecting productive functionality.

Electrical overhauls and control system consistency

Electrical integration and consignment

We collaborated in the review of electrical cabinets, identification of LOTO consignments and verification of the consistency of emergency shutdowns, following:

• UNE-EN 60204-1 – Safety of electrical equipment of machines.
• Good practices for signal and interlocking integration.

These improvements provided operational clarity and facilitated technical intervention tasks.

Functional integration with Cartesian robot and pneumatic system

Operational coordination between teams

The interaction between robot, belt and injector was reviewed to ensure:

• Synchronized and consistent stops.
• Predictable responses to emergency situations.
• Greater stability in automated behavior.

This made it possible to improve efficiency without profound structural changes.

UNE-EN ISO 13849-2 validation: functional integrity assurance of the safety system

Technical validation of the control system

Added value provided by functional validation

The project included validation according to UNE-EN ISO 13849-2, ensuring that the safety control system met the established performance levels (PL).

The validation allowed:

• Verify the reliability of security subsystems.
• Confirm the integrity of interlocks and redundant channels.
• Provide traceable documentation for audits.

This process provides a differential value to the customer, consolidating the functional safety of the installation.

Project benefits for the client

Increased operational safety

The intervention reduced risks and improved personnel confidence during operation and maintenance.

Production continuity and technical efficiency

The consistency between robot, injector and conveyor has optimized process stability, reducing incidents and increasing availability.

Enhanced regulatory compliance

The customer now has a system aligned with:

• RD 1215/1997
• UNE-EN ISO 13849-1 and 13849-2
• UNE-EN ISO 14120
• UNE-EN 60204-1

And with adequate documentation for audits or future expansions.

PRODENGROUP: engineering, adaptation and functional validation throughout Catalonia

This case in Barcelona demonstrates PRODENGROUP ‘s ability to integrate engineering, partial suitability and advanced functional validation, providing high value-added solutions to industrial companies throughout Catalonia.