The Academy area of PRODEN GROUP has developed a training project on machine safety and safe interventions, aimed at a manufacturer of paper products in the province of Girona. The initiative has enabled the client to strengthen internal competencies, reduce its exposure to risk and move towards a stronger preventive culture. As always, PRODEN GROUP offers these training services throughout Catalonia.

In the paper converting industry, continuous production, automated lines and frequent format changes require complex machinery, high production rates and intensive maintenance operations. All this poses a permanent challenge in terms of industrial safety, especially in terms of machine safety, maintenance interventions and coordination between production, quality, engineering and prevention.

Machinery safety in the paper industry: challenges and need for training

The paper sector presents particularities that increase the criticality of industrial machinery safety:

• Production lines with moving elements, cylinders, rollers, rollers and cutting systems.
• Recurrent adjustment, cleaning and tooling change operations.
• Corrective and preventive maintenance interventions in environments with mechanical, electrical, pneumatic and hydraulic power.
• Need to maintain high availability of equipment in a very competitive market.

In this scenario, specialized training becomes a key tool for middle management and technicians to have an in-depth knowledge of the applicable regulations, legal responsibilities and good practices in blocking and lockout (LoTo), work permits and coordination of activities.

Objectives of the training project

The training was designed for a multidisciplinary group of 12 attendees, with profiles belonging to the quality, safety, maintenance, production and engineering departments.

The main objectives were:

• To provide a clear view of the legal requirements regarding the safety of machinery and work equipment.
• To provide technical criteria for interpreting and enforcing compliance with the Essential Health and Safety Requirements (EHSR).
• Provide practical tools to organize safe interventions (LoTo, work permits, intervention modes, coordination).
• Create a common language between departments that facilitates safe decision making.

PRODEN GROUP Methodology: Applied and plant-oriented machine safety training

Practical approach adapted to the industrial environment

The machine safety training was structured in a 4.5-hour classroom session, based on:

• Technical exposition and conceptual clarity.
• Real examples and typical situations, contextualized in the paper sector.
• Guided discussions to align criteria and responsibilities between departments.
• Use of templates and checklists to support the standardization of best practices.

The practical approach allowed attendees to easily relate the content to their daily operations.

Key contents for machine safety training: regulations, responsibilities and safe work

The structure of the training content was organized in two main blocks:

1. Block 1 – Machine safety and legal responsibilities
   • Applicable regulations:
     • Directive 2006/42/EC y RD 1644/2008 (machinery).
     • Regulation (EU) 2023/1230 on machinery.
     • RD 1215/1997 on work equipment.
     • Law 31/1995 on Occupational Risk Prevention.
   • Concepts of CE marking, technical documentation, modifications and responsibilities of the employer and controls.
   • Introduction to technical standards such as EN ISO 12100, EN ISO 13849-1, EN 60204-1, EN ISO 14120 and EN ISO 14122.
2. Block 2 – Safe interventions, LoTo and work organization
   • Principles of blocking and appropriation (LoTo).
   • Work permits for technical interventions.
   • Planning and control of interventions on machinery, verification prior to start-up and recording of actions.

As complementary regulations, cross-cutting provisions such as RD 614/2001 on electrical risk and RD 486/1997 on conditions in workplaces were also cited.

Benefits achieved by the paper manufacturer

The training was very well received, highlighting its immediate applicability and practical orientation. Among the most relevant benefits:

1. Better alignment with current regulations
   • Clarity in obligations and responsibilities.
   • Increased ability to detect deviations and prioritize corrective actions.
2. Strengthening the preventive culture
   • Cohesion between production, maintenance, quality, safety and engineering.
   • Increased safety leadership in middle management.
3. Solid basis for improving safe intervention procedures
   • Clear criteria for revising or creating LoTo procedures and work permits.
   • Templates and checklists that facilitate internal audits and standardization.
4. Reduced operational risk and improved internal coordination
   • Reduction of potential incidents in machinery interventions.
   • Better planning of shutdowns and critical tasks.

This project consolidates the role of PRODEN GROUP as a benchmark in training and consultancy in machinery safety, providing methodology, rigor and added value to the Catalan industrial sector.

PRODENGROUP ACADEMY: technical training for industry all over Catalonia

Although this project was developed in the province of Girona, PRODEN GROUP offers its training programs in machine safety, risk assessment, CE marking and process improvement throughout Catalonia.

The area PRODEN GROUP Academy area designs training programs totally oriented to the industrial reality and to the operational needs of each client, integrating:

• Specialized technical training.
• Practical plant-oriented methodology.
• Expert support by engineers specialized in machine safety.