Context of the project

The study of machine safety is framed within the philosophy of preventive engineering PRODEN’s preventive engineering philosophy, aimed at integrating safety from the early stages of industrial machinery design.

An industrial machinery manufacturer requested the collaboration of PRODEN Group to carry out a complete safety study in the design phase of a new production line for food flour, destined for a reference producer in the large-scale distribution sector. The objective of the project was to assess the risks arising from the use, maintenance and cleaning of the installation, and to establish the technical and control measures necessary to comply with European legislation on machinery.

Study approach and development

PRODEN’ s engineering team approached the project from a multidisciplinary point of view, integrating specialists in machinery safety, automation, regulations, electrical design and industrial processes.

This combination of technical profiles made it possible to analyze the design from different perspectives, ensuring a coherent result from both a regulatory and operational point of view.

Applying preventive engineering preventive engineeringThe analysis was developed on the manufacturer’s 3D model, allowing to anticipate risks and optimize the safety architecture before manufacturing, this allowed:

• Identify risk areas in early design phases.
• Evaluate access, movements and possible interferences in virtual environments.
• Propose safety solutions adapted to the actual geometry of the equipment.

1. Applicable regulations and risk assessment

The study was carried out in accordance with the essential health and safety requirements of Directive 2006/42/EC, Regulation (EU) 2023/1230 relating to machinery,Royal Decree 1215/97, Regulation ( EC) 1215/97 and Regulation (EC) 1215/97. Royal Decree 1215/97and the applicable harmonized standards.

The following were analyzed:

• Mechanical, electrical and entrapment hazards.
• Accessibility during cleaning and maintenance.
• Interaction between operators and automated elements.

The result was a detailed risk assessment, prioritized according to severity and probability of occurrence, which served as the basis for defining the required safety functions.

2. Preventive engineering: Technical definition and safety architecture

Based on the results of the analysis, the PRODEN team defined:

• The required Performance Level (PL) levels according to EN ISO 13849-1.
• The appropriate connection and redundancy categories.
• The selection of safety PLCs, relays, drives and control elements.
• The design of the electrical safety architecture, including wiring diagrams.

The work also helped to optimize the technical design and reduce manufacturing costs by defining from the outset an efficient configuration adjusted to the actual risk level.

Results of the work

The safety study allowed the manufacturer:

• To have a 3D model analyzed and validated from a safety point of view.
• Comply with current European regulations from the design phase.
• To have a documented technical basis for CE marking of the line.
• Reduce development and manufacturing costs by optimizing the electrical and control architecture.

The result was a safe and compliant installation, ready for validation and subsequent manufacturing with a comprehensive approach to safety.

Conclusion

This project on machinery safety and preventive engineering confirms how preventive engineering preventive engineering is essential to ensure functional safety and CE conformity in complex industrial environments.

The project demonstrated the value of having a multidisciplinary team specialized in industrial safety, capable of integrating engineering, automation and regulatory knowledge from the early design stages.

Working on the manufacturer’s 3D model made it possible to anticipate critical decisions. Thus reducing subsequent modifications to ensure that the installation fully complied with safety and reliability requirements, which are demanded by European regulations.