{"id":1436,"date":"2025-10-06T17:21:35","date_gmt":"2025-10-06T15:21:35","guid":{"rendered":"https:\/\/prodengroup.com\/adjustment-of-turnkey-industrial-machinery\/"},"modified":"2025-11-03T11:46:50","modified_gmt":"2025-11-03T10:46:50","slug":"adjustment-of-turnkey-industrial-machinery","status":"publish","type":"post","link":"https:\/\/prodengroup.com\/en\/adjustment-of-turnkey-industrial-machinery\/","title":{"rendered":"Retrofitting of industrial machinery: Turnkey projects"},"content":{"rendered":"\n<h2 class=\"wp-block-heading\"><strong>Introduction<\/strong><\/h2>\n\n<p class=\"wp-block-paragraph\">In modern industry, ensuring the safety of industrial machinery, workers and complying with current regulations is an unavoidable priority. <strong>Regulation (EU) 2023\/1230<\/strong>, together with the <strong>Machinery Directive 2006\/42\/EC<\/strong> and <strong>Royal Decree 1215\/1997<\/strong>, establish clear requirements to protect those who operate or interact with industrial machinery. <\/p>\n\n<p class=\"wp-block-paragraph\">However, retrofitting a machine is not just about installing a sensor or a barrier. To achieve a real, sustainable and compliant level of safety, a holistic approach is required: a <strong>comprehensive project<\/strong>, addressing all technical, legal and operational aspects from a global perspective. <\/p>\n\n<p class=\"wp-block-paragraph\">Apply a structured and proven methodology, carrying out a turnkey project. <strong>\n  <a href=\"https:\/\/prodengroup.com\/proyectos\/\">turnkey project<\/a>\n<\/strong> project, combining <strong>normative<a href=\"https:\/\/prodengroup.com\/en\/soluciones\/engineering\/\">engineering <\/a>, technical design, <a href=\"https:\/\/prodengroup.com\/en\/soluciones\/adequa\/\">adaptation<\/a>, functional validation and document management<\/strong>, ensures a complete and seamless execution.<\/p>\n\n<h2 class=\"wp-block-heading\"><strong>What does &#8220;turnkey&#8221; mean in machinery retrofitting?<\/strong><\/h2>\n\n<p class=\"wp-block-paragraph\">A <em>turnkey<\/em> project implies that <strong>the supplier assumes full responsibility for the entire process of adaptation<\/strong>, from the initial diagnosis to the final delivery in compliance with regulations.<br\/>This allows the customer to have a comprehensive industrial safety solution, with a single technical interlocutor, absolute control of traceability and the guarantee of legal and functional compliance.<\/p>\n\n<h2 class=\"wp-block-heading\"><strong>What phases are included in a turnkey project of machinery adaptation?<\/strong><\/h2>\n\n<p class=\"wp-block-paragraph\">Turnkey machinery retrofitting projects must be developed following <strong>clearly defined phases<\/strong> that ensure consistency, control and regulatory compliance at each stage.<\/p>\n\n<h3 class=\"wp-block-heading\"><strong>PHASE 0. Functional Safety Plan (FSP) and initial diagnosis <\/strong><\/h3>\n\n<ul class=\"wp-block-list\">\n<li>Complete inventory of equipment and machine assemblies.<\/li>\n\n\n\n<li>Review of existing technical documentation (dossiers, risk assessments, CE declarations).<\/li>\n\n\n\n<li>Analysis of compliance with applicable regulations.<\/li>\n\n\n\n<li>Preparation of the <strong>Functional Safety Plan (FSP)<\/strong>, which defines the scope and expected safety requirements.<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\">This phase establishes the <strong>technical and regulatory basis<\/strong> of the project, on which the adaptation actions are built.<\/p>\n\n<h3 class=\"wp-block-heading\"><strong>PHASE 1. Risk assessment and safety requirements <\/strong><\/h3>\n\n<ul class=\"wp-block-list\">\n<li>Risk assessment according to <strong>UNE-EN ISO 12100<\/strong>.<\/li>\n\n\n\n<li>Determination of the <strong>required Performance Level (PLr)<\/strong> according to <strong>UNE-EN ISO 13849-1.<\/strong><\/li>\n\n\n\n<li>Elaboration of the <strong>Checklist of Essential Health and Safety Requirements<\/strong> (Annex I of the Machinery Directive).<\/li>\n\n\n\n<li>Verification of compliance with <strong>RD 1215\/1997<\/strong>.<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\">The result is a <strong>technical and operational risk map<\/strong>, the basis for subsequent engineering solutions.<\/p>\n\n<h3 class=\"wp-block-heading\"><strong>Analysis of electrical diagrams and calculation of safety levels. <\/strong><\/h3>\n\n<ul class=\"wp-block-list\">\n<li>Study of electrical and control diagrams.<\/li>\n\n\n\n<li>Calculation of safety levels achieved (PL) according to <strong>UNE-EN ISO 13849-1.<\/strong><\/li>\n\n\n\n<li>Preliminary validation of the safety PLC software and control architecture.<\/li>\n<\/ul>\n\n<h3 class=\"wp-block-heading\"><strong>PHASE 3. Engineering of technical solutions <\/strong><\/h3>\n\n<ul class=\"wp-block-list\">\n<li>Design of <strong>guards, enclosures, handrails, walkways and platforms<\/strong> according to <strong>EN ISO 14120<\/strong> and <strong>EN ISO 14122<\/strong>.<\/li>\n\n\n\n<li>Integration of <strong>active safety systems<\/strong> (photocells, laser scanners, light curtains, safety relays).<\/li>\n\n\n\n<li>Redefinition of <strong>access and safe areas<\/strong>, prioritizing ergonomics and maintainability.<\/li>\n\n\n\n<li>Preparation of <strong>technical report, plans and execution budget<\/strong>.<\/li>\n<\/ul>\n\n<h3 class=\"wp-block-heading\"><strong>Intervention and Appropriation Instructions (LOTO) <\/strong><\/h3>\n\n<ul class=\"wp-block-list\">\n<li>Preparation of the <strong>Technical File<\/strong> in accordance with Annex VII of Directive 2006\/42\/EC.<\/li>\n\n\n\n<li>Advice on the drafting of the <strong>Instruction Manual<\/strong> (Annex I, point 1.7.4).<\/li>\n\n\n\n<li>Generation of the <strong>CE Declaration of Conformity<\/strong> and CE plate model.<\/li>\n\n\n\n<li>Follow-up of the execution of measures and final verification.<\/li>\n<\/ul>\n\n<h3 class=\"wp-block-heading\"><strong>PHASE 5. Documentary execution and CE marking <\/strong><\/h3>\n\n<ul class=\"wp-block-list\">\n<li>Preparation of the <strong>Technical File<\/strong> in accordance with Annex VII of Directive 2006\/42\/EC.<\/li>\n\n\n\n<li>Advice on the drafting of the <strong>Instruction Manual<\/strong> (Annex I, point 1.7.4).<\/li>\n\n\n\n<li>Generation of the <strong>CE Declaration of Conformity<\/strong> and CE plate model.<\/li>\n\n\n\n<li>Follow-up of the execution of measures and final verification.<\/li>\n<\/ul>\n\n<h3 class=\"wp-block-heading\"><strong>PHASE 6. Functional validation and PL verification <\/strong><\/h3>\n\n<ul class=\"wp-block-list\">\n<li><em>On-site<\/em> testing of safety functions according to <strong>UNE-EN ISO 13849-2.<\/strong><\/li>\n\n\n\n<li>Verification that the <strong>PL achieved<\/strong> matches the <strong>required PLr<\/strong>.<\/li>\n\n\n\n<li>Issuance of the <strong>Functional Validation Report<\/strong>.<\/li>\n<\/ul>\n\n<h3 class=\"wp-block-heading\"><strong>PHASE 7. Final review and certification <\/strong><\/h3>\n\n<ul class=\"wp-block-list\">\n<li>Integral verification of corrective measures.<\/li>\n\n\n\n<li>Validation of compliance with RD 1215\/1997 and the Machinery Directive.<\/li>\n\n\n\n<li>Issuance of the <strong>Certificate of Conformity<\/strong> that certifies the full adequacy of the installation.<\/li>\n<\/ul>\n\n<h2 class=\"wp-block-heading\"><strong>Benefits of the turnkey model<\/strong> <strong>in machinery adaptation projects<\/strong><\/h2>\n\n<ul class=\"wp-block-list\">\n<li><strong>A single technical interlocutor<\/strong> who centralizes all management.<\/li>\n\n\n\n<li><strong>Guaranteed<\/strong> and documented <strong>regulatory compliance<\/strong>.<\/li>\n\n\n\n<li><strong>Reduction of legal and labor risks<\/strong>.<\/li>\n\n\n\n<li><strong>Optimized planning<\/strong> with minimum production interference.<\/li>\n\n\n\n<li><strong>Full traceability and auditable documentation<\/strong>.<\/li>\n\n\n\n<li><strong>Real functional security<\/strong>, not just formal.<\/li>\n<\/ul>\n\n<h2 class=\"wp-block-heading\"><strong>Limitations of the turnkey model in machinery retrofitting projects and how to mitigate them.<\/strong><\/h2>\n\n<ol start=\"1\" class=\"wp-block-list\">\n<li><strong>Less flexibility during execution<\/strong> \u2192 avoided by defining the scope with precision and continuous communication.<\/li>\n\n\n\n<li><strong>Higher initial investment<\/strong> \u2192 offset by reducing reprocessing and risks of penalties for non-compliance.<\/li>\n\n\n\n<li><strong>Dependence on a single supplier<\/strong> \u2192 mitigated by technical solvency and proven experience.<\/li>\n\n\n\n<li><strong>Integration with existing systems<\/strong> \u2192 provide for prior compatibility audits.<\/li>\n\n\n\n<li><strong>Risk of longer lead times<\/strong> \u2192 coordinate with scheduled shutdowns and evaluation of time reduction due to reprocessing between different industrialists.<\/li>\n\n\n\n<li><strong>High documentation requirements<\/strong> \u2192 define the customer-supplier information flow from the beginning.<\/li>\n<\/ol>\n\n<h2 class=\"wp-block-heading\"><strong>Cases in which a turnkey project is not advisable<\/strong> in machinery adaptation projects.<\/h2>\n\n<p class=\"wp-block-paragraph\">Although the <em>turnkey<\/em> model is very effective, there are situations where <strong>it is not the most appropriate or proportional option<\/strong>.<\/p>\n\n<p class=\"wp-block-paragraph\"><strong>1. Facilities under continuous redesign<\/strong><\/p>\n\n<p class=\"wp-block-paragraph\">\ud83d\udd39 <em>Alternative:<\/em> progressive adaptation by phases as the line stabilizes.<\/p>\n\n<p class=\"wp-block-paragraph\"><strong>Machinery with shared integration<\/strong><\/p>\n\n<p class=\"wp-block-paragraph\">\ud83d\udd39 <em>Alternative:<\/em> technical coordination and suitability consulting between manufacturers and integrators.<\/p>\n\n<p class=\"wp-block-paragraph\"><strong>3. Newly acquired equipment<\/strong><\/p>\n\n<p class=\"wp-block-paragraph\">\ud83d\udd39 <em>Alternative:<\/em> independent post-installation compliance verification.<\/p>\n\n<p class=\"wp-block-paragraph\"><strong>4. Partial interventions on safety systems<\/strong><\/p>\n\n<p class=\"wp-block-paragraph\">Before acting, it must be assessed whether the modification is <strong>substantial<\/strong>, as it could <strong>invalidate the<\/strong> manufacturer&#8217;s <strong>CE marking<\/strong>.<br\/>\ud83d\udd39 <em>Alternative:<\/em> prior technical-legal impact analysis; if not substantial, documented action; if substantial, new integral adequacy process.<\/p>\n\n<p class=\"wp-block-paragraph\"><strong>5. Equipment without technical documentation<\/strong><\/p>\n\n<p class=\"wp-block-paragraph\">\ud83d\udd39 <em>Alternative:<\/em> documentary audit and reconstruction of the technical file.<\/p>\n\n<p class=\"wp-block-paragraph\"><strong>6. R&amp;D or prototyping environments<\/strong><\/p>\n\n<p class=\"wp-block-paragraph\">\ud83d\udd39 <em>Alternative:<\/em> operational safety protocols and dynamic risk assessments.<\/p>\n\n<h2 class=\"wp-block-heading\"><strong>In a nutshell<\/strong><\/h2>\n\n<p class=\"wp-block-paragraph\">The <strong>turnkey<\/strong> model is ideal when you are looking for a <strong>complete, certifiable and traceable<\/strong> adaptation in stable and well-documented environments.<br\/>But in changing contexts, with external dependencies or documentary limitations, <strong>Proden Group<\/strong> offers modular and consultative solutions in industrial safety, always guaranteeing safety, legality and technical proportionality.<\/p>\n\n<p class=\"wp-block-paragraph\">At <strong>\n  <a href=\"https:\/\/prodengroup.com\/en\/\">Proden Group<\/a>\n<\/strong>we analyze each case with rigor and honesty.<br\/>Our priority is not to offer a closed format, but <strong>the most coherent and adequate solution to the real needs of each client<\/strong>.<\/p>\n\n<p class=\"wp-block-paragraph\">Because industrial safety is built on trust and technical criteria:<br\/><strong>will never propose a turnkey project if it is not what you really need.<\/strong><\/p>\n\n<p class=\"wp-block-paragraph\"><\/p>\n","protected":false},"excerpt":{"rendered":"<p>Introduction In modern industry, ensuring the safety of industrial machinery, workers and complying with current regulations is an unavoidable priority. Regulation (EU) 2023\/1230, together with the Machinery Directive 2006\/42\/EC and Royal Decree 1215\/1997, establish clear requirements to protect those who operate or interact with industrial machinery. However, retrofitting a machine is not just about installing [&hellip;]<\/p>\n","protected":false},"author":2,"featured_media":1437,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[25],"tags":[59,58,61,60,62],"class_list":["post-1436","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-uncategorized","tag-adaptation-rd-1215-1997","tag-adequacy-of-machinery","tag-integral-project-for-the-adaptation-of-machinery","tag-security-engineering","tag-turnkey-projects-machinery-safety"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.6 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Retrofitting of industrial machinery: Turnkey projects - Prodengroup<\/title>\n<meta name=\"description\" content=\"Turnkey machinery retrofitting: phases, advantages and when not to apply it. 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