{"id":1529,"date":"2025-11-14T19:51:53","date_gmt":"2025-11-14T18:51:53","guid":{"rendered":"https:\/\/prodengroup.com\/proyectos\/meat-machinery-safety-adaptation-of-rd-1215-97-and-en-iso-13849-1\/"},"modified":"2026-01-27T14:32:30","modified_gmt":"2026-01-27T13:32:30","slug":"meat-machinery-safety-adaptation-of-rd-1215-97-and-en-iso-13849-1","status":"publish","type":"proyectos","link":"https:\/\/prodengroup.com\/en\/proyectos\/meat-machinery-safety-adaptation-of-rd-1215-97-and-en-iso-13849-1\/","title":{"rendered":"Meat machinery safety: adaptation RD 1215\/1997 and ISO 13849"},"content":{"rendered":"\n<p class=\"wp-block-paragraph\">In this case study we present the <strong>engineering and industrial safety<\/strong> project according to <strong>ISO 12100 and RD 1215<\/strong> developed by <a href=\"https:\/\/prodengroup.com\/en\/\">PRODENGROUP<\/a> in a meat plant in the province of <strong>Girona<\/strong>, specializing in the production of fresh meat products and sausages. The objective was to adapt an industrial grinder and its associated elevator to <strong>Royal Decree 1215\/1997<\/strong> and to the <strong>ISO 12100<\/strong> and <strong>ISO 13849<\/strong> reference standards, reinforcing the functional safety of the whole and preparing the installation for future internal and external audits.<\/p>\n\n<h2 class=\"wp-block-heading\"><strong>Safety challenges in the meat industry and in meat handling<\/strong><\/h2>\n\n<p class=\"wp-block-paragraph\">At the Girona plant, as in many food industries, the meat preparation line combines:<\/p>\n\n<ul class=\"wp-block-list\">\n<li><strong>Old and new equipment<\/strong>, with very different levels of automation.<\/li>\n\n\n\n<li><strong>Repetitive<\/strong> loading, mixing and grinding <strong>operations<\/strong>, requiring frequent access for cleaning and maintenance.<\/li>\n\n\n\n<li><strong>Demanding hygienic environments<\/strong>, requiring frequent washing and specific cleaning products.<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\">In particular, the <strong>grinder + load elevator<\/strong> combination involves managing risks typical of the meat industry: entrapment with moving parts, product falls, impacts with elevated trolleys, electrical contacts in humid environments or untimely start-ups during cleaning tasks. The plant management was looking for a partner that could provide <strong>specialized safety engineering for machinery<\/strong>, experience in <strong>RD 1215 compliance<\/strong> and the capacity to <strong>validate safety functions in accordance with EN ISO 13849<\/strong>, in line with the services offered by other relevant players in the market. <\/p>\n\n<h2 class=\"wp-block-heading\"><strong>Security Engineering Methodology applied by PRODENGROUP<\/strong><\/h2>\n\n<h3 class=\"wp-block-heading\"><strong>Initial analysis and equipment utilization limits<\/strong><\/h3>\n\n<p class=\"wp-block-paragraph\">The project began with a technical visit to the plant and a <strong>specific safety study<\/strong> for each piece of equipment:<\/p>\n\n<ul class=\"wp-block-list\">\n<li><strong>Industrial meat grinder<\/strong> for volumes from 200 to 1,500 liters.<\/li>\n\n\n\n<li><strong>Trolley elevator<\/strong> associated with the grinder feed, with a capacity of up to 250 kg.<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\">The <strong>operating modes<\/strong> (production, cleaning and maintenance) and the user profiles involved (production operators, cleaning and maintenance personnel) were defined. The <strong>limits of use<\/strong> were then established: type of product (raw sliced meat), environmental conditions, number of operators, energy present (electrical and pneumatic) and possible interventions on the equipment. <\/p>\n\n<h3 class=\"wp-block-heading\"><strong>Risk assessment according to EN ISO 12100 and RD 1215\/1997 checklist.<\/strong><\/h3>\n\n<p class=\"wp-block-paragraph\">In a second phase it was carried out:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>A <strong>systematic checklist<\/strong> of the minimum safety provisions of <strong>RD 1215<\/strong>, analyzing drive components, stops, guards, stability, signaling, electrical contacts, etc.<\/li>\n\n\n\n<li>A <strong>risk assessment in accordance with ISO 12100<\/strong>, identifying mechanical, electrical and ergonomic hazards and assessing probability, frequency and severity to prioritize improvement actions.<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\">This approach allowed us to transform the findings into a <strong>structured machinery suitability plan<\/strong>, aligned with best practices in industrial safety consulting.<\/p>\n\n<h3 class=\"wp-block-heading\"><strong>Design of improvement measures and philosophy of &#8220;integrated safety&#8221;.<\/strong><\/h3>\n\n<p class=\"wp-block-paragraph\">Based on the previous analysis, PRODENGROUP defined a set of <strong>corrective measures<\/strong> aimed at:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>Reorganize and <strong>clearly mark the control organs<\/strong>, differentiating between starts, stops and rearming.<\/li>\n\n\n\n<li>Improve the <strong>separation of energy sources<\/strong> (electrical and pneumatic), incorporating lockable disconnecting devices that facilitate lockout\/tagout (LO-TO) during maintenance.<\/li>\n\n\n\n<li>Reinforce <strong>protection against entrapment and falling objects<\/strong> by means of fixed and movable guards, mechanical locking elements and interlocking devices.<\/li>\n\n\n\n<li>Promote the <strong>signaling of risks<\/strong> (mechanical, impact and electrical) according to <strong>ISO 7010<\/strong> and <strong>RD 485<\/strong>.<\/li>\n\n\n\n<li>Integrate the operation of the grinder and elevator to avoid <strong>unwanted movements<\/strong> during cleaning and adjustment operations.<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\">All solutions were approached with <strong>safety<\/strong> criteria <strong>integrated into the design<\/strong>, seeking to reduce the need for additional PPE and avoiding purely organizational measures.<\/p>\n\n<h2 class=\"wp-block-heading\"><strong>Functional validation: EN ISO 13849 and control system safety<\/strong><\/h2>\n\n<h3 class=\"wp-block-heading\"><strong>Definition of safety functions and Performance Level (PL)<\/strong><\/h3>\n\n<p class=\"wp-block-paragraph\">A key aspect of the project was the <strong>validation of the safety-related parts of the control system (SRP\/CS)<\/strong> of the grinder and elevator in accordance with <strong>EN ISO 13849<\/strong>.<\/p>\n\n<p class=\"wp-block-paragraph\">The following <strong>security functions<\/strong>, among others, were identified:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>Emergency stop of the grinder and elevator.<\/li>\n\n\n\n<li>Interlocking of the front guard of the discharge mouth.<\/li>\n\n\n\n<li>Perimeter stop bar in the working area.<\/li>\n\n\n\n<li>Safe condition monitoring of the folding service platform.<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\">For each function, the <strong>required Performance Level (PLr)<\/strong> was determined from the risk analysis and the specific type C standard for meat mincers <strong>EN 12331<\/strong>.<\/p>\n\n<p class=\"wp-block-paragraph\">Using specialized software, the safety architectures were modeled, considering category, MTTFd, diagnostic coverage (DC) and common failures measures (CCF). The result confirmed that the safety functions reached a <strong>PL c<\/strong>, adequate to the risk level of the crusher-elevator assembly. <\/p>\n\n<h3 class=\"wp-block-heading\"><strong>Normal and abnormal operation tests<\/strong><\/h3>\n\n<p class=\"wp-block-paragraph\">The validation was completed with a <strong>Safety Control Checklist<\/strong>: the system&#8217;s response to start-up, shutdown, emergency mushroom operation, opening of guards and activation of safety devices was verified, both in normal operation and in the event of simulated failures in the safety channels.<\/p>\n\n<p class=\"wp-block-paragraph\">Thanks to this approach, the plant now has <strong>clear traceability<\/strong> of the performance of all safety elements, which is increasingly in demand for external inspections and quality certifications.<\/p>\n\n<h2 class=\"wp-block-heading\"><strong>Benefits for the Girona meat plant and added value of PRODENGROUP<\/strong><\/h2>\n\n<p class=\"wp-block-paragraph\">Although the proposed measures will be implemented in a planned and progressive manner, the meat company has already obtained several tangible benefits:<\/p>\n\n<ul class=\"wp-block-list\">\n<li><strong>Global vision of risks<\/strong> in the meat mincing and elevation line, with clear action priorities aligned with regulations.<\/li>\n\n\n\n<li>A detailed <strong>RD 1215 compliance plan<\/strong>, which facilitates investment planning and justification for prevention audits.<\/li>\n\n\n\n<li>Definition of <strong>procedures for safe intervention and assignment (LO-TO)<\/strong>, which simplify the training of maintenance teams.<\/li>\n\n\n\n<li>Improved <strong>functional safety<\/strong> of control systems, supported by documented and replicable PL calculations.<\/li>\n\n\n\n<li>Expected reduction of incidents due to entrapment, impacts and electrical contacts, maintaining the line&#8217;s productive capacity.<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\">The project has been <strong>very well received by the client<\/strong>, who particularly appreciates the combination of:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>In-depth knowledge of <strong>applicable regulations<\/strong>.<\/li>\n\n\n\n<li>Ability to <strong>translate legal requirements into viable technical solutions<\/strong>.<\/li>\n\n\n\n<li>Clear documentation oriented to the long-term operation of the equipment.<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\">In addition, although this case has been developed in the province of <strong>Girona<\/strong>, PRODENGROUP provides <strong>machinery safety engineering<\/strong> services <strong>, adaptation RD 1215, risk assessment EN ISO 12100 and validation of safety functions EN ISO 13849 throughout Catalonia<\/strong>, both in the food industry and in other sectors.<\/p>\n\n<h2 class=\"wp-block-heading\"><strong>Reference standards for the safety of machinery for the food industry<\/strong><\/h2>\n\n<h3 class=\"wp-block-heading\"><strong>Main texts applied in the project<\/strong><\/h3>\n\n<p class=\"wp-block-paragraph\">The following standards and regulations, among others, have been taken into account in the study of the grinder and elevator:<\/p>\n\n<ul class=\"wp-block-list\">\n<li><strong>Law 31\/1995<\/strong> on Occupational Risk Prevention.<\/li>\n\n\n\n<li><strong>RD 1215<\/strong>, on work teams.<\/li>\n\n\n\n<li><strong>RD 485<\/strong>, on occupational health and safety signs.<\/li>\n\n\n\n<li><strong>UNE-EN 60204-1<\/strong>, Safety of machinery &#8211; electrical equipment.<\/li>\n\n\n\n<li><strong>ISO 12100<\/strong>, general principles of design and risk reduction.<\/li>\n\n\n\n<li><strong>ISO 13849-1<\/strong>, Safety-related parts of control systems.<\/li>\n\n\n\n<li><strong>EN 12331:2022<\/strong>, food processing machinery &#8211; meat mincers.<\/li>\n\n\n\n<li>Standards for guards and interlocks<strong>(ISO 14120, ISO 14119, ISO 13855, ISO 13857, ISO 14118<\/strong>).<\/li>\n<\/ul>\n\n<h3 class=\"wp-block-heading\"><strong>Additional recommended standards<\/strong><\/h3>\n\n<p class=\"wp-block-paragraph\">In a complementary manner, and in line with best practices in the sector, PRODENGROUP also recommends considering:<\/p>\n\n<ul class=\"wp-block-list\">\n<li><strong>ISO 62061<\/strong>, focused on the functional safety of electrical, electronic and programmable electronic machinery systems.<\/li>\n\n\n\n<li><strong>ISO 14122 (permanent access to machines)<\/strong>, for the design of platforms, stairs and walkways associated with this equipment.<\/li>\n\n\n\n<li><strong>RD 773<\/strong>, on the use of personal protective equipment to support the collective protection strategy.<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\">This comprehensive regulatory framework strengthens the plant&#8217;s position in the face of inspections, certifications and national and international customer requirements.<\/p>\n\n<h2 class=\"wp-block-heading\"><strong>Conclusion: safety, productivity and regulatory compliance<\/strong><\/h2>\n\n<p class=\"wp-block-paragraph\">This success story demonstrates that a <strong>well-planned retrofit of machinery<\/strong> not only enables compliance with <strong>RD 1215\/97<\/strong> and the most stringent safety standards, but also improves <strong>line reliability<\/strong>, generates confidence in the work teams and prepares the company for future capacity growth.<\/p>\n\n<p class=\"wp-block-paragraph\">Thanks to the combination of <strong>risk assessment, redesign of safeguards, integration of safe control systems and functional validation according to EN ISO 13849<\/strong>, PRODENGROUP helps the meat industry in <strong>Girona<\/strong> and throughout Catalonia to advance towards a safer, more competitive production model aligned with the best European practices in <strong>industrial machinery safety.<\/strong><\/p>\n\n<p class=\"wp-block-paragraph\"><\/p>\n","protected":false},"featured_media":1530,"template":"","area-de-proyecto":[43],"categoria-de-proyecto":[71],"class_list":["post-1529","proyectos","type-proyectos","status-publish","has-post-thumbnail","hentry","area-de-proyecto-engineering","categoria-de-proyecto-meat"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.7 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Safety in meat mincer RD1215<\/title>\n<meta name=\"description\" content=\"Evaluation and safety of machinery. 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