BS en 00415-5-2006 PDF

BRITISH STANDARD BS EN
415-5:2006
Safety of packaging
machines —
Part 5: Wrapping machines
The European Standard EN 415-5:2006 has the status of a

British Standard
ICS 55.200
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BS EN 415-5:2006
National foreword
This British Standard was published by BSI. It is the UK implementation of

EN 415-5:2006.
The UK participation in its preparation was entrusted by Technical Committee
MCE/3, Safeguarding of machinery, to Subcommittee MCE/3/3, Packaging
machines.
A list of organizations represented on MCE/3/3 can be obtained on request to
its secretary.
This publication does not purport to include all the necessary provisions of a
contract. Users are responsible for its correct application.
Compliance with a British Standard cannot confer immunity from
legal obligations.
This British Standard was Amendments issued since publication

published under the authority
of the Standards Policy and
Strategy Committee Amd. No. Date Comments
on 29 September 2006
© BSI 2006
ISBN 0 580 49230 3

EUROPEAN STANDARD EN 415-5
NORME EUROPÉENNE
EUROPÄISCHE NORM June 2006
ICS 55.200
English Version
Safety of packaging machines - Wrapping machines
Sécurité des machines d'emballage - Partie 5 : Sicherheit von Verpackungsmaschinen - Teil 5:

Fardeleuses/enveloppeuses Einschlagmaschinen
This European Standard was approved by CEN on 23 March 2006.
CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European
Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national
standards may be obtained on application to the Central Secretariat or to any CEN member.
This European Standard exists in three official versions (English, French, German). A version in any other language made by translation
under the responsibility of a CEN member into its own language and notified to the Central Secretariat has the same status as the official
versions.
CEN members are the national standards bodies of Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France,
Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania,
Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION

COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre: rue de Stassart, 36 B-1050 Brussels
© 2006 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 415-5:2006: E
worldwide for CEN national Members.
EN 415-5:2006 (E)
Contents
Foreword......................................................................................................................................................................7
Introduction .................................................................................................................................................................8
1 Scope ..............................................................................................................................................................9
2 Normative references ....................................................................................................................................9
3 Terms and definitions .................................................................................................................................12
3.1 Definition of terms .......................................................................................................................................12
3.2 Description of wrapping machines ............................................................................................................14
3.2.1 Banding machine .........................................................................................................................................14
3.2.2 Sleeve wrapping machine...........................................................................................................................15
3.2.3 Stretch banding machine (incorporating stretch film banding machine)..............................................16
3.2.4 Spiral wrapping machine (incorporating film bundling machine) ..........................................................17
3.2.5 Fold wrapping machine...............................................................................................................................18
3.2.6 Extruded product wrapping machine ........................................................................................................19
3.2.7 Twist wrapping machine .............................................................................................................................20
3.2.8 Over-wrapping machine..............................................................................................................................21
3.2.9 Roll wrapping machine ...............................................................................................................................22
3.2.10 Foil and band wrapping machine...............................................................................................................23
3.2.11 Pleat wrapping machine..............................................................................................................................24
3.2.12 Stretch film wrapping machine ..................................................................................................................25
3.2.13 L-sealing machine........................................................................................................................................26
3.2.14 Skin packaging machine.............................................................................................................................28
3.2.15 Shrink tunnel ................................................................................................................................................28
3.2.16 Hot water dip tank........................................................................................................................................29
4 Hazards on wrapping machines.................................................................................................................30
4.1 General..........................................................................................................................................................30
4.2 General wrapping machine hazards ..........................................................................................................30
4.2.1 Mechanical hazards.....................................................................................................................................31
4.2.2 Electrical hazards ........................................................................................................................................31
4.2.3 Thermal hazards ..........................................................................................................................................32
4.2.4 Noise .............................................................................................................................................................32
4.2.5 Hazards from products and materials .......................................................................................................32
4.2.6 Hazards due to neglecting ergonomic principles ....................................................................................33
4.2.7 Hazards caused by failures ........................................................................................................................33
4.2.8 Hazards due to neglecting hygienic design principles............................................................................34
4.2.9 Hazards from mechanism used on most wrapping machines................................................................34
4.3 Hazards associated with a banding machine ...........................................................................................35
4.3.1 Product feed .................................................................................................................................................35
4.3.2 Handles and hand wheels...........................................................................................................................35
4.3.3 Reel unwind mechanism.............................................................................................................................35
4.3.4 Discharge mechanism.................................................................................................................................37
4.4 Hazards associated with a sleeve wrapping machine and a stretch banding machine.......................37
4.4.1 Product feed .................................................................................................................................................37
4.4.2 Handles and hand-wheels...........................................................................................................................37
4.4.4 Tray erecting mechanism ...........................................................................................................................38
4.4.5 Hot melt adhesive equipment.....................................................................................................................38
4.4.7 Shrink tunnel ................................................................................................................................................38
4.5 Hazards associated with spiral wrapping machines................................................................................38
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EN 415-5:2006 (E)
4.5.1 Product feed.................................................................................................................................................38

4.5.2 Wrapping head.............................................................................................................................................38
4.5.3 Product discharge .......................................................................................................................................38
4.5.4 Ergonomics ..................................................................................................................................................38
4.6 Hazards associated with fold wrapping machines ..................................................................................39
4.6.1 Product feed.................................................................................................................................................39
4.6.3 Reel unwind mechanisms...........................................................................................................................39
4.7 Hazards associated with extruded product wrapping machines ...........................................................40
4.7.1 Product feed.................................................................................................................................................40
4.8 Twist wrapping machine .............................................................................................................................40
4.8.1 Product feed.................................................................................................................................................40
4.9 Hazards associated with over-wrapping machine ...................................................................................41
4.9.1 Product feed.................................................................................................................................................41
4.9.3 Tear tape application group .......................................................................................................................42
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4.10 Hazards associated with roll wrapping machines ...................................................................................43
4.10.1 Product feed.................................................................................................................................................43
4.11 Hazards associated with foil and band wrapping machines and pleat wrapping machines...............43
4.11.1 Product feed.................................................................................................................................................43
4.12 Hazards associated with stretch film wrapping machines......................................................................44
4.12.1 Product feed.................................................................................................................................................44
4.12.3 Product discharge mechanism ..................................................................................................................45
4.13 Hazards associated with L-sealing machine ............................................................................................45
4.13.1 Semiautomatic machine..............................................................................................................................45
4.13.2 Fully automatic machine.............................................................................................................................45
4.14 Hazards associated with skin packaging machines ................................................................................46
4.14.1 Product feed.................................................................................................................................................46
4.14.3 Stability of the machine ..............................................................................................................................46
4.14.4 Ergonomics ..................................................................................................................................................46
4.15 Hazards associated with a shrink tunnel and hot water dip tank...........................................................46
4.15.1 Product transfer system .............................................................................................................................46
4.15.2 Thermal hazards ..........................................................................................................................................46
4.15.3 Hazards generated by products.................................................................................................................46
5 Safety requirements for wrapping machines............................................................................................47
5.1 General..........................................................................................................................................................47
5.2 General requirements for wrapping machines .........................................................................................47
5.2.1 Requirement to eliminate mechanical hazards ........................................................................................47
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EN 415-5:2006 (E)
5.2.2 Electrical requirements ...............................................................................................................................52

5.2.3 Thermal hazards ..........................................................................................................................................54
5.2.4 Noise reduction............................................................................................................................................55
5.2.5 Measures to control hazards generated by products and materials......................................................56
5.2.6 Ergonomic design principles .....................................................................................................................57
5.2.7 Requirements to prevent hazards caused by failures .............................................................................57
5.2.8 Hygienic design requirements ...................................................................................................................59
5.2.9 Requirements for mechanisms used on most wrapping machines.......................................................60
5.3 Safety requirements for a banding machine.............................................................................................62
5.3.1 General..........................................................................................................................................................62
5.3.2 Products feed ...............................................................................................................................................62
5.4 Safety requirements for a sleeve wrapping machine and a stretch banding machine ........................65
5.4.1 General..........................................................................................................................................................65
5.4.2 Product feed .................................................................................................................................................66
5.4.5 Tray erecting mechanism ...........................................................................................................................66
5.4.6 Hot melt adhesive equipment.....................................................................................................................66
5.4.7 Conveyor discharge ....................................................................................................................................67
5.4.8 Shrink tunnel ................................................................................................................................................67
5.5 Safety requirements for a spiral wrapping machine ................................................................................67
5.5.1 General..........................................................................................................................................................67
5.5.2 Product feed .................................................................................................................................................67
5.5.3 Wrapping head .............................................................................................................................................67
5.5.5 Ergonomics ..................................................................................................................................................67
5.6 Safety requirements for a fold wrapping machine ...................................................................................68
5.6.1 General..........................................................................................................................................................68
5.6.2 Product feed .................................................................................................................................................68
5.7 Safety requirements for an extruded product wrapping machine..........................................................68
5.7.1 General..........................................................................................................................................................68
5.7.2 Product feed .................................................................................................................................................69
5.8 Safety requirements for a twist wrapping machine .................................................................................69
5.8.1 General..........................................................................................................................................................69
5.8.2 Product feed .................................................................................................................................................69
5.8.6 Noise reduction............................................................................................................................................70
5.9 Safety requirements for an over-wrapping machine................................................................................71
5.9.1 General..........................................................................................................................................................71
5.9.2 Product feed .................................................................................................................................................71
5.9.4 Tear tape application group........................................................................................................................71
5.10 Safety requirements for a roll wrapping machine ....................................................................................72
5.10.1 General..........................................................................................................................................................72
5.10.2 Product feed .................................................................................................................................................72
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EN 415-5:2006 (E)

5.11 Safety requirements for a foil and band wrapping and a pleat wrapping machine ..............................73
5.11.1 General..........................................................................................................................................................73
5.11.2 Product feed.................................................................................................................................................73
5.12 Safety requirements for a stretch film wrapping machine ......................................................................74
5.12.1 General..........................................................................................................................................................74
5.12.2 Product feed.................................................................................................................................................74
5.12.3 Product pushing and elevating devices....................................................................................................74
5.13 Safety requirements for an L-sealing machine ........................................................................................75
5.13.1 General..........................................................................................................................................................75
5.13.2 Semiautomatic machine..............................................................................................................................76
5.13.3 Fully automatic machine.............................................................................................................................76
5.14 Safety requirements for a skin packaging machine ................................................................................77
5.14.1 General..........................................................................................................................................................77
5.14.2 Product feed.................................................................................................................................................77
5.14.4 Stability of the machine ..............................................................................................................................77
5.14.5 Ergonomics ..................................................................................................................................................77
5.15 Safety requirements for a shrink tunnel and hot water dip tank ............................................................77
5.15.1 General..........................................................................................................................................................77
5.15.2 Product transfer system .............................................................................................................................77
5.15.3 Requirement to prevent thermal hazard....................................................................................................77
5.15.4 Product .........................................................................................................................................................78
6 Verification of safety requirements and measures ..................................................................................78
6.1 General..........................................................................................................................................................78
6.2 Visual inspection with machine stopped ..................................................................................................79
6.2.1 Mechanical parts..........................................................................................................................................79
6.2.2 Pneumatic systems .....................................................................................................................................79
6.2.3 Hydraulic systems .......................................................................................................................................79
6.2.4 Electrical systems .......................................................................................................................................79
6.2.5 Guards ..........................................................................................................................................................79
6.2.6 Design requirements ...................................................................................................................................79
6.3 Measurements with machine stopped.......................................................................................................79
6.3.1 Guards ..........................................................................................................................................................79
6.3.2 Electrical testing ..........................................................................................................................................79
6.4 Visual inspections with machine running.................................................................................................79
6.4.1 Guards ..........................................................................................................................................................79
6.4.2 Interlocking devices ....................................................................................................................................79
6.4.3 Dissipation of stored energy ......................................................................................................................80
6.5 Measurements with machine running .......................................................................................................80
6.5.1 Measurement and declaration of noise emission ....................................................................................80
6.5.2 Temperature .................................................................................................................................................80
6.6 Verification procedures...............................................................................................................................80
7 Information for use ......................................................................................................................................81
7.1 Marking .........................................................................................................................................................81
7.2 Signals and warning signs .........................................................................................................................81
7.3 Instruction handbook ..................................................................................................................................82
7.3.1 General..........................................................................................................................................................82
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EN 415-5:2006 (E)
7.3.2 Agri-foodstuffs and pharmaceuticals ........................................................................................................82

7.3.3 Machines handling hazardous products...................................................................................................82
7.3.4 Hot melt adhesive systems.........................................................................................................................83
7.3.5 Moveable machines fitted with wheels......................................................................................................83
7.3.6 Machines incorporating lifting equipment ................................................................................................83
Annex A (normative) Noise test code for wrapping machines - grade of accuracy 2 and grade 3.................84
A.1 Scope ............................................................................................................................................................84
A.2 Definitions ....................................................................................................................................................84
A.3 Determination of emission sound pressure level at the workstation ....................................................84
A.4 Sound power level determination ..............................................................................................................85
A.5 Installation and mounting conditions........................................................................................................85
A.6 Operating conditions...................................................................................................................................85
A.7 Measurement uncertainties ........................................................................................................................88
A.8 Information to be recorded .........................................................................................................................88
A.9 Information to be reported..........................................................................................................................89
A.10 Declaration and verification of noise emission values............................................................................89
Annex B (normative) Methods of safeguarding small and medium sized apertures .......................................91
B.1 Interlocked guard.........................................................................................................................................91
B.2 Interlocked guard with ESPE trip device...................................................................................................93
B.3 ESPE trip device ..........................................................................................................................................94
B.4 Automatic guard ..........................................................................................................................................95
Annex C (normative) ESPE Muting .......................................................................................................................96
Annex ZA (informative) Relationship between this European Standard and the Essential
Requirements of EU Directives 98/37/EC ..................................................................................................98
Bibliography ..............................................................................................................................................................99
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EN 415-5:2006 (E)
Foreword
This document (EN 415-5:2006) has been prepared by Technical Committee CEN/TC 146 “Packaging machines -
Safety”, the secretariat of which is held by UNI.
This European Standard shall be given the status of a national standard, either by publication of an identical text or
by endorsement, at the latest by December 2006, and conflicting national standards shall be withdrawn at the latest
by December 2006.
This document has been prepared under a mandate given to CEN by the European Commission and the European
Free Trade Association, and supports essential requirements of EU Directive(s).
For relationship with EU Directive(s), see informative Annex ZA, which is an integral part of this document.
EN 415 Safety of packaging machines
Part 1: Terminology and classification of packaging machines and associated equipment
Part 2: Pre-formed rigid container packaging machines
Part 3: Form, fill and seal machines
Part 4: Palletisers and depalletisers
Part 6: Pallet wrapping machines
Part 7: Group and secondary packaging machines

Part 8: Strapping machines
According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following
countries are bound to implement this European Standard: Austria, Belgium, Cyprus, Czech Republic, Denmark,
Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta,
Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United
Kingdom.
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EN 415-5:2006 (E)
Introduction
Wrapping machines are used extensively in Europe, in an increasingly wide range of industries.
They contain several significant hazards and have the potential to cause serious injury.
This document is a type C standard as defined in EN ISO 12100-1:2003.
The machinery concerned and the extent to which hazards, hazardous situations and events are covered are
indicated in the scope of this standard.
When provisions of this type C standard are different from those which are stated in type A or B standards, the
provisions of this type C standard take precedence.
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EN 415-5:2006 (E)
1 Scope
This European Standard applies to the following groups of machines:
 wrapping machines which partially wrap products (see Figures 1-4)
 wrapping machines which form a complete wrap without sealing (see Figures 5-7)
 wrapping machines which form a complete wrap with sealing (see Figures 8-14)
 shrinking equipment which is connected to wrapping machines covered by this standard (see Figures 15-16)
The individual machines are described in 3.2 of this standard.
This European Standard deals with safety requirements for machine design, construction, installation,
commissioning, operation, adjustment, maintenance and cleaning of wrapping machines.
The extent to which hazards, hazardous situations and events are covered are indicated in Clause 4 of this
document.
Exclusions:
This standard is not applicable to larger examples of wrapping machines designed to handle products higher than
400 mm and wider than 400 mm. These machines are covered by EN 415-6.
This document is not applicable to wrapping machines which are manufactured before the date of publication of
this document by CEN.
This standard does not consider the following hazards:
• Use of wrapping machines in potentially explosive atmospheres;
• Health, safety or hygiene hazards associated with the products that may be handled by the machines but
does include general advice on this subject;
• Hazards that may be associated with electromagnetic emissions from wrapping machines;
• Hazards that may be associated with decommissioning wrapping machines.
2 Normative references
The following referenced documents are indispensable for the application of this document. For dated references,
only the edition cited applies. For undated references, the latest edition of the referenced document (including any
amendments) applies.
EN 294:1992, Safety of machinery - Safety distance to prevent danger zones being reached by the upper limbs
EN 415-1:2000, Packaging machines safety - Part 1: Terminology and classification of packaging machines and
associated equipment
EN 418, Safety of machinery - Emergency stop equipment, functional aspects - Principles for design
EN 563, Safety of machinery - Temperatures of touchable surfaces - Ergonomics data to establish temperature
limit values for hot surfaces
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EN 415-5:2006 (E)
EN 574:1996, Safety of machinery - Two-hand control devices - Functional aspects - Principles for design
EN 614-1:1995, Safety of machinery - Ergonomic design principles – Part 1: Terminology and general principles
EN 619, Continuous handling equipment and systems – Safety and EMC requirements for equipment for
mechanical handling of unit loads
EN 626-1, Safety of machinery - Reduction of risks to health from hazardous substances emitted by machinery -
Part 1: Principles and specifications for machinery manufacturers
EN 626-2, Safety of machinery - Reduction of risks to health from hazardous substances emitted by machinery –
Part 2: Methodology leading to verification procedures
EN 811, Safety of machinery – Safety distances to prevent danger zones being reached by the lower limbs
EN 894-1, Safety of machinery – Ergonomics requirements for the design of displays and control actuators – Part
1: General principles for human interactions with displays and control actuators
2: Displays
3: Control actuators
EN 953:1997, Safety of machinery – Guards - General requirements for the design and construction of fixed and
movable guards
EN 954-1:1996, Safety of machinery – Safety-related parts of control systems – Part 1: General principles for
design
EN 982:1996, Safety of machinery –Safety requirements for fluid power systems and their components - Hydraulics
EN 983:1996, Safety of machinery - Safety requirements for fluid power systems and their components –
Pneumatics
EN 999, Safety of machinery - The positioning of protective equipment in respect of approach speeds of parts of
the human body
EN 1005-2, Safety of machinery – Human physical performance – Part 2: Manual handling of machinery and
components parts of machinery
EN 1005-3, Safety of machinery – Human physical performance – Part 3: Recommended force limits for machinery
operation
EN 1037, Safety of machinery - Prevention of unexpected start-up
EN 1050, Safety of machinery - Principles for risk assessment
EN 1088:1995, Safety of machinery – Interlocking devices associated with guards - Principles for design and
selection
EN 1672-2:2005, Food processing machinery - Basic concepts – Part 2: Hygiene requirements
EN 1760-2, Safety of machinery - Pressure sensitive protective devices - Part 2: General principles for the design
and testing of pressure sensitive edges and pressure sensitive bars
EN 13478, Safety of machinery - Fire prevention and protection
EN 60204-1:1997, Safety of machinery - Electrical equipment of machines - Part 1: General requirements (IEC
60204-1:1997)
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EN 415-5:2006 (E)
EN 61310-1:1995, Safety of machinery - Indication, marking and actuation - Part 1: Requirements for visual,
auditory and tactile signals (IEC 61310-1:1995)
EN 61310-3, Safety of machinery - Indication, marking and actuation - Part 3: Requirements for the location and
operation of actuators (IEC 61310-3:1999)
EN 61496-1:2004, Safety of machinery - Electro-sensitive protective equipment - Part 1: General requirements and
tests (IEC 61496-1:2004, modified)
EN 62061, Safety of machinery - Functional safety of safety-related electrical, electronic and programmable
electronic control systems (IEC 62061:2005)
EN ISO 3744:1995, Acoustics - Determination of sound power levels of noise sources using sound pressure -
Engineering method in an essentially free field over a reflecting plane (ISO 3744:1994)
Survey method using an enveloping measurement surface over a reflecting plane (ISO 3746:1995)
Comparison method for use in situ (ISO 3747:2000)
EN ISO 4871:1996, Acoustics - Declaration and verification of noise emission values of machinery and equipment
(ISO 4871:1996)
EN ISO 9614-2:1996, Acoustics - Determination of sound power levels of noise sources using sound intensity -
Part 2: Measurement by scanning (ISO 9614-2:1996)
EN ISO 11201:1995, Acoustics - Noise emitted by machinery and equipment - Measurement of emission sound
pressure levels at a work station and at other specified positions - Engineering method in an essentially free field
over a reflecting plane (ISO 11201:1995)
pressure levels at a work station and at other specified positions - Survey method in situ (ISO 11202:1995)
pressure levels at a work station and at other specified positions - Method requiring environmental corrections (ISO
11204:1995)
EN ISO 12001:1996, Acoustics - Noise emitted by machinery and equipment - Rules for the drafting and
presentation of a noise test code (ISO 12001:1996)
EN ISO 12100-1:2003, Safety of machinery - Basic concepts, general principles for design - Part 1: Basic
terminology, methodology (ISO 12100-1:2003)
EN ISO 12100-2:2003, Safety of machinery - Basic concepts, general principles for design - Part 2: Technical
principles (ISO 12100-2:2003)
EN ISO 14122-1:2001, Safety of machinery - Permanent means of access to machinery - Part 1: Choice of fixed
means of access between two levels (ISO 14122-1:2001)
EN ISO 14122-2, Safety of machinery - Permanent means of access to machinery - Part 2: Working platforms and
walkways (ISO 14122-2:2001)
EN ISO 14122-3,Safety of machinery - Permanent means of access to machinery - Part 3: Stairs, stepladders and
guard-rails (ISO 14122-3:2001)
EN ISO 14122-4, Safety of machinery - Permanent means of access to machinery - Part 4: Fixed ladders (ISO
14122-4:2004)
ISO 7000, Graphical symbols for use on equipment – Index and synopsis
IEC 60417:2002, Graphical symbols for use on equipment
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EN 415-5:2006 (E)
3 Terms and definitions

For the purposes of this document, the terms and definitions given in Clause 3 of EN ISO 12100-1:2003, EN 415-
1:2000 and the following apply.
3.1 Definition of terms
3.1.1
band
strip of packaging material
3.1.2
cold adhesive
adhesive which is liquid at room temperature
3.1.3
deformable material
material which can be formed by the application of pressure only
3.1.4
change parts
machine parts designed to handle a specific product, packaging material or pack size or kind, that need to be
changed when the machine is set up to handle a different product, packaging material or pack size or kind
3.1.5
film compensator
device which maintains tension in the film during the intermittent motion of the wrapping cycle. It is also called
"tension roller assembly"
3.1.6
film (packaging material) reel
continuous sheet of paper, carton board, plastics film, metal foil or flexible laminate wound on a cylindrical core
3.1.7
film web
continuous sheet of paper, plastic film, metal foil or laminate
3.1.8
fold wrapping
wrap in which the material, due to its plasticity, keeps the fold
3.1.9
fin seal
seal in which the two edges of the material are joined together inner surface to inner surface
3.1.10
flexible packaging material
relatively thin paper, plastic film or flexible laminate
3.1.11
hand operated
machine functions or modes where the only power source is directly applied manual effort
3.1.12
hot melt adhesive
adhesive that is solid at room temperature and which is melted so that it can be applied
3.1.13
lay flat tubular film
continuous tube of plastic film usually supplied wound on a core
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EN 415-5:2006 (E)
3.1.14
longitudinal seal
seal made on a package in line with the direction of material travel in the machine
3.1.15
magazine
mechanical assembly designed to hold stacks of cartons, carton blanks, leaflets, labels, lids or stackable containers
3.1.16
mandrel
mechanical assembly around which a bag or carton is formed and also a film reel support
3.1.17
modified atmosphere
when a normal atmosphere within a package or unit load is replaced by one or more selected gases. The objective
is to extend shelf or storage life of the packaged products
3.1.18
overlap seal
seal in which two edges of the material are joined together inner surface to outer surface
3.1.19
pack, package
assembly of product and packaging materials produced by packaging machine
3.1.20
packaging material
material used to make a package e.g paper, polypropylene
3.1.21
packaging material transport mechanism
mechanical assembly which transports packaging material through the packaging machine
3.1.22
paper laminate
paper that has been coated or bonded to one or a number of other materials e.g. polyethylene or aluminium foil
3.1.23
product
the substance or article being packed in a wrapping machine
3.1.24
roll wrapping
wrap of cylindrical products with a roll shaped form
3.1.25
shrink wrapping
process in which a package is wrapped in a thermoplastic film which is then heated so that the film shrinks and
closely fits to the package
3.1.26
skin packaging
packaging process in which a product is covered by a closely fitting usually transparent plastic film. The product is
placed on a porous rigid paperboard sheet, which is often printed. Heated film is draped over it and vacuum is
applied to draw the film tightly over the article
3.1.27
stretch film
flexible, elastic plastic film which can be pulled tightly around a package. It may stick to itself on contact or require
heat sealing
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EN 415-5:2006 (E)
3.1.28
stretch wrapping
wrapping process in which the stretch film is stretched around the product and sealed under tension
3.1.29
tear tape
plastic tape which is sealed to a packaging material, usually plastic film, to assist opening of the pack
3.1.30
shrink film
plastic film which shrinks when heated
3.1.31
thermoplastic film
material which when heated can be formed by pressure and/or vacuum
3.1.32
transverse seal
seal made on a package at right angles to the direction of material travel in the machine
3.1.33
twist wrap
wrap sealed by twisting the open end
3.2 Description of wrapping machines
3.2.1 Banding machine
A wrapping machine which wraps a band of material around a product, or group of products, and secures it with
adhesive or by application of heat (the machine may have one or two reels).
The characteristic features are:
 feeding mechanism
 reel unwind mechanism and film compensator
 discharge mechanism
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EN 415-5:2006 (E)
Figure 1 — Banding machine
3.2.2 Sleeve wrapping machine
A wrapping machine which wraps a web of thermoplastic material loosely around a product or group of products
before the pack is passed through a shrink tunnel to form a shrink-wrap pack. The web may be formed from one or
two reels of film.
 product feeding device with chain, belt, pusher and/or elevator;
 reel unwind mechanism with film compensator;
 discharge mechanism often connected to a shrink tunnel;
 in some machines a tray erecting group is present (see EN 415-7).
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EN 415-5:2006 (E)
Figure 2 — Sleeve wrapping machines
Figure 3 — Sleeve wrapping machine with tray erecting group
3.2.3 Stretch banding machine (incorporating stretch film banding machine)
A wrapping machine which wraps a web of film or paper tightly around a product or group of products. The web
may be formed from one or two reels of film.
 product feeding device with chain, belt, pusher and/or elevator;
 reel unwind mechanism with film compensator and two stretching rolls;
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EN 415-5:2006 (E)
 discharge mechanism.
Figure 4 — Stretch banding machine
3.2.4 Spiral wrapping machine (incorporating film bundling machine)
A wrapping machine which wraps a web of stretch film or paper tightly around a product or group of products in a
series of turns while the products are conveyed through the machine. This machine applies primary packaging to
long articles/products lower than 400 mm
 feeding group with a horizontal belt often with vertical rolls;
 wrapping head turning around the product;
 discharge conveyor.
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EN 415-5:2006 (E)
Figure 5 — Spiral wrapping machine
3.2.5 Fold wrapping machine
A wrapping machine which wraps a product in a deformable material e.g. aluminium foil or paper in a series of
folding operations.
 feeding group with belt conveyor pusher and/or pincers;
 discharge mechanism with belt, chain or wheel sometimes connecting to another machine.
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Figure 6 — Fold wrapping machine
3.2.6 Extruded product wrapping machine
A fold wrapping machine in which the product is extruded, cut to size and then wrapped in a deformable material
e.g a fat/butter wrapping machine.
 feeding group with rolls;
 discharge mechanism with belt;
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EN 415-5:2006 (E)
Figure 7 — Extruded product wrapping machine
3.2.7 Twist wrapping machine
A wrapping machine which seals the open ends of the wrap by twisting. The machine is normally used to wrap
confectionery.
 feeding group with rotating disk;
 reel unwind mechanism with film compensator and often an automatic splicing mechanism;
 discharge mechanism with belt conveyor.
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Figure 8 — Twist wrapping machine
3.2.8 Over-wrapping machine
A wrapping machine which wraps a product or group of products in flexible packaging material with a series of
folding, heat sealing or gluing operations.
 product feed conveyor;
 often a tear tape application group and an automatic splicing group;
 reel unwind mechanism with film compensator and often automatic splicing group;
 discharge mechanism with belt.
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Figure 9 — Over-wrapping machine
3.2.9 Roll wrapping machine
A wrapping machine which wraps a cylindrical product or group of products in a series of folding heat sealing or
gluing operations to form a roll shaped pack.
 conveyor feed;
 automatic product feed mechanism usually using vibration;
 reel unwind mechanism with film compensator and often automatic splicing group;
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Figure 10 — Roll wrapping machine
3.2.10 Foil and band wrapping machine
A wrapping machine which wraps a product in aluminium foil, before applying a paper band (simultaneously or
intermittent) to complete the pack.
 product feed with belt conveyor, pusher and elevator;
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Figure 11 — Foil and band wrapping machine
3.2.11 Pleat wrapping machine
A wrapping machine which gathers and folds flexible material around a product and seals it at one point by
applying a label.
 product feed with belt conveyor, pusher and elevator;
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EN 415-5:2006 (E)
Figure 12 — Pleat wrapping machine
3.2.12 Stretch film wrapping machine
A wrapping machine which pulls a web of stretch film around a product. Usually the film edges are gathered and
heat sealed below the product after the wrapping process.
 conveyor feed;
 discharge mechanism with belt and heat sealer.
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EN 415-5:2006 (E)
Key
1 Feeding
2 Film stretching
3 Elevating
4 Folding
5 Sealing
a Film
Figure 13 — Stretch film wrapping machine
3.2.13 L-sealing machine
A wrapping machine which uses thermoplastic centre folded film along its length. Products or groups of products
are placed between the two halves of film before the film is sealed around the product with an L shaped sealing bar
to produce a fully enclosed pack sealed on three sides.
 supporting plane;
 “L shaped” heating device;
 conveyor belt often connected to a shrink tunnel.
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EN 415-5:2006 (E)
Key
1 Tunnel
Figure 14 — Semiautomatic L-sealing machine
The characteristic features of a fully-automatic machine are:
 feeding belt;
 "L shaped" heating device;
 conveyor belt connected to a shrink tunnel.
Figure 15 — Fully automatic L-sealing machine
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EN 415-5:2006 (E)
3.2.14 Skin packaging machine
A wrapping machine which seals products placed on perforated carton or plastic blanks with a web of thermoplastic
film.
 supporting plane;
 vacuum system;
 film reel.
Figure 16 — Skin packaging machine
3.2.15 Shrink tunnel
A machine which shrinks thermoplastic film around a product or group of products, as they pass through a heated
tunnel. The heating medium may be air, radiant heat, steam or hot water. Shrink tunnels in the scope of this
standard can be linked by a conveyor to a wrapping machine. Shrink tunnels that are covered by this standard are
intended for product not higher and/or wider than 400 mm.
 feeding conveyor;
 heating chamber;
 discharge conveyor.
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Key
1 Heater
Figure 17 — Shrink tunnel
3.2.16 Hot water dip tank
A packaging machine which uses a tank of hot water to shrink thermoplastic packages by dipping them in the water.
 feeding conveyor;
 supporting plate which plunges into water with the product;
 tank with hot water.
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EN 415-5:2006 (E)
Key
1 Conveyor
Figure 18 — Hot water dip tank
4 Hazards on wrapping machines
4.1 General
This clause lists all the significant hazards, hazardous situations and events that can be found on typical wrapping
machines.
Before using this standard, the manufacturer shall establish that the hazards on his machine correspond to the
hazards described in this standard using the principles detailed in EN 1050.
If the manufacturer identifies hazards which are not listed in this clause, he shall assess these hazards by using the
principles detailed in EN 1050.
The hazards on a specific machine can vary depending on its working principle; the type, size and mass of the
product; the packaging material; auxiliary equipment attached to the machine and the environment in which the
machine is used.
The hazards which occur on most wrapping machines are listed in 4.2 and the hazards which are specific to
particular types of wrapping machine are listed in 4.3 to 4.15.
4.2 General wrapping machine hazards
The following hazards occur on most wrapping machines.
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4.2.1 Mechanical hazards
4.2.1.1 Moving parts
Wrapping machines may incorporate moving parts which present a variety of mechanical hazards including
crushing, shearing, cutting, entanglement, friction, drawing-in. Some of these hazards may persist after the power
supply has been cut off due to stored energy.
4.2.1.2 Pneumatic and hydraulic equipment
Pneumatic and hydraulic equipment presents crushing, shearing, ejection of parts, explosion and injection of fluids
hazards. Stored energy in pneumatic or hydraulic systems may cause mechanisms to move unexpectedly even
when power supplies are disconnected. In addition hydraulic oil and pneumatic lubricating oil present a potential
fire hazard and can contaminate agri-foodstuffs.
4.2.1.3 Slip, trip and fall hazards
Slip accidents can occur if liquids or solids from the machine e.g. lubricants, packaging materials or the product,
spill onto traffic routes, work stations or means of access around the machine.
Trip accidents may occur if parts of the machine protrude beyond the machine frame at low level, or if cables and
pipes associated with the machine are installed without proper consideration of tripping hazards.
Falls may occur if people climb or stand on parts of the machine above floor level, e.g. for magazine loading, size
changing, maintenance or cleaning.
4.2.1.4 Loss of stability
If wrapping machines become unstable and move unexpectedly or fall over they can cause crushing and impact
injuries. Loss of stability can occur in the following circumstances:
1) While the machine is in operation for example:
a. If components are unbalanced;
b. If the centre of gravity of the machine is high relative to its base area;
c. If someone stands on the machine.
2) While the machine is being moved, for example:
a) If the manufacturer’s lifting instructions are not followed;
b) On machines fitted with wheels if the machine is moved on a slope or uneven surface.
4.2.1.5 Hazards from moveable guards
Movable guards may present crushing, shearing and impact hazards when they open or close if they have a high
mass or move under gravity. If excessive effort is necessary to operate the guard and/or it is positioned in an
unfavourable position, the operator may sustain strain injuries or damage to health. Powered guards may present
crushing, shearing and impact hazards.
4.2.2 Electrical hazards
4.2.2.1 Electrical equipment
Electrical equipment on the machine generates a potential electric shock and burn hazard.
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In the presence of combustible materials there is a potential fire hazard. Electrical systems may act as an ignition
source. In the presence of flammable substances or products which may create explosive atmospheres, this could
give rise to an explosion hazard.
If liquids, e.g. product spillage or cleaning substances like water, come into contact with the electrical conductors,
there is a risk of electric shock.
4.2.2.2 Electrostatic phenomena
Electric shock hazards can arise if parts of the machine or materials are electro-statically charged. Electrostatic
discharge can be a source of ignition in the presence of flammable substances or explosive atmospheres.
4.2.3 Thermal hazards
Parts of the machine e.g. sealing mechanisms and drive motors which have high surface temperatures may cause
burning hazards. See EN 563 for details of the burn thresholds for different materials and contact times. The
burning hazard will usually continue to exist for a period of time after power has been disconnected.
4.2.4 Noise
Noise generated by wrapping machines can result in:
 permanent hearing loss;
 tinnitus;
 tiredness, stress etc.;
 other effects such as loss of balance, loss of awareness;
 interference with speech communication;
 inability to hear acoustic warning signals.
4.2.5 Hazards from products and materials
4.2.5.1 Hazards generated by products
Wrapping machines are used to pack a wide range of products, some of which may be potentially hazardous to
persons operating or in the vicinity of the packaging machine during normal operation or if a package containing a
hazardous substance is damaged in the packaging machine.
Hazards generated by the product can include:
1. Ingestion of harmful substances e.g. insecticides, aggressive or harmful chemicals, pharmaceuticals;
2. Fire or explosion e.g. flammable liquids, explosives, dusty products;
3. Biological hazards e.g. vaccines;
4. Impact by ejected packaging materials or products e.g. broken glass.
4.2.5.2 Hazards generated by packaging materials
Wrapping machines are intended to use a range of packaging materials, which can present the following hazards:
1. Inhalation of harmful or unpleasant smoke or vapours from overheated or burning materials;
2. Inhalation of harmful or unpleasant dusts, e.g. from paper;
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3. Cuts from handling packaging materials e.g. film, strap or paper edges;
4. Fire due to overheating of combustible packaging materials, e.g. plastic films and paper;
5. Electric shock from electrostatic discharges, e.g. at plastic film reel unwind mechanisms and plastic sheet
feeding mechanisms.
4.2.6 Hazards due to neglecting ergonomic principles
Hazards to safety and health can occur when people are carrying out the following activities on wrapping machines:
1. Operation e.g. assuming a bad posture, mental overload including the use of manual controls that have
inadequate design, location or identification;
2. Operation, cleaning and maintenance of machines under poor lighting conditions;
3. Loading packaging materials e.g. assuming a bad posture, using excessive effort, fatigue;
4. Loading products or unloading packages e.g. assuming a bad posture, performing unnatural hand or arm
movements, using excessive effort, mental overload;
5. Size and product changing, e.g. assuming a bad posture, using excessive effort;
6. Cleaning the machine e.g. assuming a bad posture, using excessive effort;
7. Maintenance e.g. assuming a bad posture, using excessive effort;
8. Moving the machine e.g. using excessive effort.
4.2.7 Hazards caused by failures
4.2.7.1 Failure of power supplies
The following hazards can occur on wrapping machines if their power supplies fail.
1. Uncontrolled lowering or failing of machine assemblies or product;
2. Unexpected locking of brakes or other components;
3. Failure of a braking function;
4. Unexpected movement of assemblies when power is reconnected or due to stored energy.
4.2.7.2 Failure of safety related parts of control systems
Hazards can arise if components in safety related parts of control systems fail or if the system does not meet its
safety requirement specifications. Failures may occur due to mechanical damage, contact failure, electronic
component failure. Hazards may also arise if safety systems are deliberately defeated by operators.
Systematic faults may occur, especially in programmable systems as a result either of errors in the safety
requirement specifications or of failure to meet the specifications. Failures can lead to loss of safety functions
resulting in unexpected start-up of moving parts, incorrect sequencing of machine operations or prevent moving
parts from stopping as expected.
4.2.7.3 Failure of electronic drive systems
On electronic drive systems where the power supply to a drive motor is not disconnected while the guards are open,
there is a risk of unexpected start-up with consequential mechanical hazards if the control system malfunctions or
responds to an external disturbance such as electromagnetic interference.
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4.2.8 Hazards due to neglecting hygienic design principles
On machines that are intended to pack agri-foodstuffs, pharmaceuticals or other products where hygiene is a
consideration, product contamination hazards can result if inappropriate contact materials or construction methods
are used or if lubricants or other contaminating substances are allowed to come into contact with the product.
4.2.9 Hazards from mechanism used on most wrapping machines
4.2.9.1 Drive systems
Wrapping machines may incorporate mechanical, electrical, pneumatic or hydraulic drive mechanisms which
present a variety of different hazards including crushing, shearing, cutting, entanglement, friction, drawing-in,
electric shock and burning. Some of these hazards may persist after the power supply has been cut off due to
stored energy.
4.2.9.2 Belt and slat-band conveyors
Drawing-in or trapping hazards can be generated by in-running nips where belts pass over rollers or fixed parts of
the conveyor frame. These hazards are increased if flights are attached to the belt or slat band.
4.2.9.3 Roller conveyors
Drawing-in or trapping hazards can be generated by in-running nips between rotating roller of conveyors and their
frame or machine parts.
On low-level conveyors, slip, trip or fall accidents may occur if people walk or stand on the conveyor e.g. for
maintenance or cleaning. Trip accidents may occur if the conveyor starts while people are walking or standing on it.
4.2.9.4 Size and product changing
Typically, wrapping machines are constructed to handle a range of product and pack sizes. Changes of size or
product can give rise to the following hazards:
1. Danger zones on the machines may be exposed when components are moved;
2. Handling change parts may give rise to ergonomic hazards;
3. Where size or product changing is carried out under power, shearing and crushing hazards are likely to be
present.
4.2.9.5 Modified atmosphere packaging
Wrapping machines may use special atmosphere during the packing process to produce packages with enhanced
shelf life. Gasses used are typically oxygen, nitrogen and carbon dioxide. These present the following hazards:
a) Oxygen: promotion of fire and explosion
b) Nitrogen: asphyxiation
c) Carbon dioxide: asphyxiation and intoxication
When an oil lubricated rotary vane vacuum pump is in operation, aerosols are formed in the interior of the pump by
the working fluid. An oxygen content in the surrounding gas over 21 % and the presence of combustible aerosols
increase the risk of explosions. The necessary ignition energy can result from malfunction in the system, such as
metal splinters in the vacuum pump.
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4.3 Hazards associated with a banding machine
4.3.1 Product feed
4.3.1.1 General
The product feed typically consists of a horizontal run (or runs) of chain, carrying paddles, pegs or flight bars which
push the product along plates between side guides. Sometimes two lateral belts improve the feeding action.
Sometimes there is a distributing guide or draw-back belt for discharging the in-running products to prevent a
product jam in the preceding machine. This discharging device is often activated by opening a guard.
With such feed systems the products are usually fed into the in-feed chain by an automatic feeding device or a
conveyor. Alternatively the feed system may consist of flat belt conveyors which are fed automatically or manually.
Both types of product feed may present drawing-in, crushing, shearing or friction hazards.
4.3.1.2 Chains and drives
Drawing-in, crushing or shearing hazards can be generated by in-running nips where chains pass over rollers or
fixed parts of the conveyor frame. These hazards are increased if flights are attached to the chain.
4.3.1.3 Product pushing or elevating devices
Shearing hazards exist:
a) Where the devices emerge from the shroud around the tail sprocket and enter the in-feed aperture;
b) where the devices run close to a fixed point e.g. enter the machine.
4.3.1.4 In-feed belt conveyors
The potential hazards of these mechanisms are drawing-in and friction.
4.3.1.5 Automatic product feed mechanisms
Machines may be fitted with a wide variety of product feeding mechanisms, most of which present crushing and
shearing hazards.
4.3.2 Handles and hand wheels
Handles or hand-wheels are often provided to operate machines manually e.g. for adjustment or cleaning. Impact,
friction or entanglement hazards can occur if the handle or hand-wheel:
1. Moves under power;
2. Moves unexpectedly due to stored energy e.g. because of eccentric masses or springs.
4.3.3 Reel unwind mechanism
4.3.3.1 General
Reel unwind mechanisms typically comprise a mandrel which may either be fixed to the machine frame at one end
or loose, in which case the film reel and mandrel are supported on a crane assembly.
Film is drawn from the film reel by the machine’s film transport mechanism. The tension of the film is usually
controlled by a brake mechanism (or a drive operating as a brake) acting on the reel mandrel, operated by a film
compensator. Injuries due to bad posture or excessive effort may result if this mechanism is inappropriately located
or if the reel is too heavy.
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EN 415-5:2006 (E)
4.3.3.2 Film compensator
The film compensator (tension roller assembly) usually comprises a roller mounted on a pivoted arm which
operates as a braking device. A shearing hazard can occur between this arm and the frame to which it is attached.
The film compensator when driven by spring or gravity incorporates potential energy which, in case of breakage of
the material, may cause impact or crushing hazards.
4.3.3.3 Coders
Wrapping machines are frequently fitted with coding or printing devices. Reciprocating devices present crushing
and, when heated, burning hazards. Rotary devices in addition present a drawing-in hazard.
Laser coding units may be fitted, which present a burn hazard. The ink-jet marking devices may present burn or
chemical hazard by inhalation or contact. Cleaning substances may present hazards to health or fire hazards.
4.3.3.4 Film reels
Film reels present the following hazards:
1. Reels rotating at high speed generate crushing or impact hazards if stopped suddenly;
2. Reels with a high mass can generate a drawing-in hazard if they are positioned on rolls for unwinding;
3. The edges of the film can be a cutting hazard;
4. There may be a drawing-in hazard when the film is passed over rollers and there may be a shearing hazard
between film braking mechanisms and fixed parts of the reel support assembly.
4.3.3.5 Powered unwind mechanism
On some machines the weight of the film reel makes it necessary to assist the film transport with a powered unwind
mechanism. This may comprise a pair of powered rollers engaging the full width of the material which presents a
drawing-in hazard.
4.3.3.6 Automatic splicing mechanism
Some machines incorporate an automatic splicing unit to reduce the reel changeover time. These mechanisms
usually present crushing, shearing, cutting, entanglement and, when heated, burn hazards.
When the cutting action is pneumatically actuated, those hazards may arise from the potential energy stored in the
compressed air system.
Certain types of plastic films are particularly prone to the build up of static electricity when being unwound. See
4.2.2.2.
4.3.3.8 Cutting device
Mechanical cutting devices present a cutting or shearing hazard:
1. When the machine is in normal operation;
2. If when the machine's power supplies are isolated the mechanism were to move unexpectedly due to stored
energy;
3. If when threading film the operator were to touch the exposed cutting surface;
4. When the device is handled during setting-up, cleaning or maintenance.
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EN 415-5:2006 (E)
4.3.3.9 Sealing devices
Mechanical sealing devices present a crushing hazard:
1. When the machine is in normal operation;
2. If when the machine's power supplies are isolated the mechanism were to move unexpectedly due to stored
energy.
a) Heated sealing devices present a burning hazard during normal operation. They also present a burning
hazard for a period of time after power has been disconnected from the device.
b) There is a risk of electrical insulation in heating elements breaking down giving rise to an electric shock
hazard.
c) There is a risk of fire if packaging materials remain in contact with a heated sealing device for too long or if
the temperature of the sealing device is too high e.g. if the temperature of the heater controls is set too high or
if the temperature control fails and the temperature rises uncontrollably.
4.3.4 Discharge mechanism
The discharge mechanism may be belt conveyors (see 4.2.9.2), chain flights or, when connected to another
packaging machine, some other mechanism. These may present drawing-in and crushing hazards. When a shrink
tunnel is directly connected to the machine, a burn hazard is present (see 4.15).
4.4 Hazards associated with a sleeve wrapping machine and a stretch banding machine
4.4.1 Product feed
4.4.1.1 General
The product feed can be a horizontal belt which conveys the product; the potential hazards are drawing-in and
friction. Alternatively pneumatic or mechanical pushers are used, these can present crushing, impact drawing-in
and shearing hazards.
4.4.1.2 Chain and drives
See 4.3.1.2.
See 4.3.1.3.
4.4.2 Handles and hand-wheels
See 4.3.2.
See 4.3.3.
See 4.3.3.2.
4.4.3.2 Coders
See 4.3.3.3.
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EN 415-5:2006 (E)
4.4.3.3 Film reels
See 4.3.3.4.
See 4.3.3.7.
See 4.3.3.8.
4.4.4 Tray erecting mechanism
The mechanism consists of pushing and elevating devices which may present crushing, shearing and impact
hazards.
4.4.5 Hot melt adhesive equipment
When hot melt adhesive is used, there are burning hazards from contact with hot surfaces and a scalding hazard
from contact with the adhesive. When loading cold adhesive into molten adhesive, there is a risk of scalding from
splashes of molten adhesive. On machines where the adhesive is pressurised and jetted or sprayed onto the
packaging material, there is a risk of scalding from adhesive jetted out of the machine, e.g. if the glue gun is
misaligned or during maintenance operations.
The hot melt adhesive may generate unpleasant fumes, particularly if it is overheated. If the adhesive is overheated
there is a risk of it catching fire.
See 4.3.4.
4.4.7 Shrink tunnel
It is often connected to a sleeve wrapping machine. For hazards see 4.15.
4.5 Hazards associated with spiral wrapping machines
4.5.1 Product feed
It can consist of a horizontal belt which pushes the product towards the wrapping devices. This can present
drawing-in and friction hazards.
Alternatively pneumatic or mechanical pushers are used. These can present crushing hazards.
4.5.2 Wrapping head
The film is wrapped around the product with an adjustable tension strong enough to keep the product tight. This
may cause trapping of parts of the body (e.g. hands and arms). The rotating reel may cause impact hazard.
4.5.3 Product discharge
A conveyor with powered rollers pushes the product toward the outlet. Drawing-in and trapping hazards may be
present.
4.5.4 Ergonomics
When the product to be wrapped is handled by the operator hazards due to the mass and size of the product may
be present. The repetition of the task may give rise to general or localised muscle fatigue or other health effects.
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EN 415-5:2006 (E)
4.6 Hazards associated with fold wrapping machines
4.6.1 Product feed
4.6.1.1 General
Product feed typically consists of a belt conveyor. For hazards see 4.2.9.2. Checking or inspection devices for the
ejection of faulty products may be present.
Before the product arrives at the wrapping station a device synchronises it with the mechanisms downstream.
Otherwise the product is placed in spaces with the right dimension and the belt is timed with the wrapping
mechanisms. In both cases crushing, cutting and trapping hazards may be present.
See 4.3.1.2.
4.6.1.3 Product pushing devices or pincers
See 4.3.1.3.
See 4.3.2.
4.6.3 Reel unwind mechanisms
See 4.3.3.
See 4.3.3.2.
4.6.3.2 Coders
See 4.3.3.3.
4.6.3.3 Film reel
See 4.3.3.4.
4.6.3.4 Powered unwind mechanisms
See 4.3.3.5.
See 4.3.3.6.
See 4.3.3.8.
The discharge mechanism may be a belt, conveyors, chain or wheel. Sometimes the discharge mechanism is
connected with another machine. This may present crushing and drawing-in hazards.
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EN 415-5:2006 (E)
4.7 Hazards associated with extruded product wrapping machines
4.7.1 Product feed
There is normally a feeding group (not considered in this standard) connected to the wrapping machine having a
speed electronically synchronised. Unsynchronised feed of product may cause the build up of product with the
need to provide for a manual cleaning which creates ergonomic hazards and in case of harmful substances to be
used a chemical or fire hazard.
See 4.3.2.
See 4.3.3.
See 4.3.3.2.
4.7.3.2 Coders
See 4.3.3.3.
4.7.3.3 Film reels
See 4.3.3.4.
See 4.3.3.5.
See 4.3.3.6.
Discharge mechanism may be a belt conveyor (see 4.2.9.2) or an inclined plane. The discharge aperture may allow
access to a danger zone. This may present a crushing, cutting and drawing-in hazard.
4.8 Hazards associated with twist wrapping machine
4.8.1 Product feed
4.8.1.1 General
The feeding group consists of a disk with vanes of an appropriate size for the product to be wrapped which turns
with an intermittent motion. A certain quantity of product is fed to the disk by a vibratory feeder.
During rotation the spaces of the disk are filled up with products assisted by a rotating brush which disposes the
product in the spaces.
When the disk is stationary a pusher moves the product towards the wrapping station. This may present crushing,
cutting and friction (due to the brush) hazards.
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EN 415-5:2006 (E)
4.8.1.2 Feeding belt
It is normally used to feed soft candies to a feeding disk. For hazards see 4.3.1.4.
4.8.1.3 Product pushing or elevating device
See 4.3.1.3.
See 4.3.2.
See 4.3.3.
See 4.3.3.2.
4.8.3.2 Film reels
See 4.3.3.4.
See 4.3.3.5.
See 4.3.3.6.
See 4.3.3.8.
Normally the wrapped product falls by gravity on to a conveyor belt which may present a trapping and drawing-in
hazard; sometimes the ejection of the product is assisted by a pusher which presents a crushing hazard (See
4.3.1.3.
4.9 Hazards associated with over-wrapping machine
4.9.1 Product feed
4.9.1.1 General
The product is typically fed by belt in-feed conveyor. An alternative feed system may consist of a horizontal run (or
runs) of chain, carrying paddles pegs or flight bars which push the product along plates between side guides. Often
two lateral belts improve the feeding action. Product is fed into the in-feed chain by automatic feeding devices. For
hazards see 4.3.1.
See 4.3.1.2.
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EN 415-5:2006 (E)
4.9.1.3 In-feed belt conveyor
See 4.3.1.4.
See 4.3.2.
4.9.3 Tear tape application group
Many machines have a device for the application of a tear tape which makes opening the pack easier.
The tear tape consists of an unwinding device, in a cutting unit and a device which sticks the tape to the film. Often
there is a stitch knife, which cuts the edge of the film parallel to the tear tape to make it easier to grip the tear tape.
Sometimes the tape is gummed. In other cases the tape is fixed by means of glue or hot melt.
Crushing, trapping, cutting and scalding hazards may be present.
See 4.3.3.
See 4.3.3.2.
4.9.4.2 Coders
See 4.3.3.3.
4.9.4.3 Film reels
See 4.3.3.4.
4.9.4.4 Power unwind mechanism
See 4.3.3.5.
See 4.3.3.6.
See 4.3.3.7.
See 4.3.3.8.
The discharge mechanism may be belt conveyors, or chain flights. Heating devices are often used to seal the
wrapping material or dry the glue. The discharge aperture may allow access to danger zones.
This may present drawing-in, crushing and burn hazards.
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EN 415-5:2006 (E)
4.10 Hazards associated with roll wrapping machines
4.10.1 Product feed
4.10.1.1 Conveyor belt
When the feeding group consists of a conveyor belt, single products are conveyed towards a stacking station
where they are assembled into a predetermined number. From the assembling station a pusher inserts the grouped
products into the wrapping station. Crushing, trapping and friction burn hazards may be present.
4.10.1.2 Automatic product feed mechanism (vibration feed)
When the feeding group takes the form of a vibrating device a noise hazard due to vibration and crushing of
products is present.
In the feeding zone, vibration may generate dust which presents an inhalation hazard.
A crushing hazard may be present between the vibration feed and machine frame.
See 4.3.2.
See 4.3.3.
See 4.3.3.2.
4.10.3.2 Coders
See 4.3.3.3.
See 4.3.3.5.
See 4.3.3.6.
See 4.3.3.8.
See 4.3.4.
4.11 Hazards associated with foil and band wrapping machines and pleat wrapping machines
4.11.1 Product feed
See 4.3.1.
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See 4.3.1.2.
4.11.1.2 Product pushing and elevating devices
See 4.3.1.3.
See 4.3.1.4.
See 4.3.2.
See 4.3.3.
See 4.3.3.2.
4.11.3.2 Coders
See 4.3.3.3.
4.11.3.3 Film reels
See 4.3.3.4.
See 4.3.3.7.
See 4.3.3.8.
The discharge mechanism may be a belt conveyor. These present drawing-in and friction burn hazards.
4.12 Hazards associated with stretch film wrapping machines
4.12.1 Product feed
4.12.1.1 General
Product is fed into the machine by a conveyor belt. For hazards see 4.3.1.4.
4.12.1.2 Product pushing and elevating device
See 4.3.1.3.
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See 4.3.3.
See 4.3.3.2.
4.12.3 Product discharge mechanism
The discharge mechanism consists of a belt conveyor which supports the product and two lateral belts which are
normally heated in order to seal the film. Trapping, crushing and burning hazards may be present.
4.13 Hazards associated with L-sealing machine
4.13.1 Semiautomatic machine
4.13.1.1 Product feed
Products can be manually inserted between two flaps of film on a supporting plane.
The film is unwound manually or by means of a powered roll which also collects wasted material.
Impact hazards may be present.
4.13.1.2 L-sealing station
The three flaps are sealed by means of a sealing device/beam having a shape fitting the product to be wrapped
which is operated manually or by means of a pneumatic device. The sealing device/beam has a high temperature.
Crushing and burning hazards may be present.
4.13.1.3 Shrink tunnel
Sometimes product is fed by a conveyor belt into a shrink tunnel.
A burning hazard may be present. See 4.15.
4.13.1.4 Stability of the machine
Machines are often mounted on castors. Uncontrollable movements may cause crushing or impact hazards.
4.13.1.5 Ergonomics
The operator may make hand-operations during the wrapping process.
Hazards due to the inappropriate position of controls or unsuitable height of the working table for the operator may
be present.
4.13.2 Fully automatic machine
See 4.3.1.4.
4.13.2.2 Reel unwind mechanism
See 4.3.3.
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See 4.3.3.7.
See 4.3.3.8.
Product is fed by a conveyor belt into a shrink tunnel.
See 4.15.
4.14 Hazards associated with skin packaging machines
4.14.1 Product feed
Product is fed manually on a perforated carton-board or plastic blanks. The film is fed manually and overlaps the
product.
A vacuum system causes the film to stick the product. Impact and trapping hazards may be present.
Wrapped product is removed by hand. This presents ergonomics hazards.
4.14.3 Stability of the machine
See 4.13.1.4.
4.14.4 Ergonomics
See 4.13.1.5.
4.15 Hazards associated with a shrink tunnel and hot water dip tanks
4.15.1 Product transfer system
Products are usually transferred through the tunnel or tank by a conveyor consisting of woven wire or chain driven
rollers. The in-feed and discharge aperture allows the flow of products and therefore will have dimensions which
may let parts of the body come into contact with the heating medium and mechanical parts. Burning, scalding,
drawing-in, cutting, crushing and impact hazards may be present.
The heating medium in shrink tunnels and shrink tanks will have a high temperature which will be transferred to
both the conveyor and shrinking film. Since the conveyor usually extends beyond the main body of the machine,
operators will be exposed to burning and scalding hazards. Some tunnels have hinged covers or removable panels
to give access for setting, cleaning and clearing product jams. These features may expose operators to burning or
scalding hazards.
4.15.3 Hazards generated by products
There is a risk of burning and scalding from the hot packages as they transfer out of the machine. If the conveyor
stops with product inside there is a risk that the product will overheat, even after the power supply has been
disconnected. This may damage the product or cause bursts, spillage of product or damage. In tunnels and tanks
where the heating medium is air there may be a risk of fire.
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Products are conveyed by a belt (woven wire) which presents drawing-in and crushing hazards.
Furthermore the product and belt may be hot and this causes a burning hazard.
5 Safety requirements for wrapping machines
5.1 General
The wrapping machine shall comply with the safety requirement and/or protective measures of this clause. In
addition the machine shall be designed according to the principles of EN ISO 12100 for relevant but not significant
hazards, which are not dealt with by this standard.
Safety requirements which are appropriate for most wrapping machines are listed in 5.2 and safety requirements
which are specific to particular types of wrapping machine are listed in 5.3 to 5.15.
5.2 General requirements for wrapping machines
The following requirements apply to all wrapping machines where the equivalent hazard exists.
5.2.1 Requirement to eliminate mechanical hazards
5.2.1.1 Safeguarding of moving parts
When selecting the most appropriate safeguarding method for each part of a wrapping machine, preference shall
be given to eliminating mechanical hazards by design e.g. by limiting the force, power or movement of moving parts.
See 5.2.1.2 for details.
Where mechanical hazards cannot be eliminated by design, these hazards shall, wherever possible, be
safeguarded using guards that comply with EN 953. The choice of guards shall be guided using Annex A of EN
953:1997.
5.2.1.2 Safety by design
Moving parts can be considered safe by design if the force exerted by the moving parts does not exceed 75 N, the
pressure they exert against an object is less than 250.103 Pa (25 N/cm²) and their energy is less than 4 J and the
parts do not have sharp edges. If the hazardous movement is automatically reversed within 1 s when resistance is
detected, the movement can be considered as safe if the force does not exceed 150 N, the pressure does not
exceed 500.103 Pa (50 N/cm²) and the energy is less than 10 J.
Moving parts can also be made safe by design against injury from crushing hazards by ensuring sufficient distance
between moving and fixed parts and between one moving part and another using the dimensions indicated in EN
349.
Rotating parts, handles or hand wheels can be considered safe by design provided they are not spoked, have no
projections and are smooth. Rotating shaft ends can be considered safe by design provided they are smooth, have
no protruding parts and do not protrude from the machine more than ¼ of their diameter or 20 mm, whichever is the
smaller.
NOTE The measures indicated above may not be effective in all circumstances. However subsequent clauses of this
standard indicate situations where these measures are known to be effective. Where the measures indicated above are not
effective, moving parts should be safeguarded by complying with 5.2.1.3 to 5.2.1.5.
5.2.1.3 Fixed and interlocked guards
Moving parts which cannot be made safe by design shall be safeguarded by fixed or interlocked guards complying
with EN 953 and dimensioned and positioned using Table 2 or 4 of EN 294:1992.
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Where open topped distance guards are used they shall be dimensioned and positioned in accordance with Table
2 of EN 294:1992 and be at least 1600 mm from the floor level.
The gap for cleaning, under such distance guards shall be no greater than 240 mm, and the reach distance under
the guards to the nearest danger zone shall be at least 850 mm.
Where it is foreseeable that persons will try to put their lower limbs into a machine, guards shall be dimensioned
and positioned in accordance with EN 811.
The design of the guards and the number, size and position of access doors in guards shall ensure that the
machine can be operated, cleaned, fitted with change parts and maintained easily and safely.
The guards shall be sufficiently robust to retain products or packs that are ejected or fall down and be designed so
that fallen or ejected products and packs can be retrieved safely.
Guards and access doors to hazardous areas that are required to be opened or removed regularly for operation,
maintenance, cleaning and setting purposes shall be interlocked with the machine’s control system where the risk
assessment indicates that it is necessary on the grounds of the frequency of access and the hazards arising.
Where access is required to a hazardous area once per day or more frequently, interlocking systems shall be
incorporated.
However, where severe hazards exist, interlocking systems may be necessary where the frequency of access is
lower than once per day, and this should be considered during the design risk assessment. The interlocking
devices shall comply with 5.2.1.5.
5.2.1.4 Apertures in guards
5.2.1.4.1 General
Apertures in guards shall be positioned and dimensioned to prevent access to danger zones within the machine
when standing on the floor or access level and reaching into the aperture.
5.2.1.4.2 Small apertures
For apertures where the width or height are less than or equal to 120 mm, the minimum reach distance to the
nearest danger zone through the aperture shall comply with Table 4 of EN 294:1992.
NOTE Where there is insufficient space to achieve the reach distances indicated in a) and b), the safeguarding methods
indicated in Annex B may be used.
5.2.1.4.3 Medium sized apertures
a) Where the width and height of the aperture are greater than 120 mm, but less than or equal to 400 mm and
access is restricted by a conveyor, the minimum reach distance to the nearest danger zone shall be at
least 850 mm and a prohibition symbol complying with Figure 19 – Prohibition sign “Do not reach in” shall
be fitted to the guards near the aperture (see also Figure 20 – Tunnel guard on a machine),
b) Where access to the aperture is not restricted by a conveyor the reach distance to the nearest danger zone
shall comply with Table 2 of EN 294:1992
NOTE Where there is insufficient space to achieve the reach distances indicated in a) and b), the safeguarding methods
indicated in Annex B may be used.
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Figure 19 — Prohibition sign “Do not reach in “
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Figure 20 — Tunnel guard on a machine
5.2.1.5 Interlocking devices associated with guards
Moveable guards shall be interlocked with devices that comply with 4.2 of EN 1088:1995 and shall be installed as
indicated in Clauses 5 and 6 of that standard.
5.2.1.6 Stopping time
Unless otherwise specified in this standard, the machine controls shall ensure that hazardous movements stop
before any danger zones can be reached after opening an interlocked guard. Typically this will mean that
movement must stop within 1 s of a guard being opened.
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If this requirement cannot be achieved, the guards shall be fitted with guard locking devices that prevent access to
the danger zone until the hazardous movement has stopped. The guard locking device shall comply with 4.2.2 of
EN 1088:1995 and shall be installed according to 5.5 of that standard.
5.2.1.7 Operations with open guards
The design objective shall be for all machine adjustments, maintenance, repair, cleaning and servicing to be carried
out while the machine is isolated from all power sources or from outside the danger zones. However if this objective
cannot be achieved for technical reasons, operations with open guards are permissible where hazardous
movements of moving parts may take place, when initiated by an operator using a hold to run control device, but
only if all of the following requirements are fulfilled:
a) Design of the guards and control system shall minimise the risks of injury to the operator and other persons in
the vicinity of the machine;
b) Hold to run control device shall be positioned in such a way that the operator has a clear view of all the parts of
the machine where movement is taking place;
c) Hold to run function shall only be available after a lockable mode selection device, e.g. a key operated switch,
is operated. Operation of this device shall prevent the machine from operating in automatic mode;
d) If it is necessary to carry out powered movements with certain interlocked guards open, all other interlocked
guards which would allow access to danger zones and are not within a clear view of the operator shall continue
to operate interlocked as during normal operation;
e) Wherever possible the control system shall ensure that movements initiated by the hold to run control are
limited e.g. step by step, or at a reduced speed or with reduced power;
f) Movement shall stop as quickly as possible, within a maximum time of 0,5 s after the hold to run control has
been released;
g) Release of the hold to run control button shall lead to a safe stop and prevent unexpected start up. See 5.2.2.4;
h) An emergency stop actuator complying with 5.2.2.8 shall be mounted next to the hold to run controls.
5.2.1.8 Pneumatic and hydraulic equipment
All pneumatic components and piping shall conform to the requirements of EN 983. All hydraulic components and
piping shall conform to the requirements of EN 982.
Where safety functions are controlled through hydraulic or pneumatic systems, these circuits shall comply with the
requirements of 5.2.2.4 and 5.2.2.8. Unexpected start-up shall be prevented using the measures described in
EN 1037.
A separate means of isolation shall be provided for each type of energy, which is readily identifiable and accessible.
Isolation valves shall be clearly labelled to indicate the method of operation of the valve and shall have the facility
to be locked in the off position as described in 5.1.6 of EN 983:1996 and 5.1.6 of EN 982:1996.
Where the machine is designed to pack agri-foodstuffs, or other products where contamination is a significant risk,
the design shall ensure that hydraulic oil or pneumatic lubricating oil cannot come into contact with the product.
5.2.1.9 Measures to minimize slip hazards
The design of the machine shall minimise the risk of liquids or solids spilling onto traffic routes, workstations or
means of access around the machine. Where spills cannot be prevented the manufacturer shall supply a means of
containment for the spill e.g. drip trays and describe the most appropriate method for removing the spillage in the
instructions for use.
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5.2.1.10 Measures to minimize trip hazards
The design of the machine should avoid assemblies at low level that are likely to pose a trip hazard. Where this is
not possible, the manufacturer shall provide railings or some other form of barrier, which guides people away from
the trip hazard.
The manufacturer shall describe, in the instructions for use, how cables and pipes associated with the machine
should be supported so they do not create a trip hazard.
5.2.1.11 Measures to minimize fall hazards
Where reasonably practicable the design of the machine shall allow it to be operated, cleaned and maintained from
floor level. If this is not reasonably practicable the following requirements shall apply:
1. Where a means of access is required for operation or cleaning or routine maintenance of the machine the
manufacturer shall provide a means for safe access with the machine.
2. Where access is required for any other purpose above floor level, the manufacturer shall specify the
appropriate safe means of access and the related installation requirements in the instructions for use.
Permanent means of access shall comply with 5.2 of EN ISO 14122-1:2001. Stairs, ladders or platforms that form
this permanent means of access shall conform to EN ISO 14122-2, EN ISO 14122-3 and EN ISO 14122-4.
5.2.1.12 Stability of machines
5.2.1.12.1 Stability during operation
The machine shall be designed and constructed so that it is stable during normal use and foreseeable abnormal
situations.
The manufacturer shall state in the instruction handbook if the machine must be anchored to the floor or to another
machine before use and give detailed information about the methods and means of anchorage.
On machines fitted with wheels, at least two wheels shall be fitted with locking devices to ensure that the machine
does not move unexpectedly when it is in use.
If it is foreseeable that someone will stand on the machine, the manufacturer shall design the machine or its fixings
to ensure stability in this situation.
5.2.1.12.2 Stability while being moved
The manufacturer shall provide information in the instruction handbook on how to move the machine safely.
Machines fitted with wheels shall be designed so that they are stable when they are placed on a 10° slope in any
orientation.
5.2.1.13 Movable guards
Moveable guards and guards that move under power, gravity or stored energy shall comply with EN 953 and shall
not give rise to any additional risk.
5.2.2 Electrical requirements
5.2.2.1 Electrical equipment
Electrical equipment shall comply with EN 60204-1. In the places where EN 60204-1 provides various options, the
options stated below shall be used.
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5.2.2.2 Supply disconnecting device
The machine shall be equipped with a readily identifiable and accessible supply disconnection device which
complies with 5.3.2 of EN 60204-1:1997.
5.2.2.3 Excepted circuits
Some circuits, e.g. machine lighting circuits, do not need to be disconnected by the supply disconnection device.
Circuits that do not have to be disconnected are listed in 5.3.5 of EN 60204-1:1997. Those circuits that are not
disconnected by the main supply disconnecting device shall each have their own supply disconnecting device, and
be fitted with the labels and warning symbols described in 5.3.5 of EN 60204-1:1997.
5.2.2.4 Prevention of unexpected start up
Devices to prevent unexpected start up shall be selected from 5.4 of EN 60204-1:1997 and shall be designed so
that they can be locked. The design of the controls shall comply with EN 1037.
The control system shall be designed so that it does not start unexpectedly e.g. under the following conditions:
a) As a result of a signal generated by a sensor (except when in automatic mode), and;
b) By closing an interlocked guard (unless it is a control guard), and;
c) By restoring the power supply after an interruption.
5.2.2.5 Protection against electric shock
Electric shock by direct contact shall be prevented by choosing one of the methods described in 6.2 of EN 60204-
1:1997 and electric shock by indirect contact shall be prevented by choosing one of the methods described in 6.3
of that standard.
5.2.2.6 Degree of protection
The protection level for electrical enclosures shall be selected on the basis of the environment in which the
machine will be used and the anticipated cleaning method for the machine and its environment. See 12.3 of
EN 60204-1:1997, Examples of suitable protection levels as defined by EN 60529 are given in Tables 1 and 2
below.
Table 1 — Degree of protection for dusty environments
Dusty Environment Required degree of protection
Non conducting dusts IP 5X
Conducting dusts IP 6X
NOTE 1 Other measures will be required if the equipment is expected to be working in a potentially explosive atmosphere.
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Table 2 — Degree of protection required for different cleaning methods using water
Method of cleaning Required degree of protection
Cleaning without water IP X3

Cleaning with damp cloth IP X4
Cleaning with low pressure water IP X5
Cleaning with medium pressure water IP X6
NOTE 2 If fluids other than water are used for cleaning, these IP ratings may not be appropriate and additional protective
measures may be necessary. Fluids other than water may lower the level of protection in the course of time. The manufacturer
should take into account the use of fluids other than water by the choice of materials, by construction and in the maintenance
instructions.
5.2.2.7 Safety related stop function
Safety related stops shall be stops of category 0 or 1 as defined in 9.2.2 of EN 60204-1:1997.
5.2.2.8 Emergency stop
Unless otherwise specified in the clauses for specific machines, machines shall be provided with an emergency
stop button located on each control station. The emergency stop function shall comply with 9.2.5.4.2 of EN 60204-
1:1997. It shall function as a category 0 or category 1 stop according to 9.2.2 of EN 60204-1:1997. The emergency
stop device shall comply with EN 418.
On machines with electronic drives, the actuation of an emergency stop control device may, contrary to the
requirements of 9.2.5.4 of EN 60204-1:1997, initiate a category 2 stop as defined by 9.2.2 of EN 60204-1:1997
provided that the requirements of 5.2.7.3 are satisfied.
Sufficient emergency stop actuators shall be provided so that a person has to walk no further than 5,0 m to find an
emergency stop actuator.
On wrapping machines where hazards may arise from the generation of static electricity, the manufacturer shall
provide sufficient earth bonding or static elimination equipment to ensure that hazardous level of static electricity do
not occur.
The external temperature of exposed parts of the machine, e.g. guards, control panels and electric motors, shall
not exceed a temperature that will cause burning. For bare metal the temperature shall be no higher than 65 °C for
contact times less than 1 s. See EN 563 for details of the burn thresholds for other materials or longer contact
times.
Where the machine includes parts with a temperature greater than the burn thresholds described in EN 563, the
manufacturer shall minimise the risk of accidental contact e.g. by fitting insulation or safeguarding against
unintentional contact and by fitting the warning sign No. 5041 "Caution, hot surface" of IEC 60417:2002 on the
outside of the machine or adjacent to the hot parts (see Figure 21 – Warning sign "Caution, hot surface"). The size,
shape and colour of the warning sign shall comply with Tables 7, 4 and 2 of EN 61310-1:1995.
If having taken these measures, there is a residual risk of touching hot surfaces this shall be stated in the
instruction handbook together with the measures which can be taken to avoid burn injuries, e.g. wearing gloves or
other personal protection equipment.
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Figure 21 — Warning sign "Caution, hot surface"
5.2.4 Noise reduction
The main sources of noise on wrapping machines are:
a) Drive mechanisms;
b) Vacuum pumps;
c) Compressed air exhaust;
d) Products (e.g. glass bottles and cans) hitting against each other;
e) Packaging materials, e.g. by unreeling the strap or film;
f) Mechanisms hitting against each other, e.g. during the welding process.
Wrapping machines shall as far as is reasonably practicable be designed to reduce noise at its source.
Measures to reduce or eliminate noise at source include the following:
i. Installing acoustic absorptive materials on the inside of machinery casings or enclosing

power transmission components in acoustic absorptive material;
ii. Designing mechanisms so that they do not hit against each other;
iii. Use of damping materials on vibrating or impacted metal surfaces;
iv. Fitting air exhausts with silencers;
v. Using rubber rollers;
vi. Use of vibration isolators;
vii. Fitting partial or full acoustic enclosures;
viii. Reducing the running speed of the machine or auxiliaries;
ix. Use of helical instead of straight cut gears;
x. Using timing belts instead of chains;
xi. Additional design measures can be found in EN ISO 11688-1.
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The criteria for assessing the efficiency of noise reduction measures are the actual noise emission values of the
machine and not the nature of the reduction measure itself.
5.2.5 Measures to control hazards generated by products and materials
5.2.5.1 Measures to control hazards generated by products
Where a machine is designed or specified to pack products that are hazardous to health or safety, the
manufacturer shall:
1. Identify the nature of the hazard and methods for controlling the hazard. If the manufacturer is unable to obtain
this information, the manufacturer shall state clearly in the instructions for use that the hazards that may be
posed by the product have not been taken into account during the design of the machine. In this case
requirements 2,3 and 4 do not apply.
2. Design a safe system for handling the product and minimising the risk of damaging packages of hazardous
products e.g. by limiting the force or torque, or by fitting shear pins or sensors.
a. If hazardous substances are likely to be discharged from the machine the manufacturer shall design the
machine in accordance with EN 626-1 and EN 626–2;
b. If the machine is intended to handle a combustible product, the manufacturer shall design the machine
following the principles of EN 13478;
c. If harmful biological substances are likely to be discharged from the machine the manufacturer shall design
the machine in accordance with EN 626-1 and EN 626–2;
d. On machines where the hazard is from falling or ejected packs or products, the manufacturer shall provide
guards that will contain these packs or products.
3. Supply any necessary ancillary equipment e.g., dust, aerosol or fume extraction or monitoring devices.
4. Provide information on how to install the ancillary equipment and operate, clean and maintain the machine
without risks to health or safety.
5.2.5.2 Measures to control hazards generated by packaging materials
Where a machine is designed or specified to use packaging materials that are hazardous to health or safety, the
manufacturer shall:
1. Identify the nature of the hazard and methods for controlling the hazard;
2. Design a safe system for handling the packaging material using relevant standards, for example
a. On machines using materials that can give off fumes hazardous to health, e.g. polyester (PET), limit
the temperature of heating devices so that fumes are not generated, e.g. below 250 °C. If this cannot
be done provide fume extraction equipment as described in 3;
b. On machines using packaging materials that produce excessive amounts of dust provide dust
extraction equipment as described in 3;
c. On machines using materials with sharp edges, which can cause cut injuries guard exposed edges on
the machine against accidental contact and recommend the use of gloves when handling the material
in the instructions for use;
d. On machines using materials that can catch fire if overheated, the design of the control system shall
minimise the risk of the packaging material catching fire. This may involve designing the control system
so that the heated sealing devices do not remain in contact with the packaging material when the
machine is stopped;
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e. On machines handling glass containers the design shall ensure that people are protected from broken
or flying glass;
f. On machines using packaging materials that can generate electrostatic charges provide suitable earth
bonding and static elimination equipment.
3. Supply any necessary ancillary equipment e.g. dust or fume extraction equipment designed in accordance with
EN 626-1 and EN 626-2.
4. Provide information on how to install the ancillary equipment and operate, clean and maintain the machine
without risks to health or safety.
5.2.6 Ergonomic design principles
5.2.6.1 Operating the machine
Controls and control panels shall be positioned according to the requirements of EN 614-1. The indicators and
actuators shall comply with EN 894-1, EN 894-2, EN 894-3, EN 61310-1 and EN 61310-3. Indication lights fitted to
the machine shall comply with the requirements 10.3.2 and 10.3.3 of EN 60204-1:1997.
5.2.6.2 Loading packaging materials
The position of mechanisms such as magazines for blanks and tape applicators shall be carefully designed to avoid
bad posture or excessive effort that can cause injury. The design shall comply with EN 614 parts 1 and 2 and
EN 1005-3 and further information is given in EN 1005-2 and EN 1005-4.
5.2.6.3 Loading products or unloading packages
On machines that are fed or unloaded by hand, the design of the hand feeding area shall use the ergonomic design
principles indicated in EN 1005-3 to minimise the risk of muscular skeletal injuries.
5.2.6.4 Size and product changes
See 5.2.9.3.3 and 5.2.9.3.4.
5.2.6.5 Cleaning the machine
The parts of the machine which must be reached for cleaning or retrieving fallen packs and products shall be easily
accessible. This may involve designing the machine so it can be cycled to a position where cleaning can be carried
out without the risk of injury.
5.2.6.6 Maintenance
The design of the machine shall minimise the risk of physical strain when carrying out maintenance.
5.2.6.7 Moving the machine
The manufacturer shall provide instructions on how to move the machine safely in the instruction handbook. Where
machines are equipped with wheels the manufacturer shall ensure that the machine can be moved without the
need for excessive effort.
5.2.7 Requirements to prevent hazards caused by failures
5.2.7.1 Power supplies
The design of the machine shall ensure that the interruption and re-establishment after an interruption of the
machine’s power supplies does not lead to a dangerous situation.
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Where the failure of a power supply can lead to packs or products falling down e.g. from a vacuum pick and place
mechanism, the design of the machine shall ensure that the falling items do not cause injuries e.g. by guarding the
area where the items might fall.
The uncontrolled lowering or falling of mechanisms can be prevented for example:
a) self-locking construction,
b) automatically acting fall restraint devices,
c) back up power supplies or compressed air vessels.
5.2.7.2 Requirements for safety related parts of control systems
Safety-related parts of control systems include, for example, emergency stop circuits, electric interlocking circuits
and operating speed on hold-to-run controls. For safety aspects see EN 954-1.
Unless stated otherwise in this standard or indicated by the risk assessment which includes an assessment of the
contribution of safety related parts of the control system to risk reduction, the following minimum requirements shall
apply:
a) On the hydraulic/pneumatic control system, the safety-related parts shall comply with at least category 1 of
EN 954-1:1996.
b) Non programmable electrical and electronic safety related part shall comply with at least category 1 of EN
954-1:1996.
c) Electro sensitive protective equipment (ESPE) shall conform to EN 61496-1:2004 type 2 or type 4. For
positioning of ESPE systems the hand approach speed, response time of the ESPE, and the stopping
performance of the machine shall be considered in accordance with EN 999, to ensure that any hazardous
movement has been stopped before the operator reaches the danger zone.
d) Computers and programmable electronic equipment used in safety related parts of control system shall
comply with EN 62061.
NOTE In a large number of machine specific standards (“C” type standard in CEN) risk estimation has been carried
out to select a required category in accordance with Annex B of EN 954-1:1996 for safety related parts of machine
control systems. Currently it is noted that for simplification, the following relationships are used: required category 1 to
SIL 1, required category 2 to SIL 1, required category 3 to SIL 2 and required category 4 to SIL 3. More comprehensive
methods of mapping between required category of EN 954-1:1996 and required SILs used in this European Standard
are under consideration.
e) Hydraulic/pneumatic two-hand controls, shall comply with type III A, and electric/electronic two-hand
controls shall comply with type III B of EN 574:1996 and type III of EN 60204-1:1997. For positioning of
two-hand-controls the hand approach speed shall be considered in accordance with EN 999, to ensure that
any hazardous movement has been stopped before the operator reaches the danger zone.
5.2.7.3 Motor drive system
Where hazardous movement of machinery is controlled by servo, rectifier or inverter or similar electronic drive
systems, the safety related parts of the control system shall prevent unexpected start up when the hazardous
movement is not safeguarded e.g. when interlocked guards are opened to allow damaged packs to be removed
during normal operation.
The following design options are examples to prevent hazards from moving elements.
a) Galvanic disconnection: The power supply to the actuators (electrical, pneumatic or hydraulic) that
creates hazardous movement is removed by hardwired means that achieve galvanic disconnection
when the interlocked guards are opened.
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The positioning of the contactor in the power circuit before or after the drive shall take full account
of electromagnetic compatibility and dc switching constraints as well as the need to ensure any
stored energy in the drive is discharged before the safe state is achieved.
NOTE An example of this is an interlocking guard with guard locking, where a guard remains locked following
a stop command until the servomotor achieves its set point. Once the set point has been achieved the guard
is unlocked by the control system and the motor drive then achieves or maintains a safe condition through
galvanic disconnection by a main contactor when the guard is opened.
b) Safe pulse blocking: in safe pulse blocking the power supply remains connected to the motor, but
the drive is prevented from moving by inhibiting the generation of pulses to the drive power
semiconductors while the guards are open. Safe pulse blocking shall be achieved by galvanic
disconnection of the power supply of either the pulse amplifier or the opto coupler of each power
semiconductor once the drive has come to a standstill.
c) Position monitoring: both the power supply and the control signal remain connected to the motor,
but the movement or position of the motor is monitored to ensure that it remains in a safe position.
If aberrant movement is detected while the guards are open, the power supply to the motor is
disconnected by galvanic disconnection. Where position monitoring is used the control system
shall ensure that any aberrant movement is detected and halted before the movement can create a
hazard and any stored energy in the drive controller is discharged.
d) Mechanical brake: the motor is fitted with a mechanical brake that is applied automatically when
the interlocked guards are open and prevents the motor from moving even if the power is supplied
to the motor. The braking torque of the mechanical brake shall be greater than the maximum
torque that the drive can generate.
e) Limitation of use: the method of preventing the unexpected start up of drives described above are
only suitable for short duration machine intervention e.g. removal of damaged packs and
packaging materials and are not a substitute for safe isolation procedures. The manufacturer shall
ensure that the instruction handbook emphasises this point and indicates how the drive shall be
isolated for other intervention, e.g. maintenance or cleaning.
5.2.8 Hygienic design requirements
When a packaging machine is designed or specified to pack agri-foodstuffs or other products where hygiene is a
requirement, the manufacturer shall:
1. Identify the level of hygienic design appropriate for the product. When the machine manufacturer is unable
to find this information, he shall define the limitation of use for the machine and clearly state this in the
instructions for use, e.g. “This machine has been designed to pack agri-foodstuffs with the following
attributes: ...”
2. Following the requirements of EN 1672-2 design a safe system for handling the product. Design features
will include:
a. Use of appropriate contact materials;
b. Measures to prevent lubricating oils coming into contact with the product e.g. fitting filters to
compressed air exhausts;
c. Food and splash areas (as defined in Clause 3 of EN 1672-2:2005) which are free from crevices
and ledges;
d. Food and splash areas that can be easily cleaned and inspected for cleanliness.
3. Describe appropriate cleaning and disinfecting procedures for the machine in the instructions for use.
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5.2.9 Requirements for mechanisms used on most wrapping machines
5.2.9.1 Drive systems
Drive systems shall be safeguarded using the methods describe in 5.2.1.
5.2.9.2 Conveyors
5.2.9.2.1 Belt and slat-band conveyors
Belt and slat-band conveyors shall comply with the relevant safety requirements of EN 619. Where fixed or
interlocked guards are used to safeguard danger zones on conveyors they shall comply with 5.2.1.3.
5.2.9.2.2 Roller conveyors
Roller conveyors shall comply with the relevant safety requirements of EN 619. Where fixed or interlocked guards
are used to safeguard danger zones on conveyors they shall comply with 5.2.1.3.
Where low level conveyors are likely to be used as a means of access to the machine, e.g. for maintenance or
cleaning of the machine, the design of the conveyor shall minimise the risk of slipping, tripping or falling e.g. by
fitting non-slip plates between the rollers.
5.2.9.3 Size and product changing
5.2.9.3.1 General
The hazards presented by size or product changing described in 4.2.9.4 shall be eliminated or minimized by
complying with the following requirements.
5.2.9.3.2 Design of guards
The design of the machine and its guards shall ensure that danger zones on the machine are safeguarded for all
the product and pack sizes for which the machine has been specified.
Where reasonably practicable and on machines where product or size changing takes place once a week or more
frequently, one of the following methods shall be used:
a) Guards designed to adjust automatically, either manually or under power e.g. by linking the fixed and
adjustable guards together, or;
b) Guards connected to change parts so that the machine cannot function without the appropriate guarding
being fitted, or;
c) Fitting interlocking devices to guards which are change parts so that the machine cannot operate without the
guards in place.
Where the measures listed above are not reasonably practicable, e.g. if size or product changes are infrequent, it is
acceptable to use guards that have to be manually adjusted and guards which are not interlocked but are change
parts, provided a warning label or pictogram is fitted in a prominent position on the machine stating that the
machine shall not be used until the guards have been correctly fitted or adjusted.
5.2.9.3.3 Change parts
On machines where change parts are used hazards from excessive effort or strain shall be eliminated or reduced
by the following measures:
a) Change parts shall be designed so that they can be lifted, installed and removed easily, following the general
requirements stated in 4.1 of EN 614-1:1995, and;
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b) Mass of change parts should not exceed 25 kg and the design of the machine and the change parts should
ensure that people do not have to assume awkward postures while carrying, fitting or removing the parts, or;
c) Where the recommendations described in b) are not possible for technical reasons, the manufacturer shall
either provide suitable mechanical lifting or handling equipment or the design of the machine and the change
parts shall allow two people to lift the parts into place. If two persons are required to lift or fit change parts this
shall be stated clearly in the instructions for use, or;
d) Where the mass of the change part is greater than 40 kg, the manufacturer shall provide suitable mechanical
lifting or handling equipment to move the part.
5.2.9.3.4 Size or product changing under power
Where parts of the machine are adjusted under power the risks presented by these powered movements shall be
eliminated using the following hierarchy of measures:
1) Ensuring that the movements are not hazardous by following the principles described in 5.2.1.2;
2) If 1) is not possible by ensuring that movements can only take place behind fixed or interlocked guards
complying with 5.2.1.3;
3) Where it is not possible to fulfil the requirements of 1) or 2), hold-to-run controls may be used provided
they comply with the requirements of 5.2.1.7.
5.2.9.4 Modified atmosphere packaging
All vessels, pipes and fittings of controlled atmosphere installations shall be designed to safely contain the pressure.
The gas supply shall be fitted with a lockable valve and means of safely venting the line downstream so that the
cleaning and maintenance operation can be carried out safely. The design of the gas control system shall ensure
that dangerous levels of gas do not build up around the machine, this may be achieved by:
a. Fitting a solenoid valve to shut off the supply of gas when the machine stops
b. Providing exhausting equipment
c. Fitting a solenoid valve upstream of flexible hoses. This valve shuts off the supply of gas when a hose
ruptures and gas flow exceeds normal limits. The safety related control system shall comply with category
1 of EN 954-1:1996
For installation in machines using oxygen, fire resisting pipes shall be used and the materials used shall not catch
fire in the presence of oxygen. The instruction handbook shall give clear information about these requirements.
In machines where mixtures of gas can be selected a display will be installed showing the concentration of the
components.
The vacuum system of the machine shall be designed to prevent gas mixtures of oxygen concentration 21 %
entering the vacuum pump. Additionally all machines shall be fitted with either:
a. Control system which ensures that the vacuum valve is closed before the gas mixture can enter the
vacuum chamber and before the vacuum valve opens again no gas mixture remains in the chamber. The
system shall be made in a way that complies with category 3 of EN 954-1:1996, or
b. Vacuum pump which operates safely in concentrations of oxygen higher than found in normal atmospheres.
If Solution a. is applied, the machine can be connected to a central vacuum system.
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5.3 Safety requirements for a banding machine
5.3.1 General
The requirement and measures detailed in 5.2 and described in this clause apply to a banding machine where the
equivalent hazards exist.
5.3.2 Product feed
Machines fitted with automatic product feeding devices shall be guarded in accordance with 5.3.2.4.
The return chain run, drive and tail sprockets of the in-feed conveyor shall be safeguarded with fixed guards,
complying with 5.2.1.3. The tail sprocket guard shall be designed to avoid a shearing hazard. Where machines are
equipped with product side guides that are adjustable without the need for tools, movement of these guides shall
not expose any hazard. The lateral belt shall be guarded according to 5.2.9.2.1.
These shall be designed so that they do not present shearing or crushing hazards in the hand loading area and
where they enter the folding box. This can be achieved by e.g.:
a) Designing the pushing devices so that they detach from the chain while the mechanisms do not exert the
values given in 5.2.1.2;
b) Designing the pushing devices so that they can bend when the values given in 5.2.1.2 are exerted;
c) Designing the linkage so that the pushing devices are free to bend backwards as they enter the folding box;
d) Fitting the in-feed conveyor drive with a torque limiter which removes power from the in-feed chain when the
values given in 5.2.1.2 are exerted.
These shall be designed to eliminate the drawing-in hazard presented by in-running nips following 5.2.9.2.1.
5.3.2.4 Automatic product feed mechanism
Automatic product feed mechanisms shall be designed in accordance with 5.2.1.1.
The variety of feeding devices fitted to wrapping machines is such that no specific requirements can be given.
However when removing or altering any product feed mechanism provided with the machine presents a hazard, a
warning notice shall be fixed in a prominent position on the machine body.
Where a handle or hand-wheel is provided to operate a machine manually, the risk of injury from the moving handle
or hand-wheel shall be eliminated by one of the following methods:
a) Measures to prevent injuries from handles or hand-wheels moving under power
1) By fitting interlocked guards complying with 5.2.1.3 or;
2) By fitting an interlocking device complying with 5.2.1.3 which prevents the machine from operating
under power until the handle or hand-wheel has been disengaged or removed, or;
3) By design using the principles set out in 5.2.1.2.
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b) Measures to prevent the handle or hand-wheel moving unexpectedly due to stored energy:
1) Balancing the torque, or;
2) Braking forward and reverse movement, or;
3) Fitting a device to prevent reverse motion.
5.3.4.1 General
The design of the machine shall eliminate the need for manual handling where the mass of the reel exceeds 25 kg
by the use of mechanical reel handling devices which are supplied with the machine.
Where the mass of a reel is greater than 15 kg but less than 25 kg the design of the machine shall allow:
a) either easy access for two people to lift the reel
b) or the use of lifting devices specified by the manufacturer
The shearing hazard between the tension roller assembly and the machine frame shall be eliminated either by
ensuring that the assembly is at least 25 mm from the frame or by incorporating one of the devices shown in Figure
22.
Key
A Solid piece welded on to eliminate trap
B Plate attached to machine frame
Figure 22 — Methods of safeguarding film compensator
5.3.4.3 Coders
The coder manufacturer’s instructions for safe mounting shall be followed. These instructions will recommend to fit
a guard so that the gap between the coding mechanism and the pressure plate is less than 4 mm. The coder will
normally be controlled so that it stops when the wrapping machine stops, however on coders that include heating
devices it will be usual for the heater to remain under power when the machine is stopped. To minimize this
residual burning hazard the heater shall be guarded against non intentional contact and a triangular warning
symbol according to 5.2.3 shall be fitted to coders where there is a residual burning hazard (see Figure 21).
A guard shall be fitted where necessary to ensure that the gap between the coding mechanism and the pressure
plate is no more than 4 mm.
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5.3.4.4 Film reels
The hazards presented by film reels described in 4.3.3.4 shall be prevented or reduced by complying with the
following requirements:
a) Design of the film reel support assembly shall ensure that the film reel does not move uncontrollably during all
modes of operation of the machine, and;
b) Drawing-in hazard on machines with high mass reels shall be prevented by safeguarding according to 5.2.1.1
and;
c) Where the film edge presents a cutting hazard the film path shall be enclosed with fixed or interlocked guards
complying with 5.2.1.3, and;
d) Where film rollers cannot be made safe by design using the measures indicated in 5.2.1.2, they shall be
enclosed in fixed or interlocked guards complying with 5.2.1.3, and;
e) Where the film braking or compensating mechanism cannot be made safe by design using the measures
indicated in 5.2.1.2, it shall be safeguarded by fixed or interlocked guards complying with 5.2.1.3.
Drive mechanisms of powered unwind devices shall be fitted with fixed guards complying with EN 953 and sized in
accordance with Table 4 of EN 294:1992. The in running nips of the film driving rollers shall be safeguarded by one
of the methods shown in Figure 23.
Figure 23 — Methods of safeguarding power unwind mechanism
They shall be guarded with interlocking guards complying with 5.2.1.3 which deny access to the dangerous
movements. The interlocking guards shall be interlocked so that the splicer cannot operate when the guards are
open, but allow the main machine to continue in operation.
The design of the guards shall ensure that hazards on the main machine cannot be reached when the splicer’s
guards are open. This can usually be achieved with fixed guards sized in accordance with EN 294:1992, Table 4.
When a pneumatic actuator is used the opening of the guards shall result in isolation of the compressed air power
source and energy dissipation.
If packaging materials are to be used which give rise to a static electricity hazard, a static elimination device shall
be fitted or fittings provided so that the electrostatic charge can be safely discharged to earth before a hazard
results.
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Where a static eliminator generates an electric shock hazard, the static eliminator power supply shall be
automatically disconnected when the interlocked guards are opened.
5.3.4.8 Cutting devices
The hazards presented by cutting devices described in 4.3.3.8 shall be prevented or reduced by complying with the
a) Device shall be safeguarded with fixed or interlocked guards complying with 5.2.1.3, and;
b) Design shall ensure that the cutting device cannot move unexpectedly due to stored energy, and;
c) Design shall minimise the risk of injury during film threading or size changing e.g. by designing the cutting
mechanism so that the cutting surfaces are protected when the machine stops, and;
d) Cutting tools shall be designed or provided with auxiliary devices so that they can be installed and removed
from the machine without any danger. Auxiliary devices may include handles, clamping devices, gripping or
holding tools.
The instruction handbook shall suggest the use of personal protective equipment when it is necessary.
5.3.4.9 Sealing devices
The hazards presented by sealing devices described in 4.3.3.9 shall be prevented or reduced by complying with
the following requirements:
a) Device shall be safeguarded with fixed or interlocked guards complying with 5.2.1.3.
b) Design shall ensure that the sealing device cannot move unexpectedly due to stored energy.
Where sealing mechanisms are heated, the hazards shall be prevented or reduced by complying with the following
requirements:
i) Thermal hazards shall be reduced as described in 5.2.3. It is acceptable for power to remain
connected to heating elements while guard doors are open provided the instructions detail those
circuits that will remain connected and the parts of the machine that can cause burn injuries;
ii) The design of the control system shall minimise the risk of the packaging material catching fire. This
may involve designing the control system so that the heated sealing devices do not remain in contact
with the packaging material when the machine is stopped;
iii) To minimise the risk of electric shock if the electrical insulation of heating elements breaks down, use
methods indicated in 5.2.2.5;
iv) Where the fumes given off by heated packaging material could be hazardous to health the design
shall comply with 5.2.5.2.
Belt conveyors shall be designed to eliminate the drawing-in and friction hazards presented by in-running nips. See
5.2.1.1. Discharge mechanisms which cannot be safeguarded by design shall be safeguarded by movable guards
complying with 5.2.1.3.
5.4 Safety requirements for a sleeve wrapping machine and a stretch banding machine
5.4.1 General
The requirement and measures detailed in 5.2 and described in this clause apply to a sleeve wrapping machine
and to a stretch banding machine where the equivalent hazard exists.
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5.4.2 Product feed
See 5.3.2.
See 5.3.2.1.
See 5.3.2.2.
See 5.3.3.
See 5.3.4.
See 5.3.4.2.
5.4.4.2 Coders
See 5.3.4.3.
See 5.3.4.4.
See 5.3.4.8.
5.4.5 Tray erecting mechanism
The tray erecting mechanism shall be safeguarded by guards complying with 5.2.1.3.
5.4.6 Hot melt adhesive equipment
On machines where a hot melt adhesive system is fitted the following requirements shall be fulfilled:
a) Design of the control system shall ensure that the adhesive cannot catch fire in the event of a control failure.
Methods of achieving this include fitting a high temperature sensor and associated trip device, which is
independent of the temperature control circuit or sizing the heating elements so that the adhesive can never
reach its ignition temperature or using a fusible link and;
b) User shall be advised in the instruction handbook, of the risk of fire or of unpleasant fumes, if controls are set
at an incorrect temperature and advised of the need to install such machines in a well ventilated room and;
c) Design shall ensure, where practicable, that exposed surfaces of adhesive application equipment does not
cause burn injuries. Where such measures are not practicable, e.g. exposed surfaces of glue nozzles,
warning signs shall be provided. See 5.2.3 for detailed requirements and;
d) Adhesive system shall be designed in such a way that it can be replenished with adhesive without the risk of
splashing the operator with hot adhesive and subjecting the operator to unpleasant fumes; if the use of
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personal protection equipment is necessary detailed information shall be given by the manufacturer in the
instruction handbook and;
e) On systems where the adhesive is pressurized and jetted or sprayed onto the packaging material, the
machine's guards shall be designed to contain any foreseeable overspray of hot melt adhesive. The control
system shall ensure that except when purge mode is selected, the system can only discharge adhesive with
the guards closed and;
f) Pressurized adhesive systems shall be equipped with a means to control the pressure, to prevent
overpressure and to safely purge and release the pressure from the system. Detailed information about the
release of the pressure shall be given in the instruction handbook and;
g) On machines where a hot melt adhesive purging or pressure reduction system is provided, this shall either
only operate with the guards closed or operate by means of a hold-to-run control located next to the glue gun,
which can only be operated via a key operated switch.
5.4.7 Conveyor discharge
Where a conveyor discharge is fitted, the guards shall effectively prevent access to the danger zones by following
the requirements of 5.2.9.2.
Where a flighted belt is fitted it shall be safeguarded by interlocked guards complying with 5.2.1.3.
Where the conveyor forms part of the guarding, it shall either be fixed in relationship to the machine, or interlocked
complying with 5.2.1.3 in such a way that ensures the conveyor is capable of operation only when in the required
position.
5.4.8 Shrink tunnel
See 5.15.
5.5 Safety requirements for a spiral wrapping machine
5.5.1 General
The requirement and measures detailed in 5.2 and described in this clause apply to a spiral wrapping machine
where the equivalent hazard exists.
5.5.2 Product feed
Roller drive mechanisms shall be safeguarded with fixed guards. Rollers shall be more than 120 mm away from
each other or will be provided with devices against drawing-in or crushing.
5.5.3 Wrapping head
The unwinding and wrapping zone shall be safeguarded complying with 5.2.1.3.
See 5.3.5.
5.5.5 Ergonomics
Sometimes products to be wrapped are kept in position by the operator. The force to be exerted by the operator
shall be limited according to EN 1005-2.
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5.6 Safety requirements for a fold wrapping machine
5.6.1 General
The requirement and measures detailed in 5.2 and described in this clause apply to a fold wrapping machine where
the equivalent hazard exists.
5.6.2 Product feed
Machine fitted with automatic product feed shall be guarded in accordance with 5.3.2.4.
See 5.3.2.1.
5.6.2.2 Product pushing and elevating devices or pincers
See 5.3.2.2.
See 5.3.3.
See 5.3.4.
See 5.3.4.2.
5.6.4.2 Coders
See 5.3.4.3.
See 5.3.4.5.
See 5.3.4.6.
See 5.3.4.8.
See 5.3.5.
5.7 Safety requirements for an extruded product wrapping machine
5.7.1 General
The requirement and measures detailed in 5.2 and described in this clause apply to an extruded product wrapping
machine where the equivalent hazard exists.
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5.7.2 Product feed
Product feeding rolls shall be easily removable for cleaning.
Operating speeds of the feeding group and the wrapping machine shall be synchronised to avoid hazards arising
from build-up of product. See also 5.2.8.
See 5.3.3.
See 5.3.4.
See 5.3.4.2.
5.7.4.2 Coders
See 5.3.4.3.
5.7.4.3 Film reels
See 5.3.4.4.
See 5.3.4.5.
See 5.3.4.6.
See 5.3.5.
5.8 Safety requirements for a twist wrapping machine
5.8.1 General
The requirement and measures detailed in 5.2 and described in this clause apply to a twist wrapping machine
5.8.2 Product feed
The feeding disk shall be safeguarded with movable interlocked guards complying with 5.2.1.3.
5.8.2.1 Feeding belt
See 5.3.2.3.
5.8.2.2 Product pusher
See 5.3.2.2.
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See 5.3.3.
See 5.3.4.
See 5.3.4.2.
See 5.3.4.5.
5.8.4.3 Film reels
See 5.3.4.4.
5.8.4.4 Automatic splicing mechanisms
See 5.3.4.6.
See 5.3.4.8.
See 5.3.5.
5.8.6 Noise reduction
The main sources of noise are:
a) vibrating unit which conveys the products to the feeding disk
b) impacts of the products in the feeding disk (in part it depends on the nature of the products)
c) drive mechanisms of the machine (Cams, gears and belts)
d) impact of the pliers used for wrapping (in part it depends on wrapping material).
The hopper vibrator shall be mounted on a vibration isolation system in order to reduce the transmission of noise.
The hopper shall be constructed to avoid resonance e.g. by applying damped material. The feeding disk and
mechanisms shall be designed with care to avoid excessive resonance.
Wrapping pliers shall be made in such a way to avoid noise generated by impact and the product fall shall be
controlled by a slide or by devices able to reduce the speed.
As noise can vary depending on the state of maintenance; the instruction handbook shall provide special criteria
and values as reference (e.g. noise level of same mechanism measured in a referred mode).
The increase of noise or vibration level can be evaluated in order to prescribe maintenance operations.
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5.9 Safety requirements for an over-wrapping machine
5.9.1 General
The requirement and measures detailed in 5.2 and described in this clause apply to an overwrapping machine
5.9.2 Product feed
See 5.3.2.
See 5.3.2.1.
See 5.3.3.
5.9.4 Tear tape application group
The tear tape application group shall be safeguarded complying with 5.2.1.1 and if a heat source is used (e.g. hot
melt tank) the requirements of 5.2.3 apply.
See 5.3.4.
5.9.5.1 Coders
See 5.3.4.3.
5.9.5.2 Film reels
See 5.3.4.4.
5.9.5.3 Power unwind mechanism
See 5.3.4.5.
See 5.3.4.6.
See 5.3.4.7.
See 5.3.4.8.
See 5.3.5.
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5.10 Safety requirements for a roll wrapping machine
5.10.1 General
The requirement and measures detailed in 5.2 and described in this clause apply to a roll wrapping machine where
5.10.2 Product feed
See 5.3.2.3.
5.10.2.2 Automatic product feed mechanism
All the mechanisms shall be safeguarded with fixed or interlocked guards complying with 5.2.1.3
For routine regular access, for example daily, interlocked guards shall be provided. Fixed guards should be
considered for infrequent access. Where necessary, guards shall provide noise attenuation and be designed for
easy cleaning.
See 5.3.3
See 5.3.4.
See 5.3.4.2.
5.10.4.2 Coders
See 5.3.4.3.
See 5.3.4.5.
See 5.3.4.6.
See 5.3.4.8.
See 5.3.5.
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5.11 Safety requirements for a foil and band wrapping and a pleat wrapping machine
5.11.1 General
The requirement and measures detailed in 5.2 and described in this clause apply to a band wrapping and pleat
wrapping machine where the equivalent hazard exists.
5.11.2 Product feed
See 5.3.2
See 5.3.2.1.
See 5.3.2.2.
See 5.3.2.3.
See 5.3.3.
See 5.3.4.
See 5.3.4.2.
5.11.4.2 Coders
See 5.3.4.3.
5.11.4.3 Film reels
See 5.3.4.4.
5.11.4.4 Cutting devices
See 5.3.4.8
See 5.3.4.7.
See 5.3.5.
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5.12 Safety requirements for a stretch film wrapping machine
5.12.1 General
The requirement and measures detailed in 5.2 and described in this clause apply to a stretch wrapping machine
5.12.2 Product feed
See 5.3.2.
5.12.3 Product pushing and elevating devices
See 5.3.2.2
See 5.3.4.
See 5.3.4.2.
See 5.3.5.
5.12.5.1 Product discharge aperture
See 5.2.1.4 As an alternative falling fingers may be used moveable only in the direction of the outlet of the product
thus preventing upper limb access to the danger zone (Figure 24):
a) each finger shall be suspended independently;
b) fingers shall fit the whole aperture;
c) fingers shall fall down to the bottom of the aperture;
d) maximum distance between the fingers and the conveyor shall not exceed 3 mm and the surface of the
conveyor shall be plain and solid;
e) fingers shall be designed and constructed such that their operating life equals the expected life of the machine;
f) fingers shall be designed in such a way that they cannot be lifted by the hand of an operator;
g) width of a finger shall not exceed 10 mm;
h) distance between the fingers shall not exceed 3 mm;
i) easy access has to be nearby or there shall not be foreseeable need for reaching through the aperture (e.g. no
trouble shooting required in this area);
j) safety distance according to Table 3 shall be used (see Figure 24).
A prohibition sign shown in Figure 19 – Prohibition sign “do not reach in” shall be fitted to the guard near the
aperture warning the risk of injury from reaching into the machine.
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Table 3 — Safety distance for tunnel guard with deterring devices
Height (A) > 20 to 30 > 30 to 40 > 40 to 60 > 60 to > 120 to > 220 to > 240 to
120 220 240 400
Safety
230 300 350 450 550 550 550
distance D
Key
1 Fixed guard
2 Fixed or interlocked tunnel shaped guard
3 Danger zone
4 Product
5 Conveyor
6 Approach to danger zone
7 Falling fingers
Figure 24— Product discharge aperture
5.13 Safety requirements for an L-sealing machine
5.13.1 General
The requirement and measures detailed in 5.2 and described in this clause apply to an L sealing machine where
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5.13.2 Semiautomatic machine
5.13.2.1 Product feed
The feeding zone shall be carefully designed in order to avoid bad posture and limitation to body movement. See
5.2.6.
5.13.2.2 L-sealing station
a) When the heater is hand operated an ergonomically designed handle shall be placed on the L shaped sealing
bar. The warning sign “caution, hot surface” complying with 5.2.3 (see Figure 21) shall be fitted indicating the
burn hazard. The temperature of the plastic handle shall not exceed 43 °C.
b) When the bar is raised and lowered under power, such as by a pneumatic cylinder, the powered movement
shall be controlled by synchronous two hand control device according to type III of EN 574:1996. So far as
possible, the workstation should be designed so that only one person can stand at the operator’s position.
Instructions for use shall be provided to advise that the controls shall be used by a single person. In addition,
a notice shall be attached to the workstation indicating “Single Operator Only”.
c) When the movement of the sealing bar is controlled automatically, guards shall be used according to 5.2.1.3
of this standard.
See 5.15.
5.13.2.4 Stability of the machine
Two wheels shall be equipped with a brake. Guards according to EN 811 shall be provided to prevent crushing
injuries to lower limbs arising from contact with wheels.
5.13.2.5 Ergonomics
The machine design shall take into consideration the position of manual controls and the height of the working
plane (EN 614-1). See also 5.2.6.
5.13.3 Fully automatic machine
See 5.3.2.3.
5.13.3.2 Reel unwind mechanism
See 5.3.4.
See 5.3.4.7.
See 5.3.4.8.
See 5.15.
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5.14 Safety requirements for a skin packaging machine
5.14.1 General
The requirement and measures detailed in 5.2 and described in this clause apply to a skin packaging machine
5.14.2 Product feed
See 5.3.2.
See 5.3.5.
5.14.4 Stability of the machine
See 5.13.2.4.
5.14.5 Ergonomics
See 5.13.2.5.
5.15 Safety requirements for a shrink tunnel and hot water dip tank
5.15.1 General
The requirement and measures detailed in 5.2 and described in this clause apply to a shrink tunnel and a hot water
dip tank where the equivalent hazard exists.
5.15.2 Product transfer system
The conveying system shall be safeguarded according to 5.2.9.2.
The internal width of the meshes of woven wire conveyors shall not exceed 5 mm in any direction or in diameter.
When the feeding belt of the tunnel and the outlet belt of the wrapping machine are the same, special care shall be
given to the integration of the guards. The instruction handbook shall provide suitable information for the correct
mounting of the guards.
5.15.3 Requirement to prevent thermal hazard
Surfaces which are designed to be handled shall not exceed 43 °C.
If necessary cooling systems shall be incorporated to ensure that the burn threshold is not exceeded by the
package or by parts of the conveying system.
A hazard warning sign according to 5.2.3 shall be fitted near the inlet and outlet aperture. The openings shall be
closed by a flexible curtain to limit the escape of heat but allow products to pass unhindered. The heaters inside the
tunnel shall be guarded against unintentional contact.
Moveable guards which give access to hot parts shall be interlocked complying with 5.2.1.3 and all heating and
motive power shall be cut off when a guard is open.
Where it is necessary to prevent fire or overheating of the conveyor a run-down function shall be incorporated
which keeps the conveyor running for a pre-determined period after the heating system has been switched off.
Other methods to prevent the hazard may be taken if they are equally effective.
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The temperature control shall be performed by an automatic system which in case of failure shall cut off the power
to avoid over-heating.
The instruction handbook shall provide information to enable all setting, clearing and maintenance tasks to be
performed safely especially in cases where the procedures involve opening or removing guards which give access
to hot parts.
These instructions shall recommend the use of personal protective equipment when it is impractical to avoid
exposure to hot parts.
5.15.4 Product
Overheating of flammable and/or explosive products as defined by Directives 94/55 EC and 67/548/EEC shall be
avoided by the following means:
a) manufacturer should provide details of the maximum working temperature for the equipment, the maximum
thermal output of the heaters, and the minimum conveyor speed. The instructions should include a
description of the safe working method for setting up the machine. This should start with setting the belt
speed, then running the machine at a low temperature setting, then progressively increasing the temperature
until a satisfactory shrink wrap is achieved. This should be done while monitoring the product to ensure that
is not overheated such that it may, for example, approach its auto-ignition temperature;
b) run out function shall be incorporated to enable all products to be discharged before the conveyor stops;
c) in the event of an emergency e.g. loss of mains power the belt shall move by a power reserve (e.g.
pneumatic or electric battery) to enable all products to be discharged before the conveyor stops;
d) alternatively once power has been isolated the tunnel or tank should be capable of being opened to enable
removal of products using protective equipment or to allow the rapid dissipation of heat;
e) automatic carbon dioxide sprayers or other suitable fire extinguishing equipment shall be mounted if there is a
significant risk of fire;
f) to prevent fire hazard a high temperature sensor and associated high temperature cut off shall be installed
independently from thermostatic control to minimise the risk of the product catching fire;
g) for safety requirements regarding external temperature of the exposed parts of the machine refer to 5.2.3.
See 5.15.2 and 5.15.3.
If there is risk of the product or parts of the conveying system exceeding the burn threshold given in EN 563 cooling
device shall be provided or fixed guards shall be fitted. Contact should only be possible where the temperature is
lower than the burn threshold for the expected contact time.
6 Verification of safety requirements and measures
6.1 General
A manufacturer or supplier, who wishes to claim conformity to this standard, shall first verify that the machine fulfils
the safety requirements and measures.
The following verification procedures shall be adhered to for each machine unless stated otherwise hereafter.
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6.2 Visual inspection with machine stopped
6.2.1 Mechanical parts
Check that mechanical components are securely fixed and all unnecessary sharp edges have been removed.
6.2.2 Pneumatic systems
Check that pneumatic components and piping conform to safety requirements of EN 983 and are correctly installed.
6.2.3 Hydraulic systems
Check that hydraulic components and piping conform to safety requirements of EN 982 and are correctly installed
6.2.4 Electrical systems
Check that electrical equipment and installation is in compliance with the technical documentation described in
Clause 18 of EN 60204-1:1997.
6.2.5 Guards
Check all guards are in place and securely fixed. Check that all interlocking devices are fitted and working correctly.
6.2.6 Design requirements
Check for each type of machine that the design features stipulated in Clause 5 have been incorporated.
Check for each type of machine that the appropriate design requirements for the packaging materials being used
and the product being packed have been followed.
6.3 Measurements with machine stopped
6.3.1 Guards
For every type of machine, check that the relationship between the size of any apertures in the guards and their
distance from the nearest danger zones conform to the requirements detailed in this standard in particular 5.2.1.4.2
and 5.2.1.4.3.
6.3.2 Electrical testing
The tests as described in Clause 19 of EN 60204-1:1997 shall be performed on every machine before it is
despatched.
6.4 Visual inspections with machine running
6.4.1 Guards
Check with machine running that the guards conform to the safety requirements.
6.4.2 Interlocking devices
Check the operation of all emergency stop and interlocking devices. Check that following the operation of an
emergency stop or interlocking device, that all hazardous movements cease and that the machine does not restart
without resetting the emergency stop device or the interlocking devices and without an intentional start command.
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6.4.3 Dissipation of stored energy
Check for each type of machine that stored energy e.g. from pneumatic systems or mechanisms that can move
under gravity is either dissipated automatically before accessing danger zones or can be made safe by the use of a
means provided for this purpose.
6.5 Measurements with machine running
6.5.1 Measurement and declaration of noise emission
For every type of machine measure the noise emission values in the manner described in Annex A.
6.5.2 Temperature
For every type of machine, with the machine fully warmed up, check that the external guard temperatures are not
higher than the burn threshold limits for the foreseen contact times and materials shown in EN 563 (see 5.2.3).
Identify all areas within the machine's guards with higher temperature than the burn thresholds so that they can be
recorded in the instruction handbook and the warning sign shown in Figure 21 – Warning sign "Caution, hot
surface", 5.2.3 can be fitted.
6.6 Verification procedures
Verification procedures for each safety requirement detailed in Clause 5 are shown in Table 4.
Table 4 — Verification procedures for safety requirements identified in Clause 5
Safety Visual Functional Measurement Calculation Safety Visual Functional Measurement Calculation
requirement inspection test requirement inspection Test
5.2.1 X x x 5.2.2 X x x
5.2.3 X x x 5.2.4 X x x x
5.2.5 X x 5.2.6 X x x x
5.2.7 X x x 5.2.8 x x
5.2.9 X x x 5.3.2 x x
5.3.3 X x 5.3.4 x x
5.3.5 X x 5.4.2 x x
5.4.3 x x 5.4.4 x x
5.4.5 x x 5.4.6 x x x
5.4.7 x x 5.4.8 x x x
5.5.2 x x 5.5.3 x x
5.5.4 x x 5.5.5 x x x
5.6.2 x x 5.6.3 x x
5.6.4 x x 5.6.5 x x
5.7.2 x x 5.7.3 x x
5.7.4 x x 5.7.5 x x
5.8.2 x x 5.8.3 x x
5.8.4 x x 5.8.5 x x
5.8.6 x x x x 5.9.2 x x
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Safety Visual Functional Measurement Calculation Safety Visual Functional Measurement Calculation
requirement inspection test requirement inspection Test
5.9.3 x x 5.9.4 x x
5.9.5 x x 5.9.6 x x
5.10.2 x x 5.10.3 x x
5.10.4 x x 5.10.5 x x
5.11.2 x x 5.11.3 x x
5.11.4 x x 5.11.5 x x
5.12.2 x x x 5.12.3 x x
5.12.4 x x x 5.13.2 x x x
5.13.3 x x x 5.14.2 x x
5.14.3 x x 5.14.4 x x
5.14.5 x x x x 5.15.2 x x x
5.15.3 x x x 5.15.4 x x x
5.15.5 x x
7 Information for use
7.1 Marking
Machines shall be marked with the following information:
a) Name and address of the manufacturer or his authorised representative established in the European
Economic Area;
b) Mandatory marks, if appropriate e.g. CE mark, Ex symbol for equipment which can be used in a potentially
explosive atmosphere;
c) Year of construction of the machine;
d) Designation of series or type, if any;
e) Serial number, if any;
f) Electrical markings as indicated in Clause 17 of EN 60204-1:1997. Refer to that standard for full details;
g) Rating information required for lifting equipment, if appropriate e.g. carrying capacity, safe working load, load
limit, centre of gravity, gross weight.
7.2 Signals and warning signs
The machine shall be equipped with the signs, signals and pictograms required in Clause 5. Signs, signals and
pictograms shall be selected from those illustrated in Clause 5, EN 61310-1 and ISO 7000 wherever possible.
Where other signs or pictograms are used, they shall be selected so they cannot be confused with the signs,
signals or pictograms described in these standards.
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7.3 Instruction handbook
7.3.1 General
The instruction handbook shall contain all the information listed in 6.5 of EN ISO 12100-2:2003 where the
equivalent hazard exists. In addition and in particular the instruction handbook shall contain the following
information that is specific to wrapping machines:
1. A repetition of the markings on the machine as stipulated in 7.1;
2. A description of the foreseen use for the machine e.g. the function of the machine, the product to be packed,
packaging materials, pack sizes and speeds;
3. A drawing indicating the work stations likely to be occupied by operators;
4. Details of how high-level areas of the machine can be accessed in safety. The method of installing steps and
platforms supplied with the machine and the specification of ladders or other temporary means of access that
the user is to provide for other purposes than operation, cleaning or routine maintenance;
5. Tests that should be carried out before the machine is used for the first time;
6. Explicit instructions on fitting of change parts, fitting of change part guards and adjustment of adjustable guards
so that the machine is safe to use following a size or product change;
7. A record of and explanation of the significance of all warning devices, signs or pictograms attached to the
machine and the warning signals provided by the machine;
8. Details of the control systems including circuit diagrams for the electrical, pneumatic and hydraulic systems.
The diagrams shall show the interfaces between all permanently wired parts and programmable devices.
Wiring diagrams and documentation of the electrical equipment shall comply with Clause 18 of EN 60204-
1:1997;
9. Noise emission declaration according to Annex A;
10. Where appropriate, instructions on how the machine shall be installed to minimise noise;
11. Specifications of fluids to be used in the machine e.g. lubricating oil, hydraulic fluid;
12. Details of drainage requirements and any residual spillage risks;
13. A statement indicating whether the machine is or is not suitable for use in a potentially explosive atmosphere.
7.3.2 Agri-foodstuffs and pharmaceuticals
On machines intended for use with agri-foodstuffs or pharmaceuticals or other products which can be contaminated
if hygienic design principles are neglected, the instruction handbook shall contain instructions for cleaning and
disinfecting of the machine, together with details of appropriate and inappropriate cleaning and disinfecting
materials. The instruction handbook shall indicate the limitation for use of these products.
7.3.3 Machines handling hazardous products
Where the machine is intended for packing hazardous products, the instruction handbook shall indicate how these
products can be handled safely and state any limitations for use of the machine with hazardous products e.g. “This
machine is not suitable for use with products that can generate explosive atmosphere” or “This machine has been
designed to pack products that are/are not …”.
Where harmful dusts, smoke or fumes will be emitted by the machine, the manufacturer shall provide information
on a suitable exhausting system for these substances, including the required air speed at the emission point.
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7.3.4 Hot melt adhesive systems
The instruction handbook shall describe how the hot melt system can be filled, cleaned and maintained without the
risk of injury or harm to health.
The instruction handbook shall advise the user of the importance of setting the temperature controls at an
appropriate level for the adhesive being used and of the importance of effective ventilation in the room where the
machine is located.
The instruction handbook shall advise operators of the need to wear gloves or eye protection when refilling the
system.
7.3.5 Moveable machines fitted with wheels
For moveable machines fitted with wheels, the instructions shall state how the machine can be moved safely and
how it can be stabilised before use.
7.3.6 Machines incorporating lifting equipment
For machines incorporating lifting equipment, the instruction handbook shall include a statement of the load for
which the equipment has been designed, including the maximum working load and the maximum mass of lifting
accessories.
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Annex A
(normative)
Noise test code for wrapping machines - grade of accuracy 2 and grade 3
Requirements for determination and declaration of noise emission values – grade 2 or grade 3
A.1 Scope
These rules for the noise determination and declaration of noise emission values are applicable to wrapping
machines subject to this standard.
A.2 Definitions
Definitions shall comply with EN ISO 12001:1996, Clause 3.
Work cycle: Period describing the time for the product being handled by the machine from the in feed to the
discharge.
Work station: position defined by the manufacturer, in the vicinity of the machine which is intended to be assumed
by the operator.
A.3 Determination of emission sound pressure level at the workstation

For every type of machine the manufacturer shall determine the A-weighted emission sound pressure level LpA and
LpC,peak at the workstations and specified positions detailed in Table A.2.
The A-weighted emission sound pressure level at the workstation LpA shall be determined according to
EN ISO 11201:1995 or EN ISO 11204:1995 grade 2. If it is not possible to comply with the requirements of grade 2,
EN ISO 11202:1995 or EN ISO 11204:1995, grade 3 shall be applied.
When EN ISO 11202 is applied, 2,5 dB shall be used as the estimated local environmental correction, if the
calculated value of K3 exceeds 2,5 dB.
If EN ISO 11204:1995 grade 3 is applied, the local environmental correction value K3 shall be applied as specified
in Table A.1.
For wrapping machines with typical operator positions, the measurement shall be carried out at the usual position
of the operator without the operator being present.
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Table A.1 — Specification of K3 (based on K2)
z K3
dB
z ≤ 0,2 7
0,2< z ≤ 1 K 3 = − 10 lg ( z )
z>1 0
where
z = 1 − ( 1 − 10
− 0 ,1 K 2
) ⋅10 − 0,1⋅DI ′ , DI’=L’p- L′p
and where K2 is the average environmental indicator for the measurement surface S for which L ′ has been
determined (see Annex A of EN ISO 3744:1995 or of EN ISO 3746:1995).
A.4 Sound power level determination

The A-weighted sound power level LWA shall be determined according to EN ISO 3744, EN ISO 9614-2:1996,
grade 2, or EN ISO 3747:2000, grade 2. If these standards are not possible to comply with, EN ISO 3746,
EN ISO 9614-2:1996, grade 3, or EN ISO 3747:2000, grade 3 shall be applied.
A.5 Installation and mounting conditions

The installation and mounting conditions shall be identical for the determination of both sound power level and
emission sound pressure level at specified positions and for declaration purposes.
Care may be taken to ensure that any electrical conduits, piping or air ducts which are connected to the machine
do not radiate significant amounts of sound energy.
For the purpose of measurements, the machine shall be installed on a sound reflecting plane either outside (e.g. a
parking space) or in a room providing for the necessary free field above the reflecting plane.
The test environment has to meet the requirements of the basic standards stated in A.3 and A.4 and for the applied
grade.
A.6 Operating conditions

The operating conditions have to be the same for the determination of the sound power level and of the emission
sound pressure level at specified positions and for declaration purposes.
Measurements shall be taken during dry cycling and/or loading with the product and packaging material for which
the machine has been specified. In situations where this is not possible e.g. because the product is frozen, the
machine shall be tested with a representative product which is likely to produce similar noise emission to the
specified product. The specification of the product shall be described.
The measuring time for determination of the emission sound pressure level as well as for the sound power level
shall be 30 s and cover at least 5 work cycles.
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For wrapping machines with typical operator positions, the measurement of the sound pressure level shall be
carried out at the operator's position without the operator being present with the microphone oriented towards the
machine surface. The height of the measurement position shall be 1,6 m above the reflecting plane and all
measurements shall be taken at a horizontal distance of 1 m from the machine.
The operating conditions of the machines are described and defined in Table A 2.
Table A 2 – Typical workstations for the determination of the emission sound pressure level and operating
conditions for all noise emission measurements
Machine Workstations where noise shall be Operating conditions for

measured measurement
(for all points: height 1,6 m from
ground)
Banding machine Pos. 1: 1 m from control panel Machine running at maximum
speed
Pos. 2: 1 m from in-feed aperture
With typical product (from the
Pos. 3: 1 m from discharge
foreseen range of products the
aperture
product which generates the
highest noise emission shall be
used)
Sleeve wrapping, stretch banding Pos. 1: 1 m from control panel Machine running at maximum
machine speed
aperture
used)
Spiral wrapping machine Pos. 1: 1 m from control panel Machine running at maximum
speed
aperture
used)
Fold wrapping machine Pos. 1: 1 m from control panel Machine running at maximum
speed
aperture
used)
Extruded product wrapping Pos. 1: 1 m from control panel Machine running at maximum
machine speed
With typical product
aperture
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Twist wrapping machine Pos. 1: 1 m from control panel Machine running at maximum
speed
Pos. 2: 1 m from hand wheel
With typical product (candies)
aperture
Over wrapping machine Pos. 1: 1 m from control panel Machine running at maximum
speed
Pos. 2: 1 m from hand wheel
Pos. 4: 1 m from discharge product which generates the
aperture highest noise emission shall be
used)
Roll wrapping machine Pos. 1: 1 m from control panel Machine running at maximum
speed
aperture
used)
Foil, band, pleat wrapping Pos. 1: 1 m from control panel Machine running at maximum
machine speed
aperture
used)
Stretch film wrapping machine Pos. 1: 1 m from control panel Machine running at maximum
speed
aperture
used)
L-sealing machine semi automatic Pos. 1: 1 m from sealing station Machine running
Pos. 5: 1 m from discharge Without product
aperture shrink tunnel
L-sealing machine automatic Pos. 1: 1 m from control panel Machine running at maximum
speed
shrink tunnel
Pos. 5: 1 m from discharge highest noise emission shall be
aperture shrink tunnel used)
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Skin packaging machine Pos. 1: 1 m from control panel Machine running at maximum
speed
Without product
Shrink tunnel, hot water dip tank Pos. 1: 1 m from control panel Machine running at maximum
speed
Without product
aperture
A.7 Measurement uncertainties
The standard deviation of reproducibility σR is expected as shown in Table A.3.
Table A.3 — Expected standard deviations of reproducibility σR
Applied standard, grade σR [dB]
EN ISO 11201 0,5 – 1,5
EN ISO 11204:1995 grade 2 0,5 – 2,5
EN ISO 11202 up to 4
EN ISO 11204:1995, grade 3 up to 5
EN ISO 3744 0,5 – 1,5
EN ISO 9614-2:1996, grade 2 0,5 – 1,5
EN ISO 3747:2000, grade 2 0,5 – 1,5
EN ISO 3746 up to 4
EN ISO 9614-2:1996, grade 3 up to 4
EN ISO 3747:2000, grade 3 up to 4
A.8 Information to be recorded

The information to be recorded comprises all technical requirements laid down in these rules for noise
measurement and shall comply with the requirements of the basic standards stated in A.3 and A.4. Any deviations
from the noise test code and/or from the basic noise emission measurement standards used are to be recorded
together with the technical justification for such deviations.
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A.9 Information to be reported

The information to be included in the noise test report is at least that which the manufacturer requires to prepare a
noise declaration or the user requires to verify the declared values.
The following minimum of information shall be given:
 identification of the manufacturer, machine type, machine model, serial no. and year of manufacture;
 place and date of the test and personnel involved;
 reference to the basic standards applied and the grade of reproducibility;
 description of installation and operating conditions;
 type and specific characteristics of the product and material used during measurement;
 location of work stations and other specified positions;
 description of microphone positions (work station and other specified positions);
 description of the measurement instrument and year of calibration;
 description of the test room/environment by background and environmental corrections;
 determined emission values:

- LpA;
- LpC,peak, if it exceeds 130 dB at any work station;
- LWA, if LpA exceeds 85 dB at any work station;
 confirmation that all requirements of this noise test code have been fulfilled, or, if this is not the case, any
unfulfilled requirements shall be identified. All unfulfilled requirements shall be specified; deviations from
requirements shall be stated as well as the technical reasons;
 detailed information on the reasons for using the measurement methods grade 3 if the methods according to
grade 2 are not applied.
A.10 Declaration and verification of noise emission values

The declaration of the noise emission values shall be made as a dual number noise emission declaration according
to EN ISO 4871. It shall declare the noise emission values L (LpA and LWA) and the respective uncertainty K (KpA
and KWA as given in Table A 4) according to A.9 of this noise test code.
The uncertainties KpA and KWA are expected to have values as given in Table A.4.
Table A.4 — Uncertainties expected
Standard grade 2 grade 3

EN ISO 11204 KpA= 3 dB KpA= 4 dB
EN ISO 11202 KpA= 6 dB
EN ISO 3744 KWA= 3 dB
EN ISO 3746 KWA= 4 dB
EN ISO 9614-2 KWA= 3 dB KWA= 4 dB
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The noise emission value shall be rounded to the nearest decibel.
The noise emission declaration shall explicitly state that the emission values have been measured according to the
specification of this noise test code as well as to the basic standards stated in A.3 and A.4 of this noise test code. If
this statement is not true, the noise declaration shall indicate clearly what the deviations are from this noise test
code and/or from the basic standards.
The above information has to be given in the instructions of use as well as in the sales documentation.
An example of a noise emission declaration according to B.2 of EN ISO 4871:1996 is given in Table A.5
Table A.5 — Example of a noise emission declaration (the values in this table are examples)
Wrapping machine
Type: ..., model: ...serial number……...
Declared dual-number noise emission values in accordance with EN ISO 4871
Load dry cycling
Measured A-weighted emission sound pressure level LpA (ref. 92 89
20 µPa) at the operator’s position in dB
Uncertainty KpA in dB 3 3
Measured A-weighted sound power level LWA (ref. 1 pW) in dB 97 95
Uncertainty KWA in dB 3 3
Values determined according EN ISO 11204, EN ISO 3744
NOTE The sum of a measured noise emission value and its associated uncertainty represents an
upper boundary of the range of values which is likely to occur in measurements.
NOTE Additional noise emission values can be given in the declaration.
If undertaken, verification shall be done according to EN ISO 4871 by using the same mounting, installation and
operating conditions as those used for the initial determination of noise emission values.
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Annex B
(normative)
Methods of safeguarding small and medium sized apertures
The following methods of safeguarding apertures can be used where there is insufficient room to comply with the
reach distances required in 5.2.1.4.2 and 5.2.1.4.3.
Table B.1 — Safety distances for alternative safeguarding methods
Aperture > 20 to 30 > 30 to 40 > 40 to 60 > 60 to > 120 to > 220 to > 240 to
height (A) 120 220 240 400
Dimension Reach distances
B 230 350 450 550 850 850 850
C 230 250 300 400 500 550 550
D 230 230 230 230 230 230 230
E 5 5 5 5 5 5 5
Dimensions in millimetres
B.1 Interlocked guard

This comprises an interlocked tunnel shaped guard complying with 5.2.1.3. The interlocking device shall comply
with 5.2.1.5 and be interlocked in such a way that if it is disturbed, the hazardous movements will stop and/or
reverse to a safe position within 0,5 s. For this type of device, the reach distances shown against dimension B in
Table B.1 can be used. See Figure B.1 — Interlocked guard. The interlocked guard shall, as far as possible, be
designed in such a way that no objects can be put on it to prevent the guard operating and the machine’s
instructions shall warn the user that the guard can become ineffective if a heavy object is placed on it.
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Key
1 Fixed guard
2 Interlocked tunnel shaped guard
3 Danger zone
4 Product
5 Conveyor
Figure B.1 — Interlocked guard
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B.2 Interlocked guard with ESPE trip device

When the interlocked guard described in B.1 is supplemented with electro-sensitive protection equipment (ESPE)
complying with 5.2.7.2 of this standard, the reach distances shown against dimension C in Table B.1 can be used.
See Figure B.2 — Interlocked guard with ESPE.
Key
1 Fixed guard
2 Interlocked tunnel shaped guard
3 Danger zone
4 Product
5 Conveyor
7 ESPE
Figure B.2 — Interlocked guard with ESPE
The ESPE may be muted while a product is passing the ESPE provided the muting system complies with the
requirements of Annex C.
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B.3 ESPE trip device

This device comprises one or a number of ESPE complying with B.2 which monitor the whole aperture. The control
system shall ensure that the machine stops hazardous movements if an object is detected in the danger zone. In
this case the safety distances shown against dimension D in Table B.1 can be used. See Figure B.3.
Key
1 Fixed guard
2 Fixed or interlocked tunnel shaped guard
3 Danger zone
4 Product
5 Conveyor
7 ESPE array
Figure B.3 — ESPE trip device
The ESPE may be muted while a product is passing the ESPE provided the muting system complies with the
requirements of Annex C.
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B.4 Automatic guard

This guard is powered independently of other movements on the machine. It moves into place after the transport
cycle, and before any hazardous movement starts. It shall be interlocked with the machine, to ensure that
hazardous movements cannot start until the guard is in position. The guard shall either be made safe by design
according to 5.2.1.2 or be fitted with a pressure sensitive device complying with EN 1760-2 incorporated in a
control circuit complying with category 3 of EN 954-1:1996 that stops the guard moving into position if someone or
something is in the way. In this case the safety distances shown against dimension E in Table B.1 may be used.
See Figure B.4.
Key
1 Fixed guard
2 Automatic guard
3 Danger zone
4 Product
5 Conveyor
Figure B.4 — Automatic guard
95
EN 415-5:2006 (E)
Annex C
(normative)
ESPE Muting
The signals from electro-sensitive protection equipment (ESPE) may have to be ignored or “muted” to allow packs
to enter or exit the machine. Muting is a feature of the control system that disables the safety function of an ESPE
during the time a pack is passing the ESPE. The muting controls shall comply with 5.9 of EN 954-1:1996 and the
 Muting shall only be allowed during a time in the operating cycle when safety is obtained by alternative
means, for example when a product is obstructing access to the danger zone,
 Muting shall be fully automatic and independent of any operator intervention. Manual inhibiting or
bypassing of the ESPE is not permitted.
 The initiation of muting shall not rely on a single electrical signal and shall not rely entirely on software
signals,
 Muting signals that occur in an incorrect sequence shall either not allow a muted condition or lead to an
emergency stop;
 The safety function of the ESPE shall be automatically re-activated immediately following the passage of
the recognised product through the detection field,
 If the product stops while passing the ESPE, the muting shall be disabled and the controls shall initiate an
emergency stop of the machine. A manual control, that only allows operation of the required conveyor,
shall be provided to permit the load to be removed. Restart of the machine shall only be possible by a
voluntary action after a safe condition has been reached.
96
EN 415-5:2006 (E)
An example of a muting assembly is shown in Figure C.1.
Key
A - Main ESPE
B – Direction of movement of load
C - Load conveyor
D - Danger zone
G - Guards
M1, M2 - Muting ESPE
Figure C.1 — Positioning of muting ESPE
97
EN 415-5:2006 (E)
Annex ZA
(informative)
Relationship between this European Standard and the Essential

Requirements of EU Directives 98/37/EC
This European Standard has been prepared under a mandate given to CEN by the European Commission and the
European Free Trade Association to provide one means of conforming to Essential Requirements of the New
Approach Directive.
For Machinery 98/37/EC, amended by Directive 98/79/EC.
Once this standard is cited in the Official Journal of the European Communities under that Directive and has been
implemented as a national standard in at least one Member State, compliance with the normative clauses of this
standard confers, within the limits of the scope of this standard, a presumption of conformity with the relevant
Essential Requirements of that Directive and associated EFTA regulations.
WARNING: Other requirements and other EU Directives may be applicable to the product(s) falling within the
scope of this standard.
98
EN 415-5:2006 (E)
Bibliography
[1] ISO 13849-1:1999, Safety of machinery - Safety-related parts of control systems - Part 1: General principles for
design
[2] EN 349, Safety of machinery - Minimum gaps to avoid crushing of parts of the human body
[3] EN 415-2, Packaging machines safety - Part 2: Pre-formed rigid container packaging machines
[4] EN 415-3, Safety of packaging machines – Part 3: Form, fill and seal machines
[5] EN 1005-1, Safety of machinery – Human physical performance – Part 1: Terms and definitions
[6] EN 1005-4, Safety of machinery – Human physical performance – Part 4: Evaluation of working postures and
movements in relation to machinery
[7] EN 60529, Degrees of protection provided by enclosures (IP code) (IEC 60529:1989)
[8] EN 61310-2, Safety of machinery - Indication, marking and actuation - Part 2: Requirements for marking (IEC
61310-2:1995)
[9] CLC/TS 61496-2, Safety of machinery - Electro-sensitive protective equipment - Part 2: Particular requirements
for equipment using active opto-electronic protective devices (AOPD) (IEC 61496-2:1997
[10] CLC/TS 61496-3, Safety of machinery - Electro-sensitive protective equipment - Part 3: Particular requirements
for Active Opto-electronic Protective Devices (AOPDDR) (IEC 61496-3:2001)
[11] EN ISO 11688-1, Acoustics - Recommended practice for the design of low-noise machinery and equipment -
Part 1: Planning (ISO/TR 11688-1:1995)
[12] EN ISO 13849-2, Safety of machinery - Safety-related parts of control systems - Part 2: Validation (ISO 13849-
2:2003)
[13] EN ISO 14163, Acoustics – Guidelines for noise control by silencers (ISO 14163:1998)
[14] EN 614-2, Safety of machinery - Ergonomic design principles - Part 2: Interactions between the design of
machinery and work tasks
[15] EN 415-7, Safety of packaging machines – Part 7: Group and secondary packaging machines
[16] EN 61508 (all parts), Functional safety of electrical/electronic/programmable electronic safety-related systems
99
BS EN
415-5:2006
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BRITISH STANDARD BS EN

The European Standard EN 415-5:2006 has the status of a

This British Standard was published by BSI. It is the UK implementation of

This British Standard was Amendments issued since publication

ISBN 0 580 49230 3

Safety of packaging machines - Wrapping machines

Sécurité des machines d'emballage - Partie 5 : Sicherheit von Verpackungsmaschinen - Teil 5:

This European Standard was approved by CEN on 23 March 2006.

EUROPEAN COMMITTEE FOR STANDARDIZATION

Management Centre: rue de Stassart, 36 B-1050 Brussels

4.5.1 Product feed.................................................................................................................................................38

5.2.2 Electrical requirements ...............................................................................................................................52

5.10.4 Reel unwind mechanism.............................................................................................................................72

7.3.2 Agri-foodstuffs and pharmaceuticals ........................................................................................................82

EN 415 Safety of packaging machines

Part 1: Terminology and classification of packaging machines and associated equipment

Part 2: Pre-formed rigid container packaging machines

Part 3: Form, fill and seal machines

Part 4: Palletisers and depalletisers

Part 6: Pallet wrapping machines

Part 7: Group and secondary packaging machines

This document is a type C standard as defined in EN ISO 12100-1:2003.

 wrapping machines which partially wrap products (see Figures 1-4)

The individual machines are described in 3.2 of this standard.

This standard does not consider the following hazards:

• Use of wrapping machines in potentially explosive atmospheres;

• Hazards that may be associated with decommissioning wrapping machines.

EN 1037, Safety of machinery - Prevention of unexpected start-up

EN 1050, Safety of machinery - Principles for risk assessment

EN 1672-2:2005, Food processing machinery - Basic concepts – Part 2: Hygiene requirements

EN 13478, Safety of machinery - Fire prevention and protection

IEC 60417:2002, Graphical symbols for use on equipment

3 Terms and definitions

3.1 Definition of terms

3.2 Description of wrapping machines

3.2.1 Banding machine

The characteristic features are:

 reel unwind mechanism and film compensator

Figure 1 — Banding machine

3.2.2 Sleeve wrapping machine

The characteristic features are:

 product feeding device with chain, belt, pusher and/or elevator;

 reel unwind mechanism with film compensator;

 discharge mechanism often connected to a shrink tunnel;

 in some machines a tray erecting group is present (see EN 415-7).

Figure 2 — Sleeve wrapping machines

Figure 3 — Sleeve wrapping machine with tray erecting group

3.2.3 Stretch banding machine (incorporating stretch film banding machine)

The characteristic features are:

 product feeding device with chain, belt, pusher and/or elevator;

Figure 4 — Stretch banding machine

3.2.4 Spiral wrapping machine (incorporating film bundling machine)

The characteristic features are:

 feeding group with a horizontal belt often with vertical rolls;

 wrapping head turning around the product;

Figure 5 — Spiral wrapping machine

3.2.5 Fold wrapping machine

The characteristic features are:

 feeding group with belt conveyor pusher and/or pincers;

 reel unwind mechanism with film compensator;

Figure 6 — Fold wrapping machine

3.2.6 Extruded product wrapping machine

The characteristic features are: