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eLibrary > BS EN 415-2:2025 Safety of packaging machines - Packaging machines for pre-formed rigid containers >

BS EN 415-2:2025 Safety of packaging machines - Packaging machines for pre-formed rigid containers, 2025

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BS EN 415-2:2025 Safety of packaging machines - Packaging machines for pre-formed rigid containers, 2025

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European foreword
Introduction
1 Scope
2 Normative references
3 Terms and definitions [Go to Page]
3.1 Definitions of terms
3.2 Description of machines in the scope of this document
4 Safety requirements and protective measures [Go to Page]
4.1 General requirements [Go to Page]
4.1.1 General
4.1.2 Inherently safe design
4.1.3 Safeguarding
4.1.4 Reduction of risks from packaging material
4.1.5 Reduction of slip, trip or fall risks
4.1.6 Reduction of risks from loss of stability
4.1.7 Reduction of risks from pneumatic or hydraulic equipment
4.1.8 Reduction of electrical risks
4.1.9 Reduction of thermal risks
4.1.10 Reduction of risks from noise
4.1.11 Reduction of risks from radiation [Go to Page]
4.1.11.1 General
4.1.11.2 Artificial optical radiation [Go to Page]
4.1.11.2.1 Laser equipment
4.1.11.2.2 Ultraviolet (UV) radiation, visible light and infrared light
4.1.11.3 Non-optical electromagnetic fields
4.1.11.4 Ionizing radiation
4.1.12 Reduction of chemical risks [Go to Page]
4.1.12.1 General
Figure 1 — Example of an extraction of hazardous substances at the container in-feed or discharge – sectional view
Figure 2 — Measurement of substances — schematic of measurement distance – a) front view, b) side view of the machine [Go to Page]
4.1.12.2 Requirements for cleaning in place, strainers and drainage
4.1.13 Reduction of biological risks
4.1.14 Reduction of ergonomic risks
Figure 3 — Schematic for reach of access points [Go to Page]
4.1.15 Prevention of unexpected start-up by another person
4.1.16 Requirements for safety related control functions [Go to Page]
4.1.16.1 Emergency stop
4.1.16.2 Performance levels
Table 1 — Safety functions and related Performance Levels required PLr [Go to Page]
4.1.17 Devices for energy isolation
4.2 Risk reduction on equipment [Go to Page]
4.2.1 General
4.2.2 Conveyors [Go to Page]
4.2.2.1 General
4.2.2.2 Gripper chain conveyor
Figure 4 — Example of measures on a gripper chain conveyor – top view [Go to Page]
4.2.2.3 Air conveyor
4.2.2.4 Neck gripper conveyor
4.2.2.5 Vacuum transfer conveyor [Go to Page]
4.2.2.5.1 Reduction of mechanical risks
4.2.2.5.2 Reduction of noise risks
4.2.3 Container diversion or ejection mechanism (pusher)
Figure 5 — Example for safe design of a pusher top view [Go to Page]
4.2.4 Keg stopping device
4.2.5 Keg lift and inverting machine
4.2.6 Extraction or ventilation system [Go to Page]
4.2.6.1 General
4.2.6.2 Reduction of mechanical risks
4.2.6.3 Reduction of fall risks
4.2.6.4 Reduction of noise risks
4.2.6.5 Reduction of chemical risks
4.2.6.6 Reduction of fire or explosion risks
4.2.6.7 Reduction of biological risks
4.2.7 Closure unscrambler [Go to Page]
4.2.7.1 Reduction of slip, trip or fall risks
4.2.7.2 Reduction of noise risks
4.2.7.3 Reduction of ergonomic risks
4.2.8 Carousel type machines [Go to Page]
4.2.8.1 Reduction of mechanical risks
Figure 6 — Schematic example of safeguarding the rotary mechanism - top view [Go to Page]
4.2.8.2 Reduction of ergonomic risks
4.2.9 Coding and marking equipment incorporated in a packaging machine [Go to Page]
4.2.9.1 All coding equipment – reduction of risks from applied energy
4.2.9.2 Hot foil coding equipment [Go to Page]
4.2.9.2.1 Reduction of mechanical risks
4.2.9.2.2 Requirements for Safety functions
4.2.9.3 Laser coding equipment [Go to Page]
4.2.9.3.1 Reduction of radiation risks
4.2.9.3.2 Reduction of chemical risks
4.2.9.3.3 Requirements for Safety functions
4.2.9.4 Ink jet coding equipment [Go to Page]
4.2.9.4.1 Reduction of slip, trip or fall risks
4.2.9.4.2 Reduction of chemical risks
4.2.9.4.3 Reduction of fire or explosion risks
4.2.9.5 Emboss coding equipment
4.3 Plastic bottle unscrambling machine
4.4 Machines for applying caps or removing packaging components or materials from containers [Go to Page]
4.4.1 Screw cap removing machine, screw capping machine, crown capping machine, roll-on capping machine and plugging/corking machine [Go to Page]
4.4.1.1 General
Figure 7 — Schematic example of measures on a carousel type capping machine – 3-dimensional view [Go to Page]
4.4.1.2 Reduction of biological risks
4.4.2 Crown cork removing machine [Go to Page]
4.4.2.1 Reduction of mechanical risks
Figure 8 — Example of safety measures on a crown cork removing machine - sectional view [Go to Page]
4.4.2.2 Reduction of slip, trip or fall risks
4.4.2.3 Reduction of noise risks
4.5 Cleaning machines [Go to Page]
4.5.1 Bottle washing machines [Go to Page]
4.5.1.1 Reduction of mechanical risks [Go to Page]
4.5.1.1.1 Moving parts in general
4.5.1.1.2 Moving parts in the in-feed area for containers
Figure 9 — Example of safeguarding of the bottle in-feed of a single end bottle washing machine – sectional view [Go to Page]
4.5.1.1.3 Moving parts in the discharge area for containers
Figure 10 — Example of safeguarding the discharge of a bottle washing machine – side view [Go to Page]
4.5.1.2 Reduction of slip, trip or fall risks
Figure 11 — Example for measures against falling from height on a bottle washing machine – 3-dimensional view [Go to Page]
4.5.1.3 Reduction of noise risks
4.5.1.4 Reduction of chemical risks
4.5.1.5 Reduction of fire or explosion risks
4.5.1.6 Reduction of biological risks
4.5.1.7 Reduction of ergonomic risks
4.5.1.8 Reduction of combined risks [Go to Page]
4.5.1.8.1 Hatches
Figure 12 — Example of an interlocked hatch – front view
Figure 13 — Example of spindle fixture of a hatch – sectional view [Go to Page]
4.5.1.8.2 Inspection windows
Figure 14 — Example of a fixture of an inspection window - 3-dimensional view [Go to Page]
4.5.2 Carousel type keg cleaning, filling and combined cleaning and filling machine [Go to Page]
4.5.2.1 Reduction of mechanical risks
Figure 15 — Example of safeguarding of a carousel type keg cleaning/filling machine - top view [Go to Page]
4.5.2.2 Reduction of noise risks
4.5.2.3 Reduction of chemical risks
4.5.3 In-line keg cleaning, filling and combined cleaning and filling machine
4.5.4 Semi-automatic keg cleaning, filling and combined cleaning and filling machine (single head machine) [Go to Page]
4.5.4.1 Reduction of mechanical risks
Figure 16 — Example of safeguarding of a semi-automatic keg cleaning or filling machine – side view [Go to Page]
4.5.4.2 Reduction of thermal risks
4.5.4.3 Reduction of chemical risks
4.5.4.4 Reduction of ergonomic risks
4.5.5 Crate washing machine [Go to Page]
4.5.5.1 Reduction of mechanical risks
4.5.5.2 Reduction of noise risks
4.5.5.3 Reduction of chemical risks
4.5.5.4 Reduction of ergonomic risks
4.5.6 Closure sanitizing machine [Go to Page]
4.5.6.1 Cap sanitizing machine using chemicals
4.5.6.2 Cap sanitizing machine using ultraviolet light [Go to Page]
4.5.6.2.1 Reduction of chemical risks
4.5.6.2.2 Reduction of radiation risks
4.6 Filling machines [Go to Page]
4.6.1 Carousel type rinsing/sanitizing or filling machine [Go to Page]
4.6.1.1 General
Figure 17 — Example of safeguarding of a carousel type rinsing filling and capping machine - top view [Go to Page]
4.6.1.2 Reduction of mechanical risks
4.6.1.3 Reduction of noise risks
4.6.1.4 Reduction of chemical risks [Go to Page]
4.6.1.4.1 General
4.6.1.4.2 Carbon Dioxide
4.6.1.5 Reduction of fire or explosion risks
4.6.1.6 Requirements for safety functions
4.6.2 In-line filling machine [Go to Page]
4.6.2.1 Reduction of mechanical risks
Figure 18 — Example of safeguarding of an in-line filler – side view [Go to Page]
4.6.2.2 Reduction of noise risks
4.6.2.3 Reduction of chemical risks
4.6.2.4 Reduction of fire or explosion risks
4.6.2.5 Requirements for safety related functions
4.7 Sealing, seaming, crimping, flanging machine [Go to Page]
4.7.1 Foil sealing machine
4.7.2 Can filling and seaming machine
4.8 Closure securing machine / cork wiring machine
4.9 Labelling and decorating machines [Go to Page]
4.9.1 Reduction of mechanical risks
4.9.2 Reduction of electrical risks
4.9.3 Reduction of thermal risks
4.10 Heating or cooling machine for packed product working at atmospheric pressure (pasteurizing machine) [Go to Page]
4.10.1 Reduction of chemical risks
4.10.2 Reduction of biological risks [Go to Page]
4.10.2.1 Germs
4.10.2.2 Reduction of risks by inhalation
4.10.2.3 Reduction of risks by contact
4.10.3 Reduction of combined risks
4.11 Inspection machines [Go to Page]
4.11.1 Reduction of radiation risks
4.11.2 Requirements for safety related functions
Table 4 — Safety functions and related Performance Levels required PLr
5 Verification of safety requirements and measures [Go to Page]
5.1 General
5.2 Visual inspections with the machine stopped [Go to Page]
5.2.1 Mechanical parts
5.2.2 Pneumatic systems
5.2.3 Hydraulic systems
5.2.4 Electrical systems
5.2.5 Safeguards
5.2.6 Design requirements
5.2.7 Marking and warning signs
5.3 Measurements with the machine stopped [Go to Page]
5.3.1 Safeguards
5.3.2 Electrical testing
5.4 Visual inspections with the machine running [Go to Page]
5.4.1 Safeguards
5.4.2 Interlocking devices
5.4.3 Dissipation of stored energy
5.5 Measurements with the machine running [Go to Page]
5.5.1 Electrical testing
5.5.2 Measurement and declaration of noise emission
5.5.3 Temperature
5.5.4 Radiation
5.6 Verification procedures
Table 3 — Verification procedures for safety requirements identified in Clause 4
6 Information for use [Go to Page]
6.1 General
6.2 Marking
6.3 Signals and warning signs
Figure 19 — Pictograms for use on machines in the scope of this document [Go to Page]
6.4 Instructions [Go to Page]
6.4.1 General
6.4.2 Ergonomic hazards
6.4.3 Radiation hazards
6.4.4 Chemical hazards
6.4.5 Fire or explosion hazards
6.4.6 Additional information for specific machines [Go to Page]
6.4.6.1 Filling machines
6.4.6.2 Cleaning machines
6.4.6.3 Ink jet coding machines
6.4.6.4 Machines which handle barrels, casks, or kegs
Annex A (normative) Noise test code
A.1 General
A.2 Terms and definitions
A.3 Determination of emission sound pressure level at the workstation
Table A.1 — Additional positions for the determination of the emission sound pressure level for noise emission measurements
Figure A.1 — Location of additional measurement points for a plastic bottle unscrambler
Figure A.2 — Location of additional measurement points for a crown cork removing machine
Figure A.3 — Location of additional measurement points for a container cleaning machine (bottle washing machine)
A.4 Determination of the sound power level
A.5 Alternative method for very large machines
A.6 Operating conditions
A.7 Measurement
A.8 Measurement uncertainty
A.9 Information to be recorded
A.10 Information to be reported
A.11 Declaration and verification of the noise emission values
Annex B (informative) List of significant hazards
B.1 General
B.2 Hazards that occur on most machines in the scope of this document
Table B.1 — Hazards that are present on most machines in the scope of this document
B.3 Components and equipment
B.3.1 General
B.3.2 Conveyors
B.3.2.1 Gripper chain conveyor
Figure B.1 — Principal parts and hazard zones of a typical gripper chain conveyor – side view
Figure B.2 — Principal parts and hazard zones of a gripper chain conveyor – top view of the lower section
Table B.2 — Hazards of a typical gripper chain conveyor
B.3.2.2 Air conveyor
Figure B.3 — Principal parts and hazard zones of a typical air conveyor for PET bottles – sectional view
Table B.3 — Hazards of an air conveyor
B.3.2.3 Neck gripper conveyor
Figure B.4 — Principal parts and hazard zones of a typical neck gripper conveyor – top view
Table B.4 — Hazards of a neck gripper conveyor
B.3.2.4 Vacuum transfer conveyor
Figure B.5 — Principal parts and hazard zones of a typical vacuum transfer conveyor – side view
Table B.5 — Hazards of a vacuum transfer conveyor
B.3.2.5 Magnetic belt conveyor
Table B.6 — Hazards of a magnetic belt conveyor
B.3.3 Container diversion or ejection mechanism (pusher)
Figure B.6 — Principal parts and hazard zones of a typical diversion device (cascaded pusher) – top view
Figure B.7 — Principal parts and hazard zones of a typical pusher attached to a conveyor – top view
Figure B.8 — Principal parts and hazard zones of a typical crate or keg pusher attached to a conveyor – three-dimensional view
Table B.7 — Hazards of a container ejection mechanism (pusher)
B.3.4 Keg stopping device
Figure B.9 — Principal parts and hazard zones of a typical keg stopping device – 3-dimensional view
Table B.8 — Hazards of a keg-stopper
B.3.5 Keg lift and inverting machine
Figure B.10 — Principal parts and hazard zones of a typical keg lifting and inverting machine – side view
Table B.9 — Hazards of a keg lifting and inverting machine
B.3.6 Extraction or ventilation equipment
Figure B.11 — Principal parts and hazard zones of typical extraction equipment – sectional view
Table B.10 — Hazards of an extraction equipment
B.3.7 Closure unscrambler
Figure B.12 — Principal parts and hazard zones of a typical closure unscrambler
Table B.11 — Hazards of a closure unscrambler
B.3.8 In-line mechanisms
B.3.9 Carousel type mechanisms
Figure B.13 — Principal parts and hazard zones of a typical carousel type mechanism - top view
Figure B.14 — Principal parts and hazard zones of a typical container rotation/anti-rotation device on a carousel type mechanism - top view
Table B.12 — Hazards of carousel type mechanisms
B.3.10 Coding and marking equipment incorporated in a packaging machine
B.3.10.1 Hot foil coding equipment
Table B.13 — Hazards of a hot-foil coding equipment
B.3.10.2 Laser coding equipment
Table B.14 — Hazards of a laser coding equipment
B.3.10.3 Ink jet coding equipment
Table B.15 — Hazards of an ink-jet coding equipment
B.3.10.4 Emboss coding equipment
Table B.16 — Hazards of an emboss coding equipment
B.4 Plastic bottle unscrambling machine
Figure B.15 — Principal parts and hazard zones of a typical plastic bottle unscrambling machine – 3-dimensional view
Table B.17 — Hazards of a bottle unscrambling machine
B.5 Machines for applying caps or removing packaging components or materials from containers
B.5.1 Screw cap removing machine, screw capping machine, crown capping machine, roll-on capping machine and plugging machine
Figure B.16 — Principal parts and hazard zones of a typical capping machine - sectional view
Table B.18 — Hazards of a carousel type capping/plugging or de-capping machine
B.5.2 Crown cork removing machine
Figure B.17 — Principal parts and hazard zones of a typical crown cork removing machine - sectional view
Table B.19 — Hazards of a crown cork removing machine
B.6 Cleaning machines
B.6.1 Cleaning machine for bottles and jars (bottle washing machine)
Figure B.18 — Principal parts and hazard zones of a typical single end bottle washing machine - sectional view
Table B.20 — Hazards of a bottle washing machine
B.6.2 Carousel type keg cleaning, filling or combined cleaning and filling machine
Figure B.19 — Principal parts and hazard zones of a typical carousel type keg cleaning, filling or combined cleaning and filling machine - top view
Table B.21 — Hazards of a carousel type keg cleaning, filling, or combined cleaning and filling machine
B.6.3 In-line keg cleaning, filling and combined cleaning and filling machine
Figure B.20 — Principal parts and hazard zones of a typical in-line keg cleaning and filling machine with walking beam transport -side view
Figure B.21 — Principal parts and hazard zones of a typical in-line exterior keg cleaning machine - sectional view
Figure B.22 — Principal parts and hazard zones of a typical walking beam conveyor – side view
Table B.22 — Hazards of an in-line keg cleaning and filling machine
B.6.4 Semi-automatic keg cleaning, filling and combined cleaning and filling machine (single head machine)
Figure B.23 — Principal parts and hazard zones of a typical semi-automatic keg cleaning and filling machine – side view
Table B.23 — Hazards of a semi-automatic keg cleaning or filling machine
B.6.5 Crate washing machine
Figure B.24 — Principal parts and hazard zones of a typical crate washing machine - side view
Table B.24 — Hazards of a crate washing machine
B.6.6 Closure sanitizing machines
B.6.6.1 Cap sanitizing machine using chemicals
Figure B.25 — Principal parts and hazard zones of a typical cap sanitizing machine using vaporized agents - sectional view
Figure B.26 — Principal parts and hazard zones of a typical cap sanitizing machine using dip - side/sectional view
Table B.25 — Hazards of a typical cap sanitizing machine using chemicals
B.6.6.2 Cap sanitizing machine using ultraviolet light
Table B.26 — Hazards of a typical cap sanitizing machine using ultraviolet light
B.7 Filling machines
B.7.1 Carousel type rinsing/sanitizing or filling machine
Figure B.27 — Principal parts and hazard zones of a typical carousel type rinsing/sanitizing or filling machine – top view
Table B.27 — Hazards of a typical carousel type rinsing/sanitizing or filling machine
B.7.2 In-line filling machine
Figure B.28 — Principal parts and hazard zones of a typical in-line filling machine – side view
Table B.28 — Principal parts and hazard zones of a typical in-line filling machine
B.8 Sealing, seaming, crimping, flanging machine
B.8.1 Foil sealing machine
Figure B.29 — Principal parts and hazard zones of a typical foil sealing machine – side view
Table B.29 — Hazards on a foil sealing machine
B.8.2 Can filling and seaming machine
Table B.30 — Hazards on a typical can seaming machine
B.8.3 Closure securing machine / cork wiring machine
Figure B.30 — Principal parts and hazard zones of a typical cork wiring machine – side view
Table B.31 — Hazards on a typical closure securing/cork wiring machine
B.9 Labelling and decorating machines
Figure B.31 — Principal parts and hazard zones of a typical carousel type labelling machine for pre-cut labels – 3-dimensional view
Figure B.32 — Principal parts and hazard zones of a typical carousel type labelling machine for roll fed labels (3 labelling modules) – top view
Table B.32 — Hazards of a carousel type labelling machine
B.10 Heating or cooling machine for packed product working at atmospheric pressure (Pasteurizing machine)
Figure B.33 — Principal parts and hazard zones of a typical continuous double deck pasteurizing machine – sectional view
Table B.33 — Hazards on a pasteurizing machine
B.11 Inspection machines
Table B.34 — Hazards on an inspection machine
Annex ZA (informative) Relationship between this European Standard and the essential requirements of Directive 2006/42/EC
Table ZA.1 — Correspondence between this European Standard and Annex I of Directive 2006/42/EC
Bibliography [Go to Page]

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