Bsi bs en 00415 5 2006

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 be

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

This British Standard was

published under the authority

of the Standards Policy and

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

Amendments issued since publication

Safety of packaging machines - Wrapping machines

Sécurité des machines d'emballage - Partie 5 :

Fardeleuses/enveloppeuses

Sicherheit von Verpackungsmaschinen - Teil 5:

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

C O M I T É E U R O P É E N D E N O R M A L I S A T I O N

E U R O P Ä I S C H E S K O M I T E E F Ü R N O R M U N G

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

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

4.4.3 Reel unwind mechanism 37

4.4.4 Tray erecting mechanism 38

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

4.6.2 Handles and hand-wheels 39

4.6.3 Reel unwind mechanisms 39

4.6.4 Discharge mechanism 39

4.7 Hazards associated with extruded product wrapping machines 40

4.7.1 Product feed 40

4.7.2 Handles and hand-wheels 40

4.7.3 Reel unwind mechanism 40

4.7.4 Discharge mechanism 40

4.8 Twist wrapping machine 40

4.8.1 Product feed 40

4.8.2 Handles and hand-wheels 41

4.8.3 Reel unwind mechanism 41

4.8.4 Discharge mechanism 41

4.9 Hazards associated with over-wrapping machine 41

4.9.1 Product feed 41

4.9.2 Handles and hand-wheels 42

4.9.3 Tear tape application group 42

4.9.4 Reel unwind mechanism 42

4.9.5 Discharge mechanism 42

4.10 Hazards associated with roll wrapping machines 43

4.10.1 Product feed 43

4.10.2 Handles and hand-wheels 43

4.10.3 Reel unwind mechanism 43

4.10.4 Discharge mechanism 43

4.11 Hazards associated with foil and band wrapping machines and pleat wrapping machines 43

4.11.1 Product feed 43

4.11.2 Handles and hand-wheels 44

4.11.3 Reel unwind mechanism 44

4.11.4 Discharge mechanism 44

4.12 Hazards associated with stretch film wrapping machines 44

4.12.1 Product feed 44

4.12.2 Reel unwind mechanism 45

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

4.14.2 Product discharge 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

4.15.4 Product discharge 47

5 Safety requirements for wrapping machines 47

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

5.3.3 Handles and hand wheels 62

5.3.4 Reel unwind mechanism 63

5.3.5 Discharge mechanism 65

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

5.4.3 Handles and hand wheels 66

5.4.4 Reel unwind mechanism 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

5.5.4 Product discharge mechanism 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

5.6.3 Handles and hand wheels 68

5.6.4 Reel unwind mechanism 68

5.6.5 Discharge mechanism 68

5.7 Safety requirements for an extruded product wrapping machine 68

5.7.1 General 68

5.7.2 Product feed 69

5.7.3 Handles and hand wheels 69

5.7.4 Reel unwind mechanism 69

5.7.5 Discharge mechanism 69

5.8 Safety requirements for a twist wrapping machine 69

5.8.1 General 69

5.8.2 Product feed 69

5.8.3 Handles and hand wheels 70

5.8.4 Reel unwind mechanism 70

5.8.5 Discharge mechanism 70

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

5.9.3 Handles and hand wheels 71

5.9.4 Tear tape application group 71

5.9.5 Reel unwind mechanism 71

EN 415-5:2006 (E)

5.10.4 Reel unwind mechanism 72

5.10.5 Discharge mechanism 72

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

5.11.3 Handles and hand wheels 73

5.11.4 Reel unwind mechanism 73

5.11.5 Discharge mechanism 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

5.12.4 Reel unwind mechanism 74

5.12.5 Product discharge mechanism 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

5.14.3 Product discharge mechanism 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

5.15.5 Product discharge mechanism 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

7.3.2 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

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

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

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 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

EN 894-2, Safety of machinery – Ergonomics requirements for the design of displays and control actuators – Part 2: Displays

EN 894-3, Safety of machinery – Ergonomics requirements for the design of displays and control actuators – Part 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 ISO 11202:1995, Acoustics - Noise emitted by machinery and equipment - Measurement of emission sound pressure levels at a work station and at other specified positions - Survey method in situ (ISO 11202:1995)

EN ISO 11204:1995, Acoustics - Noise emitted by machinery and equipment - Measurement of emission sound 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)

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 1:2000 and the following apply

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

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

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

packaging material transport mechanism

mechanical assembly which transports packaging material through the packaging machine

3.1.27

stretch film

wrap sealed by twisting the open end

3.2 Description of wrapping machines

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

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)

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

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

The characteristic features are:

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

 wrapping head turning around the product;

 discharge conveyor

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

The characteristic features are:

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

 reel unwind mechanism with film compensator;

 discharge mechanism with belt, chain or wheel sometimes connecting to another machine

EN 415-5:2006 (E)

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

The characteristic features are:

 feeding group with rolls;

 reel unwind mechanism with film compensator;

 discharge mechanism with belt;

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

The characteristic features are:

 feeding group with rotating disk;

 reel unwind mechanism with film compensator and often an automatic splicing mechanism;

 discharge mechanism with belt conveyor

EN 415-5:2006 (E)

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

The characteristic features are:

 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

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

The characteristic features are:

 conveyor feed;

 automatic product feed mechanism usually using vibration;

 reel unwind mechanism with film compensator and often automatic splicing group;

 discharge mechanism with belt

EN 415-5:2006 (E)

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

The characteristic features are:

 product feed with belt conveyor, pusher and elevator;

 reel unwind mechanism with film compensator;

 discharge mechanism with belt

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

The characteristic features are:

 product feed with belt conveyor, pusher and elevator;

 reel unwind mechanism with film compensator;

 discharge mechanism with belt

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

The characteristic features are:

 conveyor feed;

 reel unwind mechanism with film compensator;

 discharge mechanism with belt and heat sealer

to produce a fully enclosed pack sealed on three sides

The characteristic features are:

 supporting plane;

 “L shaped” heating device;

 conveyor belt often connected to a shrink tunnel

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

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

The characteristic features are:

The characteristic features are:

 supporting plate which plunges into water with the product;

 tank with hot water

Key

1 Conveyor

Figure 18 — Hot water dip tank

4 Hazards on wrapping machines

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

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

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

4.2.4 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:

EN 415-5:2006 (E)

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

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

4.2.9.4 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

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

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

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

4.3.3.7 Electrostatic phenomena

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

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

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

4.4.6 Discharge mechanism

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