Integrating machinery changes the system boundary. Define intended use, access, lifecycle tasks, interfaces and responsibilities early, then confirm the design with competent safety specialists.
1. Define the integrated machinery boundary
A line can create hazards at interfaces even when each individual machine has its own safeguards. The project should identify the complete system boundary, retained equipment, conveyors, product supply, end-of-line handling, utilities, access points and control ownership.
Record intended use and reasonably foreseeable misuse across installation, setup, production, replenishment, cleaning, changeover, fault recovery, maintenance and decommissioning. The risk assessment must be completed by competent people using the actual application and site conditions.
2. Apply the risk-reduction hierarchy
Risk reduction normally begins with safer design, then safeguards and protective devices, followed by information, training and safe systems of work for residual risks. Warnings and procedures should not be used to replace practicable engineering controls.
| Lifecycle task | Information to provide | Design effect |
|---|---|---|
| Normal operation | Operator positions, replenishment, sampling and inspection | Access, guarding, controls and ergonomics |
| Changeover | Frequency, parts, adjustments and product clearance | Safe access, isolation and setup modes |
| Cleaning | Method, chemicals, wash or wipe boundaries and drains | Materials, enclosure, access and energy control |
| Fault recovery | Likely jams, reject access and manual recovery | Prevention, detection, safe access and reset position |
| Maintenance | Planned tasks, removal routes and lifting needs | Isolation, working space and component support |
3. Plan guarding around real access needs
Guards should prevent access to dangerous parts while allowing the intended operating and maintenance tasks to be completed safely. Define fixed and interlocked access, product openings, conveyor interfaces, doors, reset points and sight lines as one system.
The HSE’s current machinery safety FAQs explain that access to dangerous parts should be prevented or dangerous movement stopped before entry. The final safeguarding solution depends on the risk assessment and applicable standards.
4. Define stop, reset and restart behaviour
Emergency stops, protective-device trips, normal stops and production holds have different purposes. Specify the effect of each function across connected modules and identify where a reset is permitted. A reset should not create movement or automatic restart unless the assessed design allows it and the operating condition is safe.
- Safety zones and affected equipment
- Emergency-stop coverage and indication
- Guard-opening and safe-speed or setup requirements
- Reset position, visibility and prevention of unexpected restart
- Product already inside the line after a stop
- Interfaces with retained machinery and site emergency systems
5. Control every hazardous energy source
Electrical, pneumatic, hydraulic, thermal, gravitational, vacuum, pressure and stored mechanical energy may remain after a normal stop. The installation should provide identified isolation points and a safe method for releasing or restraining stored energy where required.
The HSE’s maintenance guidance covers safe isolation, lock-off and stored energy in general terms. The site must develop and train the specific procedure for its equipment and work.
6. Review conveyors, transfers and openings as machinery hazards
In-running nips, crush and shear points, product openings, transfer gaps and unexpected reverse movement need consideration. Guarding should not create new trapping points or prevent safe cleaning. Where product must pass through a guard boundary, the opening and distance must be justified by the risk assessment.
Include reject stations, accumulation tables, pallet handling and temporary manual tasks. A line modification can change access or stop behaviour beyond the machine being altered.
7. Control installation and later modification
Site work should use approved drawings, permits, isolation and change control. Confirm temporary guarding and access during commissioning. After a controls, conveyor, tooling or format change, review whether the risk assessment, safeguards, instructions and conformity documentation remain valid.
Training should cover normal operation and the boundaries of operator intervention. It does not replace engineering safeguards or competent maintenance procedures.
8. Check current GB conformity and documentation requirements
Current Great Britain guidance states that machinery placed on the GB market can use UKCA or CE marking under the applicable rules. Requirements can change and depend on the supply arrangement, modification and market. Confirm the current position using the official GOV.UK machinery guidance and competent specialist advice.
- Defined machinery and system boundaries
- Risk assessment and applicable standards
- Technical documentation and drawings
- Instructions in English for intended use and maintenance
- Declaration and marking appropriate to the supply route
- Records for modifications, tests and training
9. Include safety inputs in the enquiry
Send the line boundary, layout, products, safety data, hazardous-area information where applicable, operating tasks, retained equipment, site standards and expected interventions. Use the layout guide, controls architecture guide and site-readiness guide to coordinate the inputs.