Machinery safety involves identifying hazards, assessing risks and implementing appropriate safety measures throughout a machine\u2019s lifecycle. Machine safety cannot be assessed solely based on normal operation. Installation, adjustment, cleaning, maintenance, troubleshooting and reasonably foreseeable misuse must also be considered.<\/p>\n\n\n\n
Machinery hazards are not limited to moving parts. Electrical systems, hot surfaces, structural component failure, unexpected start-up and stored energy in pneumatic or hydraulic systems can also pose significant safety risks.<\/p>\n\n\n\n
For example, a production line may be safe during automatic operation, but clearing a blockage may require an employee to work close to hazardous moving mechanisms. If this situation has not been considered during machine design or risk assessment, the actual safety risk may go unnoticed.<\/p>\n\n\n\n
Therefore, machinery safety assessments must consider how a machine is used in practice, rather than focusing solely on its technical specifications or existing protective measures.<\/p>\n\n\n\n
Machinery Safety Requirements and Regulations in the EU and Estonia<\/strong><\/h2>\n\n\n\nThe placing on the market and putting into service of new machinery in the European Union are currently governed by the Machinery Directive 2006\/42\/EC<\/a>, which establishes essential health and safety requirements for machinery design and manufacturing.<\/p>\n\n\n\nFrom 20 January 2027, the new EU Machinery Regulation (EU) 2023\/1230<\/a> will generally apply<\/strong>, replacing the existing Directive. Among other changes, the Regulation clarifies requirements concerning safety-related software and obligations associated with substantial modifications to machinery.<\/p>\n\n\n\nWe have also discussed these changes in our article, \u201cMachinery safety moves into software: What manufacturers must rethink in 2026\u201d<\/a>.<\/p>\n\n\n\nFor machinery already in use, the Estonian Occupational Health and Safety Act<\/a> and the occupational health and safety regulations governing the use of work equipment<\/a> must also be considered.<\/p>\n\n\n\nAn important distinction is the responsibility of the manufacturer and the employer. The machinery manufacturer must ensure that new machinery complies with applicable product safety requirements. The employer, however, is responsible for ensuring that machinery used by employees remains safe under actual working conditions.<\/p>\n\n\n\n
Therefore, CE marking does not automatically mean that a machine is safe in every working environment. Employers must also assess the machine\u2019s condition, how it is used and any risks arising from the working environment.<\/p>\n\n\n\n
How Can Machinery Safety Be Ensured During the Development of a New Machine?<\/strong><\/h2>\n\n\n\nMachinery safety should be addressed from the earliest stages of machine design and development. During concept development, it is still possible to modify the machine\u2019s structure, operating principles and control system before technical solutions are incorporated into manufacturing drawings or completed components.<\/p>\n\n\n\n
Ensuring machinery safety begins with defining the machine\u2019s intended purpose, users, operating modes and working environment. Potential hazards are then identified, risks are assessed and appropriate technical and organisational safety measures are selected.<\/p>\n\n\n\n
The machinery risk assessment should be updated throughout the development process whenever the machine\u2019s structure, control system or intended operating conditions change.<\/p>\n\n\n\n
For example, it may become apparent during design that an operator needs access to an area containing moving mechanisms during the operating cycle. If this issue is only discovered after the machine has been manufactured, modifications to protective guards, automation or the entire structure may be necessary.<\/p>\n\n\n\n
Identifying the same safety issue during early development often allows it to be resolved more easily and at a lower cost.<\/p>\n\n\n\n
How Can Existing Machinery Be Made Safer?<\/strong><\/h2>\n\n\n\nImproving the safety of existing machinery begins with assessing the equipment\u2019s actual condition, operating conditions and potential hazards. Machinery safety deficiencies may result from outdated protective measures, changes in production processes, removed guards or previous modifications to the machine.<\/p>\n\n\n\n
A machinery safety assessment should focus particularly on access to moving parts, safety interlocks on protective doors, prevention of unexpected start-up, safe stopping functions and the ability to isolate energy sources during maintenance.<\/p>\n\n\n\n
For example, clearing a conveyor blockage may require an employee to reach close to moving rollers. In this situation, an additional warning sign may not sufficiently reduce the risk. A structural modification, protective guard or interlocked maintenance hatch with an appropriate stopping function may be required.<\/p>\n\n\n\n
Improving machine safety does not necessarily require purchasing new equipment.<\/strong> Existing machinery can often be made safer through technically justified modifications, provided that the impact of these changes on overall machinery safety is properly assessed.<\/p>\n\n\n\nWhy Is a Machinery Risk Assessment Necessary?<\/strong><\/h2>\n\n\n\nA machinery risk assessment is a systematic process used to identify machine-related hazards, evaluate the severity and likelihood of potential harm, and determine the measures needed to reduce risks.<\/p>\n\n\n\n
The purpose of a machinery risk assessment is not simply to fulfil documentation requirements. It should provide a technical basis for deciding whether to modify the machine\u2019s design, install protective guards, improve the control system or develop safer maintenance procedures.<\/p>\n\n\n\n
The general principles of machinery risk assessment and risk reduction are described in the EN ISO 12100 standard, which addresses machinery safety throughout the design process.<\/p>\n\n\n\n
It is important to distinguish a technical risk assessment of a specific machine from a company\u2019s general workplace risk assessment. A machinery risk assessment focuses on the hazards associated with particular equipment and the technical measures required to reduce them. A workplace risk assessment covers a broader range of factors affecting employee health and safety.<\/p>\n\n\n\n
These assessments complement each other, but their objectives and level of detail differ.<\/p>\n\n\n\n
Learn more about Revismo’s risk assessment services.<\/a><\/p>\n\n\n\nHow to Select Appropriate Safety Measures<\/strong><\/h2>\n\n\n\nMachinery safety measures should be selected based on the identified hazards and the available methods for reducing risks. The first priority is to eliminate hazards or reduce risks through the machine\u2019s design and operating principles.<\/p>\n\n\n\n
If risks cannot be sufficiently reduced through inherently safe design, protective guards, interlocks and other safety devices should be used. Appropriate warnings and instructions must be provided for any remaining risks.<\/p>\n\n\n\n
For example, an emergency stop button cannot replace a protective guard in situations<\/strong> where an employee could become trapped between moving mechanisms during normal operation.<\/p>\n\n\n\nIt is also necessary to verify whether opening a protective door activates a safety function that stops hazardous movement quickly enough and prevents unexpected restarting.<\/p>\n\n\n\n
Machinery safety does not depend solely on installing compliant safety components. The complete safety solution must function correctly under actual operating conditions.<\/p>\n\n\n\n
Machinery Safety Standards<\/strong><\/h2>\n\n\n\nMachinery safety legislation establishes essential health and safety requirements, while technical standards help manufacturers implement these requirements through specific engineering solutions.<\/p>\n\n\n\n
Commonly used machinery safety standards include:<\/p>\n\n\n\n
\n- EN ISO 12100 \u2013 General principles of machinery risk assessment and risk reduction.<\/li>\n\n\n\n
- EN ISO 14120 \u2013 General requirements for the design and construction of protective guards.<\/li>\n\n\n\n
- EN ISO 13849-1 \u2013 Principles for designing safety-related parts of machinery control systems.<\/li>\n<\/ul>\n\n\n\n
The selection of appropriate machinery safety standards depends on the type of machine, its intended use and the hazards identified during the risk assessment.<\/p>\n\n\n\n
Compliance with a relevant harmonised European standard may provide a presumption of conformity with the legislative requirements covered by that standard. The use of standards is generally voluntary and does not replace the need to assess the risks associated with a specific machine.<\/p>\n\n\n\n
It is also important to determine whether dedicated product standards or additional technical requirements apply to the relevant machinery category.<\/p>\n\n\n\n
Does Modifying Machinery Require a New CE Conformity Assessment?<\/strong><\/h2>\n\n\n\nRepairing, modernising or installing an additional protective guard on a machine does not automatically mean that a new CE conformity assessment is required.<\/p>\n\n\n\n
The need for reassessment depends on the extent of the modification, its impact on machinery safety and whether the modified equipment must be considered new or substantially modified machinery under the applicable legislation.<\/p>\n\n\n\n
Particular attention should be paid to modifications affecting the machine\u2019s intended purpose, operating speed, applied forces or safety-related control system.<\/p>\n\n\n\n
From 20 January 2027, the EU Machinery Regulation (EU) 2023\/1230 will clarify the conditions under which machinery modifications are considered substantial and the associated obligations of the manufacturer.<\/p>\n\n\n\n
For major machinery modifications, the need for CE conformity assessment and the applicable safety requirements should be established before work begins<\/strong>. This helps avoid situations where a completed technical solution fails to meet the relevant requirements.<\/p>\n\n\n\nWhat Should Be Avoided When Assessing Machinery Safety?<\/strong><\/h2>\n\n\n\nMachinery safety problems often arise when safety requirements are only considered at the end of the design process or when assessments focus exclusively on the machine\u2019s normal operating cycle.<\/p>\n\n\n\n
Risks may also remain unidentified when individual safety components are selected without verifying the operation of the complete safety function.<\/p>\n\n\n\n
Incomplete or outdated technical documentation is another common problem. For example, a machine may have been modified over the years, while its risk assessment, electrical diagrams and instruction manual no longer reflect its actual design or operating principles.<\/p>\n\n\n\n
Machinery safety cannot be demonstrated solely through CE marking or the presence of safety devices. Safety must be technically justified, documented and verifiable.<\/p>\n\n\n\n
How Can Revismo Help with Machinery Safety?<\/strong><\/h2>\n\n\n\nRevismo supports both developers of new machinery and companies looking to improve the safety of existing equipment.<\/p>\n\n\n\n
Depending on the project, we help assess machinery risks, plan modifications and protective measures, prepare technical documentation and address CE conformity requirements.<\/p>\n\n\n\n
Ultimately, the value of machinery safety lies in a practical result: the machine must be safe, reliable and fully functional.<\/strong><\/p>\n\n\n\nExplore our CE conformity services<\/a> or contact us<\/a> to discuss the safety requirements of your machinery or development project.<\/p>\n\n\n\n![\"\"](\"https:\/\/revismo.com\/wp-content\/uploads\/2026\/10\/Tootmisseadme_juhtpult-1024x683.jpg\")
<\/figure>\n","protected":false},"excerpt":{"rendered":"Machinery safety involves more than CE marking, protective guards or warnings in an instruction manual. The purpose of machinery safety is to ensure that machines can be operated, adjusted, cleaned and maintained without exposing workers to unacceptable risks. Machinery safety requirements must be considered both when designing new machines and when operating or modernising existing […]<\/p>\n","protected":false},"author":2,"featured_media":902210,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[16],"tags":[],"class_list":["post-902195","post","type-post","status-publish","format-standard","has-post-thumbnail","category-about-product-development"],"acf":[],"_links":{"self":[{"href":"https:\/\/revismo.com\/en\/wp-json\/wp\/v2\/posts\/902195","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/revismo.com\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/revismo.com\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/revismo.com\/en\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/revismo.com\/en\/wp-json\/wp\/v2\/comments?post=902195"}],"version-history":[{"count":2,"href":"https:\/\/revismo.com\/en\/wp-json\/wp\/v2\/posts\/902195\/revisions"}],"predecessor-version":[{"id":902209,"href":"https:\/\/revismo.com\/en\/wp-json\/wp\/v2\/posts\/902195\/revisions\/902209"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/revismo.com\/en\/wp-json\/wp\/v2\/media\/902210"}],"wp:attachment":[{"href":"https:\/\/revismo.com\/en\/wp-json\/wp\/v2\/media?parent=902195"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/revismo.com\/en\/wp-json\/wp\/v2\/categories?post=902195"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/revismo.com\/en\/wp-json\/wp\/v2\/tags?post=902195"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}
From 20 January 2027, the new EU Machinery Regulation (EU) 2023\/1230<\/a> will generally apply<\/strong>, replacing the existing Directive. Among other changes, the Regulation clarifies requirements concerning safety-related software and obligations associated with substantial modifications to machinery.<\/p>\n\n\n\n We have also discussed these changes in our article, \u201cMachinery safety moves into software: What manufacturers must rethink in 2026\u201d<\/a>.<\/p>\n\n\n\n For machinery already in use, the Estonian Occupational Health and Safety Act<\/a> and the occupational health and safety regulations governing the use of work equipment<\/a> must also be considered.<\/p>\n\n\n\n An important distinction is the responsibility of the manufacturer and the employer. The machinery manufacturer must ensure that new machinery complies with applicable product safety requirements. The employer, however, is responsible for ensuring that machinery used by employees remains safe under actual working conditions.<\/p>\n\n\n\n Therefore, CE marking does not automatically mean that a machine is safe in every working environment. Employers must also assess the machine\u2019s condition, how it is used and any risks arising from the working environment.<\/p>\n\n\n\n Machinery safety should be addressed from the earliest stages of machine design and development. During concept development, it is still possible to modify the machine\u2019s structure, operating principles and control system before technical solutions are incorporated into manufacturing drawings or completed components.<\/p>\n\n\n\n Ensuring machinery safety begins with defining the machine\u2019s intended purpose, users, operating modes and working environment. Potential hazards are then identified, risks are assessed and appropriate technical and organisational safety measures are selected.<\/p>\n\n\n\n The machinery risk assessment should be updated throughout the development process whenever the machine\u2019s structure, control system or intended operating conditions change.<\/p>\n\n\n\n For example, it may become apparent during design that an operator needs access to an area containing moving mechanisms during the operating cycle. If this issue is only discovered after the machine has been manufactured, modifications to protective guards, automation or the entire structure may be necessary.<\/p>\n\n\n\n Identifying the same safety issue during early development often allows it to be resolved more easily and at a lower cost.<\/p>\n\n\n\n Improving the safety of existing machinery begins with assessing the equipment\u2019s actual condition, operating conditions and potential hazards. Machinery safety deficiencies may result from outdated protective measures, changes in production processes, removed guards or previous modifications to the machine.<\/p>\n\n\n\n A machinery safety assessment should focus particularly on access to moving parts, safety interlocks on protective doors, prevention of unexpected start-up, safe stopping functions and the ability to isolate energy sources during maintenance.<\/p>\n\n\n\n For example, clearing a conveyor blockage may require an employee to reach close to moving rollers. In this situation, an additional warning sign may not sufficiently reduce the risk. A structural modification, protective guard or interlocked maintenance hatch with an appropriate stopping function may be required.<\/p>\n\n\n\n Improving machine safety does not necessarily require purchasing new equipment.<\/strong> Existing machinery can often be made safer through technically justified modifications, provided that the impact of these changes on overall machinery safety is properly assessed.<\/p>\n\n\n\n A machinery risk assessment is a systematic process used to identify machine-related hazards, evaluate the severity and likelihood of potential harm, and determine the measures needed to reduce risks.<\/p>\n\n\n\n The purpose of a machinery risk assessment is not simply to fulfil documentation requirements. It should provide a technical basis for deciding whether to modify the machine\u2019s design, install protective guards, improve the control system or develop safer maintenance procedures.<\/p>\n\n\n\n The general principles of machinery risk assessment and risk reduction are described in the EN ISO 12100 standard, which addresses machinery safety throughout the design process.<\/p>\n\n\n\n It is important to distinguish a technical risk assessment of a specific machine from a company\u2019s general workplace risk assessment. A machinery risk assessment focuses on the hazards associated with particular equipment and the technical measures required to reduce them. A workplace risk assessment covers a broader range of factors affecting employee health and safety.<\/p>\n\n\n\n These assessments complement each other, but their objectives and level of detail differ.<\/p>\n\n\n\n Learn more about Revismo’s risk assessment services.<\/a><\/p>\n\n\n\n Machinery safety measures should be selected based on the identified hazards and the available methods for reducing risks. The first priority is to eliminate hazards or reduce risks through the machine\u2019s design and operating principles.<\/p>\n\n\n\n If risks cannot be sufficiently reduced through inherently safe design, protective guards, interlocks and other safety devices should be used. Appropriate warnings and instructions must be provided for any remaining risks.<\/p>\n\n\n\n For example, an emergency stop button cannot replace a protective guard in situations<\/strong> where an employee could become trapped between moving mechanisms during normal operation.<\/p>\n\n\n\n It is also necessary to verify whether opening a protective door activates a safety function that stops hazardous movement quickly enough and prevents unexpected restarting.<\/p>\n\n\n\n Machinery safety does not depend solely on installing compliant safety components. The complete safety solution must function correctly under actual operating conditions.<\/p>\n\n\n\n Machinery safety legislation establishes essential health and safety requirements, while technical standards help manufacturers implement these requirements through specific engineering solutions.<\/p>\n\n\n\n Commonly used machinery safety standards include:<\/p>\n\n\n\n The selection of appropriate machinery safety standards depends on the type of machine, its intended use and the hazards identified during the risk assessment.<\/p>\n\n\n\n Compliance with a relevant harmonised European standard may provide a presumption of conformity with the legislative requirements covered by that standard. The use of standards is generally voluntary and does not replace the need to assess the risks associated with a specific machine.<\/p>\n\n\n\n It is also important to determine whether dedicated product standards or additional technical requirements apply to the relevant machinery category.<\/p>\n\n\n\n Repairing, modernising or installing an additional protective guard on a machine does not automatically mean that a new CE conformity assessment is required.<\/p>\n\n\n\n The need for reassessment depends on the extent of the modification, its impact on machinery safety and whether the modified equipment must be considered new or substantially modified machinery under the applicable legislation.<\/p>\n\n\n\n Particular attention should be paid to modifications affecting the machine\u2019s intended purpose, operating speed, applied forces or safety-related control system.<\/p>\n\n\n\n From 20 January 2027, the EU Machinery Regulation (EU) 2023\/1230 will clarify the conditions under which machinery modifications are considered substantial and the associated obligations of the manufacturer.<\/p>\n\n\n\n For major machinery modifications, the need for CE conformity assessment and the applicable safety requirements should be established before work begins<\/strong>. This helps avoid situations where a completed technical solution fails to meet the relevant requirements.<\/p>\n\n\n\n Machinery safety problems often arise when safety requirements are only considered at the end of the design process or when assessments focus exclusively on the machine\u2019s normal operating cycle.<\/p>\n\n\n\n Risks may also remain unidentified when individual safety components are selected without verifying the operation of the complete safety function.<\/p>\n\n\n\n Incomplete or outdated technical documentation is another common problem. For example, a machine may have been modified over the years, while its risk assessment, electrical diagrams and instruction manual no longer reflect its actual design or operating principles.<\/p>\n\n\n\n Machinery safety cannot be demonstrated solely through CE marking or the presence of safety devices. Safety must be technically justified, documented and verifiable.<\/p>\n\n\n\n Revismo supports both developers of new machinery and companies looking to improve the safety of existing equipment.<\/p>\n\n\n\n Depending on the project, we help assess machinery risks, plan modifications and protective measures, prepare technical documentation and address CE conformity requirements.<\/p>\n\n\n\n Ultimately, the value of machinery safety lies in a practical result: the machine must be safe, reliable and fully functional.<\/strong><\/p>\n\n\n\n Explore our CE conformity services<\/a> or contact us<\/a> to discuss the safety requirements of your machinery or development project.<\/p>\n\n\n\n Machinery safety involves more than CE marking, protective guards or warnings in an instruction manual. The purpose of machinery safety is to ensure that machines can be operated, adjusted, cleaned and maintained without exposing workers to unacceptable risks. Machinery safety requirements must be considered both when designing new machines and when operating or modernising existing […]<\/p>\n","protected":false},"author":2,"featured_media":902210,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[16],"tags":[],"class_list":["post-902195","post","type-post","status-publish","format-standard","has-post-thumbnail","category-about-product-development"],"acf":[],"_links":{"self":[{"href":"https:\/\/revismo.com\/en\/wp-json\/wp\/v2\/posts\/902195","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/revismo.com\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/revismo.com\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/revismo.com\/en\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/revismo.com\/en\/wp-json\/wp\/v2\/comments?post=902195"}],"version-history":[{"count":2,"href":"https:\/\/revismo.com\/en\/wp-json\/wp\/v2\/posts\/902195\/revisions"}],"predecessor-version":[{"id":902209,"href":"https:\/\/revismo.com\/en\/wp-json\/wp\/v2\/posts\/902195\/revisions\/902209"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/revismo.com\/en\/wp-json\/wp\/v2\/media\/902210"}],"wp:attachment":[{"href":"https:\/\/revismo.com\/en\/wp-json\/wp\/v2\/media?parent=902195"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/revismo.com\/en\/wp-json\/wp\/v2\/categories?post=902195"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/revismo.com\/en\/wp-json\/wp\/v2\/tags?post=902195"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}How Can Machinery Safety Be Ensured During the Development of a New Machine?<\/strong><\/h2>\n\n\n\n
How Can Existing Machinery Be Made Safer?<\/strong><\/h2>\n\n\n\n
Why Is a Machinery Risk Assessment Necessary?<\/strong><\/h2>\n\n\n\n
How to Select Appropriate Safety Measures<\/strong><\/h2>\n\n\n\n
Machinery Safety Standards<\/strong><\/h2>\n\n\n\n
\n
Does Modifying Machinery Require a New CE Conformity Assessment?<\/strong><\/h2>\n\n\n\n
What Should Be Avoided When Assessing Machinery Safety?<\/strong><\/h2>\n\n\n\n
How Can Revismo Help with Machinery Safety?<\/strong><\/h2>\n\n\n\n
<\/figure>\n","protected":false},"excerpt":{"rendered":"