EN 1010-5:2005

Safety of machinery - Safety requirements for the design and construction of printing and paper converting machines - Part 5: Machines for the production of corrugated board and machines for the conversion of flat and corrugated board

This standard applies to machines for the production of corrugated board and the conversion of flat and
corrugated board:
. corrugated board production machines;
. folder gluer machines;
. printer slotters, rotary die cutters and combined machines (inline machines);
. hand-fed platen machines for cutting and creasing;
. automatic platen machines for cutting and creasing;
. tube winding machines.
This document shall be used together with EN 1010-1:2004. Both parts together identify all significant hazards
relevant to machines for the production of corrugated board and the conversion of flat and corrugated board
when they are used as intended and under the conditions foreseen by the manufacturer (see clause 4). The
specific requirements in EN 1010-5 take precedence over respective requirements in EN 1010-1:2004.
This document does not deal with risks generated by noise emitted from the machines. These issues are
fundamentally covered in EN 1010-1:2004 However, this document specifies requirements for noise reduction
of corrugated board and flatbed punching machines.

Sicherheit von Maschinen - Sicherheitsanforderungen an Konstruktion und Bau von Druck- und Papierverarbeitungsmaschinen - Wellpappenerzeugungs-, Flach- und Wellpappenverarbeitungsmaschinen

Sécurité des machines - Prescriptions de sécurité pour la conception et la construction de machines d'impression et de transformation du papier - Partie 5: Machines de fabrication du carton ondulé et machines de transformation du carton plat et du carton ondulé

La présente norme s'applique aux machines de fabrication du carton ondulé et aux machines de transformation du carton plat et du carton ondulé :
- onduleuses ;
- plieuses-colleuses ;
- groupes slotters imprimants, découpeurs rotatifs et combinés (machines en ligne) ;
- presses platines manuelles à découper et à refouler ;
- presses platines automatiques à découper et à refouler ;
- machines à fabriquer les tubes.
Le présent document doit être utilisé conjointement au prEN 1010-1:2003. Les deux parties traitent en commun tous les phénomènes dangereux significatifs qui s'appliquent aux onduleuses et aux machines de transformation du carton plat et du carton ondulé en utilisation normale et conformément aux conditions prévues par le fabricant (voir Article 4). Les prescriptions spécifiques définies dans le prEN 1010-5 ont la priorité sur les prescriptions prévues par le prEN 1010-1:2003.
Le présent document aborde les risques induits par le bruit émis par les machines. Cet aspect est essentiellement traité dans le prEN 1010-1:2003. Cependant, pour les onduleuses et les presses platine automatiques, des prescriptions sont prévues en matière de réduction du bruit.
Le présent document ne s'applique pas aux onduleuses et aux machines de transformation du carton plat et du carton ondulé dont la fabrication est antérieure à la publication du présent document par le CEN.

Varnost strojev – Varnostne zahteve za načrtovanje in konstrukcijo tiskarskih strojev in strojev za obdelavo papirja – 5. del: Stroji za izdelavo valovitega kartona in lepenke in stroji za obdelavo ploskega in valovitega kartona in lepenke

General Information

• Status: Withdrawn
• Publication Date: 17-May-2005
• Withdrawal Date: 13-Apr-2025
• ICS: 85.100 - Equipment for the paper industry
• Technical Committee: CEN/TC 198 - Printing and paper machinery - Safety
• Drafting Committee: CEN/TC 198/WG 1 - Printing and paper converting machines - Drafting of safety standards
• Current Stage: 9960 - Withdrawal effective - Withdrawal
• Start Date: 13-Dec-2023
• Completion Date: 14-Apr-2025
• Directive: 98/37/EC - Machinery
• Mandate: M/079 - Mandate to CEN and CENELEC for standardization in the field of machines
• Ref Project: SIST EN 1010-5:2005 - Safety of machinery - Safety requirements for the design and construction of printing and paper converting machines - Part 5: Machines for the production of corrugated board and machines for the conversion of flat and corrugated board

Relations

• Replaced By: EN ISO 12643-4:2023 - Graphic technology - Safety requirements for graphic technology equipment and systems - Part 4: Converting equipment and systems (ISO 12643-4:2023)
• Effective Date: 28-Jan-2023
• Replaced By: EN ISO 12643-5:2023 - Graphic technology - Safety requirements for graphic technology equipment and systems - Part 5: Manually-fed stand-alone platen presses (ISO 12643-5:2023)
• Effective Date: 03-Jul-2019
• Amended By: EN 1010-5:2005/FprA1 - Safety of machinery - Safety requirements for the design and construction of printing and paper converting machines - Part 5: Machines for the production of corrugated board and machines for the conversion of flat and corrugated board
• Effective Date: 22-Dec-2008
• Parent: EN 1010-1:2004 - Safety of machinery - Safety requirements for the design and construction of printing and paper converting machines - Part 1: Common requirements
• Effective Date: 22-Dec-2008

Standards Content (Sample)

SLOVENSKI STANDARD
01-september-2005
9DUQRVWVWURMHY±9DUQRVWQH]DKWHYH]DQDþUWRYDQMHLQNRQVWUXNFLMRWLVNDUVNLK
VWURMHYLQVWURMHY]DREGHODYRSDSLUMD±GHO6WURML]DL]GHODYRYDORYLWHJDNDUWRQD
LQOHSHQNHLQVWURML]DREGHODYRSORVNHJDLQYDORYLWHJDNDUWRQDLQOHSHQNH
Safety of machinery - Safety requirements for the design and construction of printing and
paper converting machines - Part 5: Machines for the production of corrugated board and
machines for the conversion of flat and corrugated board
Sicherheit von Maschinen - Sicherheitsanforderungen an Konstruktion und Bau von
Druck- und Papierverarbeitungsmaschinen - Wellpappenerzeugungs-, Flach- und
Wellpappenverarbeitungsmaschinen
Sécurité des machines - Prescriptions de sécurité pour la conception et la construction
de machines d'impression et de transformation du papier - Partie 5: Machines de
fabrication du carton ondulé et machines de transformation du carton plat et du carton
ondulé
Ta slovenski standard je istoveten z: EN 1010-5:2005
ICS:
37.100.10 Reprodukcijska oprema Reproduction equipment
85.100 Oprema za papirno industrijo Equipment for the paper
industry
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

EUROPEAN STANDARD
EN 1010-5
NORME EUROPÉENNE
EUROPÄISCHE NORM
May 2005
ICS 85.100
English version
Safety of machinery - Safety requirements for the design and
construction of printing and paper converting machines - Part 5:
Machines for the production of corrugated board and machines
for the conversion of flat and corrugated board
Sécurité des machines - Prescriptions de sécurité pour la Sicherheit von Maschinen - Sicherheitsanforderungen an
conceptions des machines d'impression, de transformation Konstruktion und Bau von Druck- und
et définition du papier - Partie 5: Onduleuses et machines Papierverarbeitungsmaschinen - Wellpappenerzeugungs-,
de trasformation du carton plat et du carton ondulé Flach- und Wellpappenverarbeitungsmaschinen
This European Standard was approved by CEN on 2 September 2004.
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, 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
© 2005 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 1010-5:2005: E
worldwide for CEN national Members.

Contents Page
Foreword .4
Introduction.5
1 Scope.5
2 Normative references.6
3 Terms and definitions .6
4 List of significant hazards.8
5 Safety requirements and/or measures .13
5.1 General.13
5.2 Machines for the production of corrugated board.13
5.2.1 Entire machines.13
5.2.2 Unwinding stations .14
5.2.3 Splicers.17
5.2.4 Preheater .18
5.2.5 Single facer.20
5.2.6 Inclined belt conveyor.23
5.2.7 Bridge .23
5.2.8 Braking and web aligning section .24
5.2.9 Glue machine (Figure 11, item 1).24
5.2.10 Heating and pulling section .24
5.2.11 Rotary shears (Figure 11, item 16).27
5.2.12 Pulling unit (Figure 12).27
5.2.13 Slitter-scorer units.28
5.2.14 Web diverter .29
5.2.15 Sheeters.29
5.2.16 Stacker devices .30
5.3 Folding box gluer machines .32
5.3.1 Feeder.32
5.3.2 Folding section.33
5.3.3 Gluing section .34
5.3.4 Folding belt.34
5.3.5 Pressing section.35
5.3.6 Entire machine.35
5.4 Inline machines .36
5.4.1 Entire machine (Figure 20).36
5.4.2 Feeding unit (Figure 20, item 1) .36
5.4.3 Printing unit (Figure 20, item 5) .39
5.4.4 Slitter-scorer unit (Figure 20, item 7), rotary die cutter (Figure 20, item 8).39
5.4.5 Folding unit (folding box gluer) (Figure 20, item 10).40
5.4.6 Stitching unit (Figure 20, item 11).40
5.4.7 Delivery (Figure 20, item 12) .41
5.5 Hand-fed platen machines for cutting and creasing.41
5.6 Automatic flatbed punching machines.44
5.6.1 Feeder (Figure 24, item 1) .44
5.6.2 Punching section (Figure 24, item 2).45
5.6.3 Breaking section (Figure 24, item 3).45
5.6.4 Blank separating section, blank delivery (Figure 24, item 4).46
5.6.5 Trimming and delivery of gripper edge (Figure 24, item 5) .46
5.6.6 Entire machine.46
5.7 Tube winding machines.47
6 Verification of safety requirements and/or measures. 49
7 Information for use. 56
7.1 Instruction handbook . 56
7.1.1 Corrugated board machine . 56
7.1.2 Folding box gluer machines. 57
7.1.3 Inline machines. 58
7.1.4 Hand-fed platen machines . 58
7.1.5 Automatic flatbed punching machines. 58
7.1.6 Tube winding machine . 58
Annex ZA (informative) Relationship between this European Standard and the Essential
Requirements of EU Directive 98/37/EC . 59
Bibliography. 60

Foreword
This document (EN 1010-5:2005) has been prepared by Technical Committee CEN/TC 198 “Printing and
paper machinery - Safety”, the secretariat of which is held by DIN.
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 November 2005, and conflicting national standards shall be withdrawn
at the latest by November 2005.
Attention is drawn to the possibility that some of the elements of this document may be the subject of patent
rights. CEN [and/or CENELEC] shall not be held responsible for identifying any or all such patent rights.

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 Directives.

For relationship with EU Directives, see informative Annex ZA, B, C or D which is an integral part of this
document
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, Slovakia, Slovenia, Spain, Sweden, Switzerland
and the United Kingdom.
Introduction
This document is a type C standard as stated in EN ISO 12100-1:2003.
It contains additional safety requirements and/or deviations from EN 1010-1:2004. The machinery concerned
and the extent to which hazards, hazardous situations and events are covered are indicated in the scope of
this document.
For machines designed and built in compliance with this type C standard, the following rule applies: where
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 over the provisions of the other standards.
This standard consists of the following parts:
Part 1 Common requirements
Part 2 Printing and varnishing machines including pre-press machinery
Part 3 Cutting machines
Part 4 Bookbinding, paper converting and finishing machines
Part 5 Machines for the production of corrugated board and machines for the conversion of flat and
corrugated board
1 Scope
This standard applies to machines for the production of corrugated board and the conversion of flat and
corrugated board:
 corrugated board production machines;
 folder gluer machines;
 printer slotters, rotary die cutters and combined machines (inline machines);
 hand-fed platen machines for cutting and creasing;
 automatic platen machines for cutting and creasing;
 tube winding machines.
This document shall be used together with EN 1010-1:2004. Both parts together identify all significant hazards
relevant to machines for the production of corrugated board and the conversion of flat and corrugated board
when they are used as intended and under the conditions foreseen by the manufacturer (see clause 4). The
specific requirements in EN 1010-5 take precedence over respective requirements in EN 1010-1:2004.
This document does not deal with risks generated by noise emitted from the machines. These issues are
fundamentally covered in EN 1010-1:2004 However, this document specifies requirements for noise reduction
of corrugated board and flatbed punching machines.
This document is not applicable to machines for the production of corrugated board and machines for the
conversion of flat and corrugated board which are manufactured before the date of publication of this
document by CEN.
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 418:1992, Safety of machinery — Emergency stop equipment, functional aspects — Principles for design
EN 619:2002, Continuous handling equipment and systems — Safety and EMC requirements for equipment
for mechanical handling of unit loads
EN 954-1:1996, Safety of machinery — Safety-related parts of control systems — Part 1: General principles
for design
EN 983:1996, Safety of machinery — Safety requirements for fluid power systems and their components —
Pneumatics
EN 1010-1:2004, Safety of machinery — Technical safety requirements for the design and construction of
printing and paper converting machines — Part 1: Common requirements
EN 1050:1996, Safety of machinery — Principles for risk assessment
EN 1088:1996, Safety of machinery — Interlocking devices associated with guards — Principles for design
and selection
EN 13023:2003, Noise measurement methods for printing, paper converting, paper making machines and
auxiliary equipment — Accuracy categories 2 and 3
EN ISO 4871, Acoustics — Declaration and verification of noise emission values of machinery and
equipment
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 60529:1991, Degrees of protection provided by enclosures (IP code) (IEC 60529:1989).
3 Terms and definitions
For the purposes of this European Standard, the terms given in EN ISO 12100-1:2003 and EN 1010-1:2004
and the following terms apply.
3.1
ESPD
electro-sensitive protective device
3.2
stop safe section
specific part of a machine or equipment which can be provided with a separate safeguard against restart
3.3
stop safe actuator
control element which, when actuated, prevents restart of that specific part of the machine. The actuator is
locked in the stop safe position and can be disengaged by turning it
3.4
splicer
device provided on unwinds with automatic reel changing for cutting off the run-down paper web supplied
from the unwinding reel and fitting the cut web to the paper web from the new reel such as to ensure
continuous production
3.5
single facer
equipment where corrugations are embossed into a paper web by using two corrugating rollers and where a
liner is glued onto one side
3.6
preheater
equipment for preheating the paper web where the web is brought into contact with a steam-heated cylinder
3.7
wrap arm
arm moving around the preheating cylinder in such a way as to vary the length of the paper web in contact
with the preheating cylinder
3.8
inclined belt conveyor
transport system for feeding the single-faced corrugated board onto the bridge
3.9
inclined belt conveyor side
that side of a single facer where the corrugated board is delivered and fed onto the bridge by the inclined belt
conveyor
3.10
bridge
transport system positioned above the single facers, serving as storage facility. The inclined belt conveyor
feeds the single-faced corrugated board to the bridge where it is deposited in loops and subsequently fed to
the following machines
3.11
braking and web aligning section
unit which is fitted on the bridge for taking up slacks in the single-faced corrugated web and guiding the web
into the following machines
3.12
glue machine
separate machine for applying an even layer of glue onto the top of the corrugations of one or more single-
faced board webs
3.13
heating and pulling section
equipment for joining one or more single-faced webs coated with glue on the corrugated side with a liner and
for drying and transporting it to following machines
3.14
rotary shears
rotary cutter for cutting the running corrugated web when changing the format and for removing imperfections
(waste material)
3.15
pulling section
pair of transport rollers ensuring pulling of the web
3.16
slitter-scorer unit
equipment for slitting and creasing the corrugated web
3.17
web diverter
system of movable elements for diverting and feeding the slit webs delivered from the slitting and scoring unit
into the sheeter
3.18
sheeter
cutting machine for cutting the corrugated web into specific sheet lengths. The sheeter can consist of one or
more vertically mounted cut-off units
3.19
stacking device
device for stacking sheets of corrugated board (see downstacker, upstacker)
3.20
downstacker (auto-piler)
stacking device on corrugated board machines where the position of the feeding conveyor remains
unchanged and the pile is created by the lowering movement of the pile carrier
3.21
upstacker
stacking device on corrugated board machines where the position of the pile carrier remains unchanged and
the pile is created by the upward movement of the conveyor belt
3.22
inline machine
machine for processing board and corrugated board, consisting of a number of units such as a feeding unit,
one or more printing units, slitter-scorer unit, rotary die cutter, gluing unit, folding unit, stitching unit.
Depending on the type of machine, one or more of the units listed may be missing
4 List of significant hazards
4.1 This clause contains all the significant hazards (noise is fundamentally dealt with in EN 1010-1:2004),
as far as they are dealt with in this standard, identified by the risk assessment significant for this type of
machinery and which require action to eliminate or reduce the risk. When carrying out the risk assessment,
the machine designer shall check whether the list of hazards in Table 1 is complete and applicable with
respect to the particular machine.
4.2 It is of great importance that the users of this standard, i. e. the designer or manufacturer, take into
account the following principal aspects in accordance with EN 1050:1996:
 the intended use of the machine including setting-up (make-ready), cleaning and maintenance, including
foreseeable misuse;
 identification of all hazards existing on the machine.
Table 1 — Significant hazards, danger zones, safety measures
Safety measures: reference to clauses in
EN 1010-1:
This standard EN ISO
Hazards Danger zone
12100-1:
Corrugated board production
Mechanical hazards
4.2.1
machines
crushing
 unwind
shearing 5.2.2.1 to 5.2.2.4 5.3.5.9 to
5.3.5.11
cutting or severing
entanglement
drawing-in  splicer
5.2.3.1 to 5.2.3.4 5.2.1.1,
trapping
5.2.10.1,
5.2.10.2,
impact
5.2.3.3
ejection of high-pressure fluids

 splicing knives
5.2.3.5
5.2.1
 preheater
5.2.4.1 to 5.2.4.6,
5.2.4.8
 single facer, corrugating rollers
5.2.5.1 to 5.2.5.2, 5.2.3.2 a) 2,
5.2.5.4 5.2.2
 pressing belt, pressure roller, 5.2.5.5
corrugating roller
 glue rollers 5.2.5.8 to 5.2.5.10

 guide rollers
5.2.5.11
 drive
5.2.5.15 5.2.2
 inclined belt conveyor
5.2.6.1 to 5.2.6.3 5.2.1
 bridge
5.2.7.1 to 5.2.7.3 5.2.1, 5.2.2

 braking and aligning section
5.2.8 5.2.1.1
 glue machine
5.2.9.2 to 5.2.9.4
5.2.2
 heating and pulling section 5.2.10.1 to 5.2.10.3,

5.2.10.5 to 5.2.10.8
 rotary shears
5.2.11.1 to 5.2.11.7, 5.2.2
7.1.1.8
 pulling unit
5.2.12.1 to 5.2.12.3 5.2.2
 slitter-scorer unit
5.2.13.1 to 5.2.13.3, 5.2.2,
5.2.13.6, 5.2.13.7
5.2.3.2 a ) 2
 web diverter section
5.2.14 5.2.2
 sheeters
5.2.15.2 to 5.2.15.5 5.2.2
 stacking devices
5.2.16.1 to 5.2.16.7, 5.2.3.1,
7.1.1.9 5.2.12, 5.3.4,
5.2.2.2, 5.2.2
Folding box gluer machines
 feeder
5.3.1.1 to 5.3.1.4 5.3.4, 5.3.4.8

 folding section
5.3.2.1 to 5.3.2.3 5.2.3.2 a) 2

 gluing section
5.3.3.1 to 5.3.3.2 5.2.2
folding belt
 5.3.4.1 to 5.3.4.2 5.2.2
Table 1 (continued)
Safety measures: reference to clauses in
EN ISO
EN 1010-1:
Hazards Danger zone
This standard 12100-1:
 pressing section
5.3.5.1 to 5.3.5.2 5.2.2
 power-driven shafts
5.3.6.1
 format setting
5.3.6.3 5.2.3.3
Inline machines
 travel of individual units 5.4.1.1 to 5.4.1.4 5.2.6.1.1,
5.2.1.4
 inrunning nips on conveying
5.4.1.5
belts
 feeding unit
5.4.2.1 to 5.4.2.8 5.2.2,
5.3.4.8,
5.2.6.1.5,
5.3.4
 printing unit 5.4.3.1. 5.4.3.2, 5.2.2,
5.4.3.4, 5.4.3.5, 5.2.3.2,
7.1.3.2 5.2.6.1.1
 slitter-scorer, rotary die cutter
5.4.4.1 to 5.4.4.5 5.2.3.2,
5.2.6.1.1,
5.2.12
 folding unit
5.4.5.1 to 5.4.5.6 5.2.2,
5.2.3.1,
5.2.3.2,
5.2.6.1.1,
5.3.6.1
 stitching unit
5.4.6.1 to 5.4.6.3, 5.2.2,
5.4.6.5 5.2.3.1,
5.2.3.2 a) 2,
5.2.6.1.1,
5.3.6.1
 delivery 5.4.7 5.3.4
Hand-fed platen machine
 danger points created by 5.5.1 to 5.5.4, 5.5.6 5.2.10,
closing movement 5.2.10.2,
5.2.6.1.1
 impacts caused by platen 5.5.5

 excess of stopping time 5.5.8
Flatbed punching machines
5.6.1.1 to 5.6.1.5 5.3.4, 5.3.4.8
 feeding unit
 punching section 5.6.2.1 to 5.6.2.3
breaking section 5.6.3.1 to 5.6.3.3 5.2.3.1, 5.2.2

 blank separating, delivery 5.6.4.1 to 5.6.4.2 5.2.3.1, 5.3.4

 trimming of gripper edge, 5.6.5
delivery
 gravity falling of tools 5.6.6.1

 hazards created by material 5.6.6.2
jams
Tube winding machines
 unwind
5.7.1, 5.7.2
 winding belt/winding mandrel 5.7.3, 7.1.6.1
Table 1 (continued)
Safety measures: reference to clauses in
EN ISO
EN 1010-1:
Hazards Danger zone
This standard 12100-1:
 winding belt/drive drums 5.7.4

 glue rollers 5.7.5 5.2.1.1.b)

 cutting and sawing units 5.7.6

 tube transfer 5.7.7
Avoiding direct or pending Corrugating board production 5.2.1.3 to 5.2.1.5,

hazardous situations machines 5.2.16.2, 5.2.3.9

Folding box gluer machines 5.3.6.4
Inline machines 5.4.1.2, 5.4.1.6
Hand-fed platen machines 5.5.6, 5.5.9

Automatic flatbed punching 5.6.6.3, 5.6.6.7,
5.2.7.2
machines 7.1.5.1
Tube winding machines 5.7.8
Breakages during production Corrugating board production 4.2.2
runs machines
- breakage of pressure belt
5.2.5.6
Electrical hazards Corrugating board production 4.3
machines
direct or indirect contact
 electrical equipment
5.2.1.1 5.2.5
Thermal hazards Corrugated board production 4.4
machines
burns due to possible contact
 preheater
5.2.4.7
 steam pipes, steam couplings 5.2.5.12, 5.2.5.13

 single facer 5.2.5.14, 7.1.1.7
 heating and pulling section
5.2.10.4, 5.2.10.10,
5.2.10.11
Corrugated board production 4.5
Hazards generated by noise
machines
resulting in hearing loss
(deafness)  single facer
5.2.5.16
 sheeter 5.2.15.6 5.2.14
Inline machines 5.4.4.6
Automatic flatbed punching
5.6.6.6
machines
Corrugated board production
Hazards from fire and explosion 4.8
machines
 blowers for braking systems on
5.2.2.5
unwinds
 vacuum belts
5.2.10.9 5.2.4.3.1,
5.2.4.9
 exhaust hoses 5.2.13.4 5.2.4.9
 braking systems on unwinds 5.2.2.5
Automatic flatbed punching
machines
 exhaust equipment 5.6.3.4 5.2.4.1,
5.2.4.4.1,
5.2.4.9
Hazards from substances and Corrugated board production 4.8
material used for processing, machines

machine operation or which are
 escape of steam
5.2.5.14
emitted during the process
Table 1 (continued)
Safety measures: reference to clauses in
EN ISO
EN 1010-1:
Hazards Danger zone
This standard 12100-1:
Hazards resulting from contact
with or inhalation of harmful
fluids, gases, fumes, dusts
Hazards generated by neglect of Corrugated board production 4.9
ergonomic principles in machine machines

design
 access stairs, catwalks
5.2.1.6
unhealthy body postures
 access to splicers 5.2.3.7, 5.2.3.8 5.2.12

 catwalk on preheater 5.2.4.8 5.2.12
 changing of corrugating rollers 5.2.5.3

 catwalk in front of corrugating 5.2.5.7
rollers
 access to bridge, bridge 5.2.7.4 to 5.2.7.6

 threading of paper web on 5.2.9.1 5.2.12.2
gluing unit
 waste removal on rotary 5.2.11.5
shears
 access to creasing unit, 5.2.13.5
5.2.12
catwalk
 access to sheeter
5.2.15.1 5.2.12
Folding box gluer machines
5.3.6.2
 access, working platform
Inline machines
5.4.1.7 5.2.12
 access stairs, working platform

 mounting of stereos 5.4.3.3 5.12.12.1
 changing and threading of 5.4.5.7
adhesive tape
 changing and threading of 5.4.6.4
stitching wire
Automatic flatbed punching
machines
 changing of tools 5.6.2.3, 5.6.2.4

 access stairs, working platform 5.6.6.5
Failure, malfunction of control Corrugated board production
system machines
Faults or failures in safety
 entire machine
5.2.1.2 5.2.6.1
circuits
 knife control system of  5.2.3.6
splicing device
 rotary shears 5.2.11.2
Hand-fed platen machines
 control system
5.5.7
 laser scanners
5.5.4
Automatic flatbed punching
machines
 control system, interlocking
5.6.6.4
5 Safety requirements and/or measures
5.1 General
Machinery shall comply with the safety requirements and/or measures of this clause. In addition, the machine
shall be designed according to the principles of EN ISO 12100 for hazards relevant but not significant which
are not dealt with by this standard (for example, sharp edges of the machine frame). The common
requirements of Part 1 shall also be satisfied.
5.2 Machines for the production of corrugated board
5.2.1 Entire machines
5.2.1.1 The electrical equipment shall comply with the requirements of 5.2.5 of EN 1010-1:2004.
5.2.1.2 The control system shall comply with the requirements of 5.2.6.1 of EN 1010-1:2004.
5.2.1.3 A start-up warning device is required. The requirements of 5.2.7.2 of EN 1010-1:2004 shall be
complied with.
5.2.1.4 An emergency stop device is required. The emergency stop actuators shall be provided on
each main control panel and at least at a distance of 15 m and they shall act on the entire machine.
The glue rollers of the gluing unit can be excluded if the danger points on the gluing unit are safeguarded by
guards.
5.2.1.5 Where stop safe actuators are provided, the following requirements apply:
 stop safe actuators shall be marked such that they clearly indicate the section they apply to;
 signal processing shall comply with category 3 in accordance with 5.2.6.1.1 of EN 1010-1:2004.
Where stop safe sections are provided, they shall be identified as follows:
Section: per single-facer group (unwind of liner with preheater, single facer, unwind of corrugated web) (see
Figure 1).
Section: liner unwind before heating up to stacker device (see Figure 1).

Key
1 Single-facer group
2 Single-facer group
3 Liner unwind up to stacker device
Figure 1 — Stop safe sections
5.2.1.6 Access stairs and catwalks shall comply with 5.2.12 of EN 1010-1:2004.
5.2.2 Unwinding stations
5.2.2.1 For automatic reel loading systems, the requirements of 5.3.5.11 of EN 1010-1:2004 shall be
satisfied.
5.2.2.2 The area where automatic reel loading takes place shall be safeguarded by the following
measures:
 provision of ESPDs according to 5.3.5.11 of EN 1010-1:2004. The safety device shall be allowed to be
muted while the material reel or core container travel through the area safeguarded by the ESPD. An
additional ESPD shall be provided at a height of 50 mm maximum above the maximum reel diameter
which ensures stopping of all hazardous movements in the automatic reel loading area the moment the
photoelectric beam is interrupted, for example, by a person entering the area (Figure 3) even while the
material reel or core contained travel through the area;
 other adequate measures ensuring safe reel changing.
Emergency stop actuators shall be provided within easy reach in the vicinity of the unwind.
Dimensions in millimetres
Key
1 ESPD 3 Additional ESPD
2 Photoelectric beam of the ESPD 4 Material reel
Figure 2 — Unwinding station, automatic reel loading
5.2.2.3 For semi-automatic reel loading systems, the safety requirements of 5.3.5.10 of EN 1010-1:2004
shall be satisfied.
5.2.2.4 For inserting the chucking cones and moving the lifting arms, the requirements of 5.3.5.3 to
5.3.5.9 of EN 1010-1:2004 shall be satisfied.
The hold-to-run speeds for inserting the chucking cones and moving the lifting arms may be increased to
15 m/min maximum if the hold-to-run buttons are located at a minimum distance of 850 mm from the lifting
arms.
5.2.2.5 The blowers for the braking systems on unwinding stations shall have at least degree of
protection IP 23 as specified in EN 60529:1991. Accumulation of inflammable dust in the brakes shall be
prevented. This can be achieved if the louvres provided in the ventilator housing open to the bottom while the
lifting arms are in operating position.
Key
1 Unwind   6 Heating section 11 Web diverter
2 Single facer   7 Pulling section  12 Sheeter
3 Bridge   8 Rotary shears  13 Upstacker
4 Preheater   9 Pulling unit  14 Downstacker
5 Glue machine   10 Slitter-scorer unit
Figure 3 — Principle of a machine for the production of corrugated board
5.2.3 Splicers
5.2.3.1 On splicers, any danger points between the dancer roll carriage and guide rollers and between
dancer roller and fixed parts of the machine shall be avoided by design measures or be safeguarded (see
Figure 4).
Safeguarding is achieved by providing:
 a minimum distance of 25 mm if the danger point is at a height of greater than 2,20 m and;
 a minimum distance of 120 mm for heights less than or equal to 2,20 m.
Safeguarding is also achieved by guards in accordance with 5.2.1.1 of EN 1010-1:2004 or safety devices
with approach reaction.
Trip bars shall satisfy the requirements of 5.2.10.1 and 5.2.10.2 of EN 1010-1:2004.

Key
1 Paper web 3 Dancer roll
2 Guide rollers 4 Gluing unit
Figure 4 — Splicer
5.2.3.2 The movement of the dancer roll into position for web threading shall be safeguarded.
Where hold-to-run control is used for safeguarding, the hold-to-run speed shall not exceed 15 m/min.
5.2.3.3 The inrunning nips on the dancer roll carriage wheels shall be safeguarded by fixed guards.
5.2.3.4 On splicers, danger points between the movable suction bar and fixed machine parts shall be
prevented by safety measures or be safeguarded (see Figure 4). Safeguarding can be achieved by:
 providing a minimum distance of 25 mm for danger points above 2,20 m and of 120 mm for heights less
than or equal to 2,20 m or;
 hold-to-run control (for siting of the actuating device, see 5.2.3.3 of EN 1010-1:2004) or;
 limiting the force of the movable glue bar to 300 N and the travel speed of the carriage to 15 m/min.
The control panel for operating the glue bar shall be provided with an emergency stop button.
5.2.3.5 The cutting edge of the knife shall be safeguarded in the rest position.
5.2.3.6 Where pneumatic or hydraulic control systems are used for starting the cutting cycle, a safety-
rated check valve shall be supplied to ensure that the knife remains in the safe position if there is leakage or
hose breakage.
5.2.3.7 Where the machine frame of the splicer is lower than 2 m at the sides, frame edges shall be
provided with black-yellow padding for protection against impacts.
5.2.3.8 Safe access shall be provided for splicers placed in raised positions in order to allow for the
movable suction bar to be prepared. Steps and handles shall comply with the requirements of 5.2.12 of
EN 1010-1:2004.
5.2.3.9 A yellow warning light shall be active before and during the automatic splicing operation. For the
warning light control system, category B of EN 954-1:1996 is considered adequate.
5.2.4 Preheater
5.2.4.1 The inrunning nips between wrap roller and preheating cylinder and between wrap roller and fixed
machine parts or guide rollers shall be safeguarded by:
 using the minimum distance of 120 mm, or;
 by guarding in accordance with 5.2.1 of EN 1010-1:2004.

Key
1 Preheating cylinder 3 Wrap roller
2 Paper web 4 Guide roller
Figure 5 — Preheater, view from the side
5.2.4.2 The inrunning nips between preheating cylinder and any cross beam shall be safeguarded by
using the minimum distance of 300 mm.
5.2.4.3 The drives for the wrap roller shall be safeguarded by fixed guards completely enclosing the
drives.
5.2.4.4 Where there are apertures in the rotating wrap arms, they shall be infilled in order to prevent the
generation of shearing hazards (Figure 6, item 2).
5.2.4.5 The distance (Figure 6, d) between preheating cylinder and rotating arm shall be 6 mm maximum
or 30 mm minimum.
5.2.4.6 The danger point between the rotating arms and the machine side frame shall be safeguarded
(Figure 6, items 2 and 4) by:
 hold-to-run control of at least category 1 as specified in EN 954-1:1996 or;
 a minimum distance of 120 mm and designing the rotating arm or machine side in such a way that parts
of the body are deflected by the arm when rotating at a circumferential speed of 5 m/min maximum.
5.2.4.7 As the temperature of preheating cylinders may be higher than 65 °C, warning signs indicating
the hot surfaces shall be fitted to both sides of the preheater.
5.2.4.8 Where catwalks pass along preheaters, fall-off protection shall be provided with a clearance of
120 mm from movable parts.
For fall-off protection and catwalks, see 5.2.2 of EN 1010-1:2004.

Key
1 Wrap roller 4 Machine frame
2 Rotating arm d Distance preheating cylinder/rotating arm
3 Preheating cylinder
Figure 6 — Preheater, view of feeding side
5.2.5 Single facer
5.2.5.1 The inrunning nip between the corrugating rollers shall be safeguarded by a fixed guard. The
maximum feeding opening of 40 mm requires a safety distance of 300 mm minimum.
5.2.5.2 The inrunning nips between the corrugating rollers and fixed machine parts shall be safeguarded
by fixed guards. The danger point between the corrugating roller and the crossbeam with fingers is considered
to be safeguarded if the clearance between the corrugating roller and the cross beam is 25 mm minimum and
and the clearance between the strippers is 60 mm maximum (Figure 7).
5.2.5.3 Where corrugating rollers are removed for changing, means of transport shall be provided that
allow easy and safe changing of rollers.
Noise enclosures shall be designed in such a way that loading and unloading of the corrugating rollers is not
impeded.
Key
1 Upper corrugating roller 4 Cross beam
2 Lower corrugating roller 5 Feeding of paper web
3 Scraper
Figure 7 — Corrugating rollers with scraper
5.2.5.4 Any danger points which can be accessed after removal or during changing of corrugating rollers
shall be safeguarded in accordance with 5.2.2 of EN 1010-1:2004.
Where corrugating rollers are mounted on an indexing turret, any movement of the turret shall be under hold-
to-run control in accordance with 5.2.3.2 a) 2 of EN 1010-1:2004.
5.2.5.5 The inrunning nip between pressure roller or pressing belt and corrugating roller (Figure 6) shall
be safeguarded by fixed guards.
The crushing point created by the lowering of the pressure roller contacting the corrugating roller shall be
safeguarded by a guard in accordance with 5.2.2 of EN 1010-1:2004 or by using a horizontal safety distance
of 1 000 mm from the danger point (see Figure 8).
Inrunning nips on the pressing belt shall be safeguarded by fixed guards.
5.2.5.6 On the delivery side of the single-faced corrugated web (inclined belt conveyor side), a
containment device shall be provided eliminating the risk of injury in the case of belt breakage.

Key
1 Pressure roller 5 Pressing belt
2 Corrugating rollers 6 Inrunning nip
3 Corrugated web 7 Inrunning nip on pressing belt
4 Liner
Figure 8 — Corrugating unit: pressure roller on the left, pressing belt on the right
5.2.5.7 The catwalk on the inclined belt conveyor side (Figure 10, item 7) shall have fall-off protection
towards the corrugating rollers. Cross beams provided for fall-off protection shall be at a height of 1,10 m
(Figure 10, number 6). Intermediate rails or toe boards are not required.
5.2.5.8 Inrunning nips between glue rollers or between glue rollers and corrugating rollers that are
accessible when the gluing unit is swung down shall be safeguarded by fixed guards in accordance with 5.2.2
of EN 1010-1:2004.
Where swinging down and lifting is an automatic operation, the gluing unit shall not create any danger points,
otherwise this movement shall only be carried out under hold-to-run control at a maximum speed of 5 m/min.
Where maintenance or cleaning operations are carried out with the interlocking guard covering the gluing unit
in an open position (Figure 9), the glue rollers (applicator, scraper roll) shall only be allowed to rotate at a
maximum circumferential speed of 6 m/min. Glue rollers shall rotate in the same direction with no possibility of
access to an inrunning nip between corrugating roller and glue roller.
5.2.5.9 The danger points between the glue and fixed machine parts (machine frame) shall be
safeguarded by one of the following measures:
 hold-to-run control with at least category 1 of EN 954-1:1996, or;
 interlocking guards, or;
 a minimum distance of 25 mm.
5.2.5.10 The cover of the gluing unit shall be designed in accordance with 5.2.2.5 of EN 10101-1:2003.

Key
1 Corrugating roller 3 Scraper roller
2 Glue applicator 4 Inrunning nip
Figure 9 — Gluing unit
5.2.5.11 The inrunning nips between pulleys and fixed machine parts shall be safeguarded by:
 fixed guards in accordance with 5.2.1.1.b) of EN 1010-1:2004, or;
 a minimum distance of 120 mm.
5.2.5.12 Steam pipes that can be accessed from any working level shall be insulated up to a height of
2,70 m for protection against burning.
5.2.5.13 When disengaging the steam couplings, the hazardous escape of pressurized steam shall be
safeguarded by:
 providing coupling systems with relief valves on the ingoing and outgoing sides of the coupling or;
 devices ensuring that the steam supply is cut off and steam is allowed to escape into the work area safely.
Also, when steam piping is opened in a way that is not intended, the escaping steam shall be led away
from the parts of the body.
5.2.5.14 Single facers shall be provided with signs warning of the risk of burning.
For warning signs, see 7.1.1.7.
5.2.5.15 Drives and drive shafts shall be safeguarded by fixed guards with interlocking gates in
accordance with 5.2.2 of EN 1010-1:2004.
5.2.5.16 Single facers shall be provided with noise enclosures. Doors shall close automatically and be
provided with signs pointing out the need to wear ear protection. The web feed and take-off openings provided
in the noise enclosure shall be designed
...