Machine Safety
What does a facility gain from a systematic approach?
Machine and Equipment Safety
Machine safety is systematic risk management throughout the entire lifecycle of an installation: from concept and design, through equipment selection, commissioning, operation, and modernization, to inspections and audits. In practice, this means combining ATEX requirements, process safety and operational requirements to reduce the probability of ignition and the consequences of a potential incident.
In industrial environments, the greatest risk occurs at the intersection of three elements: flammable substance, oxygen, and ignition source. Therefore, an effective approach to machine safety relies on several layers of protection: proper EX zone classification, appropriate equipment selection, ignition source control, work procedures and regular technical inspection of installations.
Why choose us?
Explosion Hazard Assessment
An explosion hazard assessment is the starting point for safe operation of the entire installation. We show how flammable substances, ignition sources and EX zones (0/1/2 and 20/21/22) are identified, as well as what technical and organizational recommendations genuinely reduce risk.
Explosion Protection Document (EPD)
The Explosion Protection Document (EPD) consolidates all legal and technical requirements in one place. We explain what the document must contain, how to conduct a risk assessment and zone classification, and when an update is mandatory after technological changes.
ATEX Employee Training
Effective safety starts with people. We describe the ATEX training programme for operators, maintenance staff and supervisory personnel: from ignition sources, through the rules for working in EX zones, to appropriate responses in emergency situations.
ATEX Audits/Assessments of Machines and Installations
An ATEX audit allows a quick check of whether machines and installations are safe and compliant with requirements. We show how equipment selection, markings and certificates are verified, and what corrective actions are worth implementing first.
Verification of Electrical Installations in Explosive Atmospheres (EN 60079-14)
In EX zones, electrical installations must be flawless. We explain how verification is carried out in accordance with EN 60079-14: from checking documentation and equipment selection, through execution assessment, to a final report with a concrete list of corrective actions.
ATEX Support for Machine and Installation Construction and Modernization
The cheapest corrections are those that don’t need to be made after commissioning. That is why we support the investor from the design and modernization stage: from concept analysis and zone classification to equipment and protection selection, avoiding costly last-minute changes.
Who is this offer for?
For manufacturing and process plants using flammable gases, flammable liquid vapors, combustible dusts or oil mists, as well as for companies planning line expansions, machine modernizations or inspection preparation. Services can be delivered individually (e.g., an audit) or as a phased machine safety improvement programme.
How we work
- Process recognition and data collection.
- Risk assessment and hazard classification.
- Selection of technical and organizational measures.
- Preparation of documentation and implementation recommendations.
- Support during implementation, training and updates.
Machine safety is not a single document, but a continuous process of maintaining compliance and reducing risk. By combining analyses, audits, verification and training, you can effectively raise the level of safety and operational stability of your facility.
CHECK IF YOUR MACHINES AND EQUIPMENT ARE SAFE!
Our machine safety experts will be happy to advise you on the following matters.
| No. | Machines / Services | Legal Basis | Comment |
| 1 | Audit – MINIMUM requirements | Tool Directive 2009/14/EC | Every machine used in Poland before EU accession (1 May 2004) had to be adapted to minimum requirements. |
| 2 | Audit – ESSENTIAL requirements | Machinery Directive 2006/42/EC | All newly built machines in Poland or imported from outside the EU must comply with essential requirements. |
| 3 | Audit – electrical equipment | Low Voltage Directive 2014/35/EU | All electrical equipment on all machines must comply with the Low Voltage Directive. |
| 4 | Audit – machine fire safety | EN ISO 19353 | Machines presenting a fire hazard must be protected in accordance with standard 19353. The audit also verifies whether the machine presents a fire risk under applicable regulations. |
| 5 | Audit – ATEX explosion safety (Explosion Hazard Assessment) | 1999/92/EC | All machines in use containing explosive liquids (gases) or dusts must have an Explosion Hazard Assessment. |
| 6 | EPD – Explosion Protection Document | Journal of Laws 2010 No. 138, item 931 | The operator of a machine in which an explosive atmosphere may occur is obliged to have an EPD. |
| 7 | Machine risk assessment | EN 12100 | Every newly built machine or one imported from outside the EU must have a risk assessment in accordance with standard 12100. |
| 8 | HAZOP Analysis | EN IEC 61882 | This is a functional safety analysis of machines and installations. |
| 9 | Control system analysis (SIL/PL) | EN ISO 13849-1 and 2 | When designing new safety systems (E-stops, light curtains, safety limit switches), a safety system analysis must be conducted to verify whether the designed electrical, pneumatic and hydraulic systems are correctly implemented. |
| 10 | Machine ergonomics analysis | EN 614-1 | We conduct analysis of operator work at machines. |
| 11 | Training – machine safety | Machinery Directive, Low Voltage Directive, ATEX | We conduct machine safety training – most often for design engineers, automation engineers and maintenance staff. |
| 12 | CE certification – consulting | Machinery Directive 2006/42/EC | We advise companies building new machines or electrical panels. |
| 13 | Machine electrical measurements | EN 60204-1 | We carry out measurements in accordance with standard 60204-1 during construction of new machines or their modifications. |
| 14 | ESD measurements – electrostatics | EN ISO 61340-5-1 | We conduct ESD measurements – explosion hazard zones must have ESD measurements carried out. |
| 15 | Development of machine operating instructions | EN ISO 20607 | We develop operating instructions – every machine must have operating instructions in accordance with standard 20607. |
| 16 | Machine modernizations | PIP (National Labour Inspectorate) | We carry out machine modernizations after audits or inspections by external authorities. |
| 17 | Technical opinions on machine-related accidents | Court Expert, specialization: Machine Safety | |
| 18 | Fire protection inspections – GAZEX / FPS / Hydrants / Fire Tanks | We carry out inspections: GAZEX – gas concentration sensors every 3 months. FPS – fire power switches every year. Hydrants – every year. |
If you are also interested in other valuable training courses, contact us! Safe use of diisocyanates, fire protection and much more with EHS Consulting.
Quick response!
What are the current machine safety regulations in Poland?
Machine safety in Poland is governed by two parallel pillars of regulations.
The first concerns the placing of machinery on the market and is based on the Regulation of the Minister of Economy of 21 October 2008 on essential requirements for machinery (Journal of Laws 2008 No. 199, item 1228), implementing the Machinery Directive 2006/42/EC — the manufacturer must carry out a risk assessment, prepare technical documentation, provide instructions in the relevant language, issue an EU declaration of conformity and mark the product with the CE marking, and conformity is most often demonstrated by applying harmonized standards such as PN-EN ISO 12100 (risk assessment), PN-EN ISO 13849-1 and PN-EN IEC 62061 (safety-related control systems), PN-EN 60204-1 (electrical equipment) and type C standards for specific groups of machines.
The second pillar covers the use of machines already present in the workplace — it is governed by the Regulation of the Minister of Economy of 30 October 2002 on minimum OHS requirements for the use of machinery by employees at work (Journal of Laws 2002 No. 191, item 1596, as amended), implementing Directive 2009/104/EC, and the provisions of the Labour Code (in particular Art. 215-219), which impose on the employer the obligation to provide only machines that meet minimum requirements, their periodic inspections and maintenance, and operator training. Market surveillance for products subject to conformity assessment is carried out under the Act of 13 April 2016 on conformity assessment and market surveillance systems. The most important upcoming change is Regulation (EU) 2023/1230 of the European Parliament and of the Council, which from 20 January 2027 will replace the current Machinery Directive — it applies directly (without transposition), permits documentation and instructions in digital form, introduces requirements for cybersecurity and machines incorporating artificial intelligence and self-learning control systems, and also expands the list of high-risk machinery for which a conformity assessment involving a notified body will be mandatory. The above is a summary overview — in a specific case, it is worth consulting the full text of the regulations or seeking legal advice (I am not a lawyer).