Fachbereich AKTUELL

FBRCI-002

Sachgebiet Maschinen der chemischen Industrie

Checklist – Roll Mills in the Rubber and Plastics In-

dustry (Roller Diameter D ≥ 400 mm)

As of: 18/10/2018

Field of Application safety (EmpfBS [Recommendation on operation-

al safety] 1114 of March 2018) of the Federal
This checklist can be used subject to the follow-
Ministry of Labour and Social Affairs (BMAS), is
ing conditions:
also taken into account.
• It is a roll mill with a roller diameter of
≥ 400 mm with 2 horizontally arranged rollers Note: When carrying out risk assessments in
(see Fig. 3). accordance with Section 3(7) of the Ordinance
• The roll mill was placed on the market in on Industrial Safety and Health, it must be taken
accordance with the standard DIN EN into account that the state of the art must be
1417:2015-03 "Plastics and rubber machines applied to the measures to be taken. The current
– Two roll mills – Safety requirements” version of the European harmonised standard for
roll mills (DIN EN 1417) was published in Ger-
Note: In individual cases, safety requirements are
many in March 2015. This makes it necessary to
specified that deviate from the standard but
reassess the measures taken so far as part of
which have proven themselves in practice and
the risk assessment.
are recommended by the Sachgebiet Maschi-
nen der chemischen Industrie (hereinafter re-
A generally accessible current overview of the
ferred to as SG).
standards can be viewed at:

http://eur-
Instructions for Using the lex.europa.eu/LexUriServ/LexUriServ.do?uri=OJ:
C:2012:087:0001:0055:DE:PDF
Checklist
The checklist only deals with the safety require- Other Checklists
ments for the roll mill. The environment of the Safety requirements for electrical, hydraulic and
machine, interactions with other machines, etc. pneumatic equipment are not covered by this
and additional company-specific measures (e.g. checklist. It is therefore recommended to use the
instruction of employees) are not dealt with. corresponding BG RCI (Staturory Accident Insur-
ance for the Raw Materials and Chemical Indus-
The checklist can be used when the manufactur- try) checklists for DGUV (German Statutory Acci-
er hands a new machine over to the operator or dent Insurance Association) Information 213-054
as part of the risk assessment. By differentiating for these areas:
the requirements according to the year of manu- • For the electrical system T 008-3
facture of the machine, the fact is taken into
• For the hydraulic system T 008-4
account to what extent an adaptation to the state
of the art is required.. In doing so, the "propor- • For the pneumatic system T 008-5
tionality", as stated in the recommendation on • For other protective devices T 008-1A
operational
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Fachbereich AKTUELL FBRCI-002

(Shift rod)

Drip pan

Rear side Tending side

a Shift rod height

Legend
b Horizontal distance between intake gap and shift rod
A Shift rod
in switching position
B Complementary separating protective equipment
c Distance between shift rod and roller
C Electro-sensitive protective equipment (ESPE)
d Horizontal distance between shift rod and drip pan

Fig. 1: Dimensions for shift rod arrangement according to DIN EN 1417:2015-03

Shift rod
(height adjustable)
Actuation force:
100 to 200N

Drip pan

Rear side Operating side

Fig. 2: Mounting of the shift rod deviating from the standard DIN EN 1417:2015-03
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Fachbereich AKTUELL FBRCI-002

Fig. 3: Operating side of a roll mill with shift bar at 1400 mm height

This roll mill is not safe

for persons who can
reach beyond the
marked safety limits
without tipping the
shift rod.

Fig. 4: Manipulation easily possible by clamping the shift rod

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Fachbereich AKTUELL FBRCI-002

Fig. 5: Incorrectly mounted position switches for monitoring the shift rods
• Spring fracture makes both switches ineffective
• Similar actuation of the switches (both are actuated)
• No forced actuation of a switch

Fig. 6: Correct actuation of the position switches, different in principle

• The right switch is positively actuated
• The left switch actuates its contact through the inner spring
4/5
Fachbereich AKTUELL FBRCI-002

Picture credits:
The images used in this DGUV Information of the FB RCI (Department of Raw Materials and Chemical
Industry) are for illustration purposes only. A product recommendation on the part of the DGUV is ex-
pressly not intended.

The pictures shown here were kindly provided by:

Fig. 1: Principle picture created by Sachgebiet Maschinen der chemischen Industrie

Fig. 2: Schematic created by Sachgebiet Maschinen der chemischen Industrie
Fig. 3: Westland Gummiwerke GmbH & Co. KG, Melle
Fig. 4: Westland Gummiwerke GmbH & Co. KG, Melle
Fig. 5: Westland Gummiwerke GmbH & Co. KG, Melle
Fig. 6: Maschinenbau und Konstruktion GmbH Schwerin

Annexes
Checklist
Report on the checklist

Publisher

Deutsche Gesetzliche
Unfallversicherung e.V. (DGUV)

Glinkastraße 40
10117 Berlin
Phone: +49 (0)30 13001-0 (switchboard)
Fax: +49 (0)30 13001-6132
Email: [email protected]
Internet: www.dguv.de

Sachgebiet „Maschinen der chemischen Industrie“

im Fachbereich „Rohstoffe und chemische Industrie“ der DGUV
Section of Machinery of the Chemical Industry
in the Department "Raw Materials and Chemical Industry”
of the DGUV (German Statutory Accident Insurance Association) > www.dguv.de
We have contributed to the development of this short information sheet of the DGUV:
● Berufsgenossenschaft Rohstoffe und chemische Industrie; ● Berufsgenossenschaft Holz und Metall; ● Verwaltungs-
Berufsgenossenschaft; ● Deutsches Institut für Normung; ● Verband Deutscher Maschinen- und Anlagenbau; ● Wirtschaftsverband der
deutschen Kautschukindustrie e. V.; ● ADT-Zielke GmbH & Co. KG; ● BASF;
● Bayer AG; ● Continental AG; ● Currenta GmbH & Co. OHG; ● DEGUMA-SCHÜTZ GmbH; ● Harburg-Freudenberg Maschinenbau GmbH;
● Klöckner Pentaplast GmbH; ● Reifenhäuser Group; ● Servitec Maschinenservice GmbH; ● Vibracoustic GmbH

Order number: YXYXYX

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Protective devices for the roller nip and the stockblender
Year of Manufacture Notes / Explanations / Alternatives
No. Source Requirement before from Assessment/result
03/2015 03/2015 (X) means that deviations from the requirement are considered permissible, which are described here.

1 DIN EN 1417- Attachment of shift rods Note: DIN EN 1417 also mentions separating protective equipment for
2015 on the operating side to the intake gap. As these are almost always unsuitable for working on
5.2.2.1 trigger safety functions the machine, they are not dealt with in this checklist.
EMERGENCY STOP ripcords are not sufficient as sole protective
measures.
Protective equipment is also required at the rear of the roll mill. In
addition to the shift rod, interlocked separating protective equipment
may also be considered here in exceptional cases.
If, in individual cases, a stooped working position is adopted and the
protection objectives are no longer achieved, alternative protective
devices are required (e.g. horizontal electro-sensitive protective
equipment = ESPE).

a) Is there a shift rod on the

X X a) The elevated installation of used roll mills to reach the minimum
operating side over the
entire width of the roll mill? height need only be carried out if no further elaborate modifications to
the roll mill or adjacent machinery (e.g. relocation of internal mixers)
are necessary. Below 1150 mm, however, the height of the top edge
Is the height of the top edge of the rollers must be adjusted to the footprint.
of the roller at least 1300 (X) X
mm?
b) Is the shift rod fixed at a b) According to DIN EN 1417, the shift rod must be fixed at 1250 ± 50
height of 1250 mm? (X) (X) mm. To enable ergonomic body postures or to take process-related
constraints into account, the rod may be fixed at a height ranging from
1150 mm to 1400 mm or it may be height adjustable in this range. In
justified exceptional cases (e.g. for strip discharge) the shift rod may
be arranged at the height range between 900 mm and 1150 mm.

Roll mills checklist D ≥ 400 mm As of: 10/2018 A1

 Year of Manufacture Notes / Explanations / Alternatives
No. Source Requirement before from Assessment/result
03/2015 03/2015 (X) means that deviations from the requirement are considered permissible, which are described here.
c) Is the release force a c) In the case of height-adjustable shift rods or fixed mounting heights
maximum of 200 N? X X deviating from DIN EN 1417, the release force shall not exceed the
following limits:
Note: The maximum - maximum 150 N in the bottom end position (1150 mm)
release value of 200 N as - maximum 100 N in the top end position (1400 mm)
defined in DIN EN 1417 - maximum 100 N between 900 mm and 1150 mm
should only be used in - intermediate values can be interpolated linearly
justified exceptional cases
(e. g. frequent false The lowest value must be fixed in height-adjustable shift rods.
tripping). A maximum
release force of 150 N has It shall only be possible to adjust the release force using tools.
proven to be ideal.

d) Does the horizontal d) A distance of at least 850 mm must be maintained in roll mills
distance between the shift (X) X manufactured before 03/2015 (dimension "b" in Fig. 1).
rod and the intake point
correspond at least to the
result of the calculation
equation for the dimension
"b" in Fig. 1?

Rear of the roll mill

2 DIN EN 1417-
2015 Are protective devices
5.2.1.1 provided at the rear of the X X Protective devices are always required at the rear. Preferably, shift
roll mill? rods should be used here as well. (see notes under No. 1)

Roll mills checklist D ≥ 400 mm As of: 10/2018 A2

 Year of Manufacture Notes / Explanations / Alternatives
No. Source Requirement before from Assessment/result
03/2015 03/2015 (X) means that deviations from the requirement are considered permissible, which are described here.
Other requirements for
3 DIN EN 1417- the shift rod:
2015 5.2.2.1.4 a) Does it respond in both a) The movement of the shift rod away from the roll mill serves to
directions, away from the protect persons who have come in between the rod and the roller.
roll mill (towards the X X
operator) and towards the If frequent false tripping occurs, the additional measure described in
roll mill? No. 13 should be implemented.
b) Is it difficult to
b) It must not be possible to block it, for example, by wooden wedges
manipulate? X X
(see Fig. 4).

Safety functions of the

4 DIN EN 1417- shift rod
2015 a) Braking of the rollers: (a) The braking angle is determined at maximum speed without
5.2.2.1.5 Is the braking angle less material. The standard only requires a braking angle < 60 ° for new roll
and (X) X
than 45 ° mills. This value does not correspond to the state of the art. 45 ° can
5.2.2.1.6 easily be achieved.
and is this value maintained In roll mills manufactured before 03/2015, the braking angle may not
even when a power failure exceed 60 °.
occurs? In roll mills manufactured before 1995, a braking angle of 90 ° is
considered sufficient if the following conditions are met:
- Release force for the shift rod < 100 N
- Shift rod height between 1250 mm and 1400 mm
- Top edge of the rollers > 1500 mm
- Roller diameter > 600 mm
b) Spreading of the b) Spreading is always required in addition to braking the rollers and
rollers: (X) X can usually only be achieved within 5 seconds with hydraulic drives. If
Does the spreading take automatic reversing takes place, a light barrier must be provided in the
place to a minimum gap lower area (see Fig. 1), which stops the reversing process if
width of 50 mm within 5 interrupted.
seconds? Roll mills manufactured before 03/2015:
Retrofitting the spreader is necessary in cases where a hydraulic roller
gap adjustment is already available. Retrofitting in the absence of a
hydraulic roller gap adjustment is considered disproportionate. In this
case, retrofitting according to No. 7 and No. 8 must be carried out.

Roll mills checklist D ≥ 400 mm As of: 10/2018 A3

 Year of Manufacture Notes / Explanations / Alternatives
No. Source Requirement before from Assessment/result
03/2015 03/2015 (X) means that deviations from the requirement are considered permissible, which are described here.
c) Are the movements of c) These include:
stockblenders interrupted? X Guide carriages and the rollers of the stockblender
Note: The pressure roller of the stockblender should be opened.

d) Are the stockblender d) When determining the distance, the dimensions set out in DIN EN
rollers positioned so high X 13857:2008 must be used as basis.
that they cannot be reached
without the shift rod being
tripped?

5 DIN EN 1417- Measuring system for the The measuring system must have the following properties:
2015 braking angle - Automatic measurement at least once a week
5.2.2.1.2 Is there an automatic X - Measurement of the castor angle
measuring device to check - Blocking the roll mill drive by the controller if the angle is too large
the braking angle? The measuring device must be checked every 4 years.

What to do in case of a
6 DIN EN 1417- power failure
2015 a) Is the castor angle
5.2.1.2 maintained even in the Note:
X X
and event of a power failure? For roll mills manufactured before 03/2015, the tool for manually
5.2.2.1.5 opening the roller gap must be kept in the immediate vicinity to the roll
b) Do the rollers continue to
X mill.
spread apart?

Roll mills checklist D ≥ 400 mm As of: 10/2018 A4

 Year of Manufacture Notes / Explanations / Alternatives
No. Source Requirement before from Assessment/result
03/2015 03/2015 (X) means that deviations from the requirement are considered permissible, which are described here.

Rescuing people in an Organisational: Carry out appropriate rescue exercises. Keep

7 emergency ratchet, wedges and insulating blanket ready near the roll mill. This
Is a device available with applies to all roll mills.
which the rollers can be X Note: The requirement (manual spreading) does not need to be
moved apart manually? implemented for roll mills manufactured after 03/2015, as spreading
must also be automatic when there is a power failure (DIN EN
1417:2015, 5.2.1.5).

Reversing in distance- Note: This functionserves to quickly free people. After triggering the
8 limited jog mode shift rod and/or actuating the emergency stop, only reversing in
distance-limited jog mode must be possible. The roller movement
Is it possible to reverse the must be switched off automatically as soon as 45 ° is reached. A
rollers in distance-limited further rotation of 45 ° is permissible, but must again be manually
X
jog mode? initiated by the operator.
The reversing function is not required for roll mills manufactured after
03/2015, as two safety functions (braking and spreading) are
automatically triggered.

Exception: This requirement may only be deviated from if the

retrofitting is considered disproportionate. This may be the case, for
example, in medium and high voltage drives. It is assumed here that
the requirements from No. 1 - 7 are met.

Roll mills checklist D ≥ 400 mm As of: 10/2018 A5

Technical control-related requirements
Year of Manufacture Notes / Explanations / Alternatives
No. Source Requirement before from Assessment/result
03/2015 03/2015 (X) means that deviations from the requirement are considered permissible, which are described here.

Signals of the shift rod

9 DIN EN 1417-
2015 5.2.2.1.4 Is there at least one It is necessary to ensure that two independent signals are emitted
position switch at each end X X regardless of where the shift rod is actuated.
of the shift rod? The switches must be actuated on different principles (see Fig. 6).
As a rule, two position switches at each end of the shift rods are
required, as it cannot be ensured that both sides are deflected at all
actuation points of the rod.
(Exception: The shift rod is mounted in a way that it can be rotated
and controls the switches via a lever arm).

Roll mills checklist D ≥ 400 mm As of: 10/2018 A6

 Year of Manufacture Notes / Explanations / Alternatives
No. Source Requirement before from Assessment/result
03/2015 03/2015 (X) means that deviations from the requirement are considered permissible, which are described here.

Dual-channel capability
10 DIN EN 1417-
2015 5.2.2.1.4 Doesn't a fault in the As per DIN EN 13849-1, the safety function "braking of the rollers"
controller cause the failure (X) X must correspond to PLr = d with Cat. 3 in roll mills manufactured from
of the protective functions 2015. Two independent braking systems are mandatory. Deviating
of the shift rod with regard from DIN EN 1417, they can also consist of an electronic braking
to braking the rollers? system and a spring-loaded mechanical brake.

For roll mills manufactured before 2015, dual-channel capability is

limited to signal processing. It is sufficient to have a brake designed
according to proven principles. A single electronic brake is not
sufficient.
The proven principles include in particular:
- Closed-circuit current principle
- Sufficient braking effect even after spring fracture
- High level of stability (after three braking operations in quick
succession, the braking angle must still be maintained)
Further criteria can be found in the comments of the Institute for
Occupational Safety.

Exception: If old drives are replaced when retrofitting the drive

technology (e.g. energy saving), it is required to retrofit a dual-channel
braking system as described above for roll mills manufactured from
2015.

Note: DIN EN 1417 is not clearly formulated with regard to electronic

braking systems. The maximum castor angle must be maintained
even if the electronic braking system fails.

Roll mills checklist D ≥ 400 mm As of: 10/2018 A7

Strip-cutting equipment
Year of Manufacture Notes / Explanations / Alternatives
No. Source Requirement before from Assessment/result
03/2015 03/2015 (X) means that deviations from the requirement are considered permissible, which are described here.

Power-operated knife
11 DIN EN 1417-
2015 movements
5.2.1 Are protective devices
provided for the knives
swivelling in and out?

a) Are both hands required Note: The requirement in No. 11 a) is not very practical. It is unclear
for manual swivelling in and how this requirement can be implemented.
out?

b) For power-operated b)
swivelling in and out with - The two-hand control must correspond to type I according to DIN EN
two-hand control or in jog 574.
mode with a distance of 2 X X - The jog button control must be made of reliable tried and tested
m to the danger point components. The controller must not take over the swivelling
movement until at least 4 mm in front of the roller surface (self-
restraint principle).

Roll mills checklist D ≥ 400 mm As of: 10/2018 A8

Additional measures to increase safety
- Note: These devices are not dealt with in DIN EN 1417-2015! -
Year of Manufacture Notes / Explanations / Alternatives
No. Source Requirement before from Assessment/result
03/2015 03/2015 (X) means that deviations from the requirement are considered permissible, which are described here.

12 If an internal mixer is
positioned above the roll
mill

Is there a swivel-mounted It is recommended to install such systems if experience shows that

camera/monitor system to caking occurs frequently. This usually makes it unnecessary to climb
check whether the internal (X) (X) onto the roll mill to check the internal mixer.
mixer contains caked
materials? Note: Additional lighting must be provided to light up the internal
mixer.

13 Is it possible to operate the It is recommended that this device be provided if experience shows
roll mill at reduced speed (X) (X) that false tripping of the shift rod frequently occurs when stiff mixtures
for a limited period of time are processed. With reduced speed, it is often possible to significantly
to avoid false tripping of the reduce false tripping by manually guiding the mixture, thus avoiding
shift rod? incentives for manipulation.
The system should be easy to operate. For example, pressing a
pushbutton once triggers a reduction in speed for a limited time. The
usual processing speed is automatically reset by the controller after a
time interval has elapsed.

Roll mills checklist D ≥ 400 mm As of: 10/2018 A9

 Report on the checklist

Updating the risk assessment (adapting to the state of the art)

Part of the acceptance report between manufacturer and operator (first inspection)

Machine type: Year of manufacture:

Manufacturer: Date/place of the inspection:

Name of the examiner(s):

The assessment was based on the following checklists

for roll mills for hydraulic system T008-4

for electrical system T008-3 for pneumatic system T008-5

Summary assessment of the results of the inspection:

the machine has minor defects, start-up/continued operation can take place

the machine has major defects, start-up/continued operation can only take place after the defects have been rectified

Manufacturer's signature Operator’s signature

Roll mills checklist D ≥ 400 mm As of: 10/2018