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Testing of Industrial Machinery

 Testing and Evaluation of Industrial Machinery | TÜV Rheinland

Optimize the Operational Safety and Efficiency of Your Industrial Machinery

Reliability and safety are the most important requirements for industrial machinery to ensure smooth manufacturing processes. With our comprehensive service portfolio for industrial machinery, you create the best conditions for the conformity and safe operation of your equipment in accordance with national and international regulations. As part of the machine assessment, risk potentials are identified early on and downtime rates are reduced. The internationally recognized reports and approvals provided by our independent experts enable you to demonstrate your commitment to a safe working environment and to high quality standards.

This firm commitment to safety, quality and sustainability gives you an enormous advantage over your competitors. Contact our experts to discuss your specific requirements.

Experience the Benefits of an Expert Machinery Inspection

We test industrial machinery thereby contributing to the reduction of defects and liability risks.
We test industrial machinery thereby contributing to the reduction of defects and liability risks.

Benefit from the advantages of an independent certificate upon successfully completing the test. With a globally recognized certification, you document compliance with safety standards, reduce your liability risk, and offer your customers a valuable tool for decision-making when selecting a product.

By testing your industrial machinery, you can internally identify mistakes during development at an early stage and avoid risks, costs, and malfunctions.

We conduct our machinery assessment according to international norms and standards – from the EU Machinery Directive 2006/42/EC for the European Economic Area to the OSHA Directive 29 CFR 1910 for the USA. We keep track of the ever-changing safety regulations for new, operating, and modified machinery at the local and the global level and ensure the conformity of your machinery.

Our Services for Testing and Evaluating Industrial Machinery

Our experts reliably test and evaluate your industrial machinery. Thus, you can be sure that your machines meet highest quality and safety standards. We support you with the following services:

  • Ensuring conformity with EU Machinery Directive 2006/42/EC and with Machinery Regulation (EU) 2023/1230
  • Services for machines with increased risk potential
  • Consumption measurement for industrial machinery
  • Customized solutions for improved machine safety
  • Machine testing for international markets and Market Access Services for easier access to new markets abroad
  • Services to cyber security

Conformity with the EU Machinery Directive 2006/42/EC

We test industrial machinery to help reducing errors and liability risks. | TÜV Rheinland
Product examples for industrial machinery testing

Our machinery assessments are based on EU directives and standards such as the following, and include:

  • EC type examinations for machinery according to Annex IV of the European Machinery Directive as a “Notified Body”
  • Conformity assessment for products within the scope of Machinery Directive

Technical testing in accordance with the German Ordinance on Industrial Safety and Health, including the following details:

  • Quick check for safe operation including documentation review
  • Comprehensive analysis with consideration of all risk areas (explosion, cyber security, pressure, etc.)
  • State-of-the-art safety analysis as requested by the customer

Conformity with the Machinery Regulation EU 2023/1230

The European Machinery Regulation was published on June 14, 2023 and will replace the current Machinery Directive 2006/42/EC from January 20, 2027. Starting from this date, the CE marking of machinery or assessment of partly completed machinery is only possible according to the Machinery Regulation EU 2023/1230. The Machinery Regulation specifies a 42-month transition period. All machinery placed on the market or put into service before January 20, 2027 must still be CE-marked in accordance with the Machinery Directive 2006/42/EC.

Manufacturers of industrial machinery should prepare for the new requirements in advance. Take advantage of the transition period to adapt your machines to the Machinery Regulation EU 2023/1230. TÜV Rheinland will be happy to test your current machines in accordance with the essential health and safety requirements of Annex III. Or have Annex III of the Machinery Regulation tested as an option for new machine developments.

Testing of Digitalization in Accordance with EU 2023/1230

While about 90 percent of the Machinery Regulation EU 2023/1230 is in line with the Machinery Directive 2006/42/EC, the remaining ten percent of the regulation focuses on digitalization and connectivity. This covers aspects of artificial intelligence (AI) as well as cyber security and the connection of devices to the internet (IoT). In other words, the regulation is adapting to the current state of technology. For manufacturers, this means additional processes that include thorough testing of the machines.

This is where a reliable partner like TÜV Rheinland is needed, because we are already dealing with the new requirements. If you as a manufacturer want to launch your machine in 2027, you need a service provider able to check the listed test standards before 2027 – like TÜV Rheinland.

We will be happy to provide you with advice and assistance in checking the documents submitted for cyber security for plausibility. If there are any irregularities or if the documents are incomplete or inconclusive, our experts will examine them in detail and help you with improvements.

While about 90 percent of the Machinery Regulation EU 2023/1230 is in line with the Machinery Directive 2006/42/EC, the remaining ten percent of the regulation focuses on digitalization and connectivity. This covers aspects of artificial intelligence (AI) as well as cyber security and the connection of devices to the internet (IoT). In other words, the regulation is adapting to the current state of technology. For manufacturers, this means additional processes that include thorough testing of the machines. This is where a reliable partner like TÜV Rheinland is needed, because we are already dealing with the new requirements. If you as a manufacturer want to launch your machine in 2027, you need a service provider able to check the listed test standards before 2027 – like TÜV Rheinland. We will be happy to provide you with advice and assistance in checking the documents submitted for cyber security for plausibility. If there are any irregularities or if the documents are incomplete or inconclusive, our experts will examine them in detail and help you with improvements.

Our Services for Machines

The operation of machines with a considerable risk potential necessitates increased safety requirements.

We provide you with a wide range of services:

  • Safety assessment of work equipment (in accordance with the German Ordinance on Industrial Safety and Health, international regulations, the requirements of statutory accident insurance companies and the requests of the operator)
  • Preparation of safety analyses on the current state of technology & assessment of machinery in compliance with the current state of technology
  • Coordination of the results with the client and collective determination of any measures

Consumption Measurement for Industrial Machines

TÜV Rheinland carries out energy consumption measurements on industrial machines according to many factors.
TÜV Rheinland carries out energy consumption measurements on industrial machines according to many factors.

For many of our customers, the energy consumption of an industrial machine is an important factor when making a purchase decision. This is because companies are increasingly focusing on sustainability and the economic benefits of an energy-efficient machine. In the future, the energy consumption of industrial machines will therefore become even more relevant when deciding whether to buy a machine.

However, the energy consumption is not just information you can pass on to customers. Knowing the consumption is also important for you as a manufacturer of industrial machinery. This allows you to modify the design of your machines to minimize energy consumption.

TÜV Rheinland can support you in measuring the energy consumption of your machines. Since consumption does not only consist of electrical energy, our experts will measure and evaluate all other relevant aspects for you:

  • Electrical power
  • Pneumatic power
  • Process cooling water
  • Provision of vacuum
  • Supply of water and nitrogen
  • Energy consumption due to exhaust air

In the evaluation, we list all these energy aspects. If a factor does not apply to your machine, it is rated as zero.

But how do the different energies become comparable? The answer lies in a calculation method introduced by experts from the semiconductor industry (see SEMI standard S23). With this method, the listed energy values can be related to electrical energy using conversion factors. Consequently, the energy contributions can ultimately be compared and added.

Moreover, our experts use a model that makes the operating times of industrial machines comparable. Prior to the evaluation, the operating, standby and pause modes are defined to then be included in the consumption evaluation.

The result is an annual energy consumption figure. Until now, the figure has only been used in the semiconductor industry and is not yet common in other sectors. However, it can also be transferred to industrial machines in further sectors. For maximum transparency in terms of energy consumption, we can support you with reliable calculations.

Customized Solutions for More Machine Safety

We offer you a testing portfolio customized to your company and your machinery, including services such as:

  • Safety testing based on German, European and global standards and regulations
  • Testing according to the specifications of the international SEMI association: SEMI S2 (general safety), SEMI S8 (ergonomics), SEMI S23 (sustainability) and SEMI F47 (voltage sag immunity)
  • Testing of ergonomics, ease of use and service
  • On-site or laboratory electromagnetic compatibility (EMC) testing
  • Testing of the functional safety of your machine control system
  • Safety assessments during commissioning of machines and assessment of consumption figures
  • Support in the preparation of risk analyses and risk assessments as well as hazard assessments
  • Support with interim tests for new products and product modifications
  • Quality assurance during construction (e.g., review of construction drawings and circuit diagrams or quality control of the production before shipment)
  • (In-house) training

Market Access Services and Machinery Testing for International Markets

Global trade has enormous growth potential for companies. This means that markets outside the European Union are becoming increasingly attractive. However, international markets have specific demands on products and companies and require different documents and certificates for the approval of machinery.

Thanks to our extensive experience in this field, we keep an overview, manage the process for you and support you in word and deed. As a globally recognized and authorized testing body (NoBo, NRTL, CB, etc.) for impartial approvals, we support you in firmly establishing yourself in the industry. Your needs are important to us. Thus, our experts pay close attention to the unique requirements of your specific situation. We will prepare your quotation while considering your target markets as well as the applicable regulations.

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United Kingdom

UKCA – your access to the UK. Now that the UK has left the EU, the regulations for product approval and labeling requirements are changing if you want to bring a product to the market in the UK. With the Brexit process complete, manufacturers and exporters are now confronted with the question of what requirements they will be facing.

Manufacturers are obliged to provide UKCA marking for machines in the UK. The transition period of the CE marking has already been extended several times and is valid indefinitely beyond 2024. It is currently unclear how long the CE marking of machinery in the UK will remain valid. TÜV Rheinland is listed as a "Designated Body" by the authorities in the UK and can support you with the UKCA marking.

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Saudi Arabia

Saudi Arabia is a very attractive market for European machinery manufacturers. Before April 1, 2018, a shipping certificate was sufficient to import products into Saudi Arabia. However, since then, a completely new system has been introduced: the SALEEM program, and new technical regulations have come into force.

You may export goods to Saudi Arabia only if your products meet the criteria specified in these regulations and if you can prove compliance with a certificate recognized by the Saudi Standards, Metrology and Quality Organization (SASO). This proof must be presented to the customs authorities upon import. TÜV Rheinland can support you with entering the market. We test your machinery according to Saudi Arabian requirements and can issue the certificate of conformity for the product and the shipment.

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USA and Canada

The governments of the USA and Canada established clearly defined regulations that machines must meet before they can be put into operation for commercial or industrial use. These products are subject to mandatory testing and certification by an independent testing organization approved in the respective country. As a Nationally Recognized Testing Laboratory (NRTL), the services provided by TÜV Rheinland can help get your industrial machinery to market faster.

Depending on the application, we offer the right services for you:

  • Field Evaluation Services for customized machines according to NFPA 791, NFPA 79 and SPE 1000
  • cTUVus certification according to UL and CSA standards
  • LPC (Limited Production Certification) for small series of machines
  • Control Panel Shop Program to certify manufacturers of control panels according to UL508A and NFPA 79

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Brazil

We support manufacturers in their conformity assessment with our safety assessment of machines in accordance with NR 12 (machine safety). The specified technical instructions, principles and protective measures of NR 12 are intended to ensure the health and physical integrity of workers. NR 12 defines the minimum requirements for the prevention of accidents and occupational diseases in the phases of construction, manufacture, import, marketing, exhibition and movement of machinery and equipment. In addition, we test your machines according to IEC 60204-1, a standard that typically covers the electrical requirements for manufacturers of machines according to NR 10.

South Korea

The Korean Occupational Safety and Health Administration (KOSHA) and the National Radio Research Agency have standardized the approval procedure under a Korean law. Only products that have been tested by an internationally accredited testing body (registered with the above-mentioned authorities) and that carry the KC (RRA) and KCs mark may be placed on the Korean market.

TÜV Rheinland supports you with the Korean approval procedures, specifically with the mandatory KC (RRA) (EMC for industrial equipment) and KCs (EMC and safety for high-risk machinery) approvals and the voluntary KOSHA S-Mark for machinery.

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Australia/New Zealand

In Australia and New Zealand, manufacturers are required by occupational health and safety legislation to design and manufacture machines in such a way that they do not pose any risks to the health and safety of the user. These standards regulate different safety-relevant aspects.

Although testing of the standards is not mandatory for export, proof and compliance are required by the market and the respective industry. TÜV Rheinland tests your machines according to Australian and New Zealand standards from the AS/NSZ 4024.xxx series of standards.

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Extensive Operational Security is no Longer Possible Without Cyber Security

Technical systems that are particularly hazardous when it comes to steam, pressure, falling, fire or explosion must already be inspected regularly. In the future, they will also have to be tested for cyber security as well as functional safety. Find out which legal changes are expected.

Your Valued Partner

When testing your industrial machinery, we emphasize the importance of a smooth process. As a "Notified Body", accredited testing laboratory, inspection body and recognized certification body, we are a reliable partner for testing your machinery. Of course, we also offer our experience and expertise for on-site testing at your facility.

For your convenience, we have optimized the process and reduced it to just two simple steps. First, we prepare a quotation based on the documentation you provide about machinery and target markets. In the second step, we perform all the required tests and issue either a certification (positive assessment) or a comprehensive report detailing any open issues, based on which the necessary modifications can be made (negative assessment).

Regardless, our experts are available to answer questions at any point during the testing phase. Contact us if you are interested in an initial review of a similar machine, or in reviews of circuit diagrams or other documents.

Make an appointment with our experts now! Together we will find the right services for you.

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Downloads

pdf Flyer: Conformity with the new Machinery Regulation EU 2023/1230 471 KB Download
pdf Export machines worldwide 1 MB Download

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