EN 1010-4:2004

SLOVENSKI STANDARD
01-september-2004
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Safety of machinery - Safety requirements for the design and construction of printing and
paper converting machines - Part 4: Bookbinding, paper converting and finishing
machines
Sicherheit von Maschinen - Sicherheitsanforderungen an Konstruktion und Bau von
Druck- und Papierverarbeitungsmaschinen - Teil 4: Buchbinderei, Papierverarbeitungs-
und Papierveredelungsmaschinen
Sécurité des machines - Exigences de sécurité pour la conception et la construction de
machines d'impressions et de tranformation du papier - Partie 4: Machines a relier les
livresmachines de transformation et de finition du papier
Ta slovenski standard je istoveten z: EN 1010-4:2004
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 1010-4
NORME EUROPÉENNE
EUROPÄISCHE NORM
January 2004
ICS 37.100.10; 85.100
English version
Safety of machinery - Safety requirements for the design and
construction of printing and paper converting machines - Part 4:
Bookbinding, paper converting and finishing machines
Sécurité des machines - Exigences de sécurité pour la Sicherheit von Maschinen - Sicherheitsanforderungen an
conception et la construction de machines d'impressions et Konstruktion und Bau von Druck- und
de tranformation du papier - Partie 4: Machines à relier les Papierverarbeitungsmaschinen - Teil 4: Buchbinderei,
livresmachines de transformation et de finition du papier Papierverarbeitungs- und Papierveredelungsmaschinen
This European Standard was approved by CEN on 21 November 2003.
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
© 2004 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 1010-4:2004: E
worldwide for CEN national Members.

Contents Page
Foreword .3
Introduction.4
1 Scope.4
2 Normative references.5
3 Terms and definitions .6
4 List of significant hazards.9
5 Safety requirements and/or measures .16
5.1 General.16
5.2 Bookbinding machines .16
5.2.1 Stitching, riveting, eyeletting and attaching machines (with manual feeding).16
5.2.2 Gang stitchers .18
5.2.3 Gathering machines.20
5.2.4 Perfect binders (Figure 11) .22
5.2.5 Paper drills.24
5.2.6 Book signature presses .25
5.2.7 Book presses.25
5.2.8 Sheet folding machines (Figure 16).26
5.2.9 Book production lines for the production of hard cover books.27
5.2.10 Back rounding and pressing machines.29
5.2.11 Backlining and head banding machines .30
5.2.12 Casing-in machines.30
5.2.13 Book cover crease forming machines (presses) .31
5.3 Paper converting machines.32
5.3.1 Machines for the production of envelopes.32
5.3.2 Machines for the production of sanitary items .39
5.3.3 Inserting machines (Figure 28) .44
5.3.4 Counter-stackers.45
5.3.5 Paper embossing machine .45
5.4 Finishing machines.47
5.4.1 Coaters.47
5.4.2 Laminators.51
6 Verification of safety requirements and/or measures.55
7 Information for use.65
7.1 Instruction handbook.65
7.1.1 Stitching, riveting, eyeletting and attaching machines.65
7.1.2 Perfect binders .65
7.1.3 Machines for the production of envelopes.65
7.1.4 Machines for the production of sanitary items .66
7.1.5 Paper embossing machines.66
7.1.6 Coaters.66
7.1.7 Hold-to-run speeds of above 10 m/min under two-hand control.66
7.1.8 High contact temperatures .66
Annex A (normative) General requirements .67
A.1 Production lines .67
A.2 Start-up warning device.67
A.3 Limit values for interlocking guards.67
Annex ZA (informative) Relationship of this document with EC Directives.68
Foreword
This document EN 1010-4:2004 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 July 2004, and conflicting national standards shall be withdrawn at the
latest by July 2004.
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 Directive(s).
For relationship with EU Directive(s), see informative annex ZA, which is an integral part of this document.
Annex A of this standard is normative.
According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following
countries are bound to implement this European Standard: Austria, Belgium, Czech Republic, Denmark,
Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway,
Portugal, Slovakia, Spain, Sweden, Switzerland and the United Kingdom.

Introduction
This document is a type C standard as stated in EN 1070. It defines additional safety requirements and/or
deviations from the stipulations in prEN 1010-1:2003.
The machinery concerned and the extent to which hazards, hazardous situations and events are covered are
indicated in the scope of this document.
When 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 for machines
that have been designed and built according to the provisions of this C standard.
The EN 1010 series of standards 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 document applies to
 bookbinding machines:
 stitching, riveting, eyeletting and attaching machines;
 gang stitchers;
 gathering machines;
 perfect binders;
 paper drills;
 book signature presses;
 book presses;
 sheet folding machines;
 book production lines for the production of books with hard covers;
 back rounding and pressing machines;
 backlining and head banding machines;
 casing-in machines;
 book cover crease forming machines.
 paper converting machines:
 machines for the production of envelopes;
 machines for the production of sanitary items;
 inserting machines;
 counter-stackers;
 paper embossing machines.
 paper finishing machines:
 coaters;
 laminators.
This document shall be used together with prEN 1010-1:2003. Both parts together identify all significant
hazards relevant to bookbinding, paper converting and paper finishing machines when they are used as
intended and under the conditions foreseen by the manufacturer (see clause 4). The specific requirements in
EN 1010-4 take precedence over respective requirements in prEN 1010-1:2003.
This document does not deal with risks generated by noise emitted from the machines. These issues are
covered basically in prEN 1010-1:2002. However, for machines like sheet folding machines and machines for
the production of envelopes and sanitary items, some specific proposals for noise reduction measures are
given.
This document is not applicable to bookbinding, paper converting and finishing machines manufactured before
the date of publication of this document by CEN.
2 Normative references
This European Standard incorporates by dated or undated reference, provisions from other publications.
These normative references are cited at the appropriate places in the text and the publications are listed
hereafter. For dated references, subsequent amendments to or revisions of any of these publications apply to
this European Standard only when incorporated in it by amendment or revision. For undated references the
latest edition of the publication referred to applies (including amendments).
EN 292-1:1991, Safety of machinery — Basic concepts, general principles for design — Part 1: Basic
terminology, methodology.
EN 292-2:1991+A1:1995, Safety of machinery — Basic concepts, general principles for design — Part 2:
Technical principles and specifications.
EN 294:1992, Safety of machinery — Safety distances to prevent danger zones being reached by the upper
limbs.
EN 349:1993, Safety of machinery — Minimum gaps to avoid crushing of parts of the human body.
EN 626-1:1994, Safety of machinery — Reduction of risks to health from hazardous substances emitted by
machinery — Part 1: Principles and specifications for machinery manufacturers.
EN 626-2:1996, Safety of machinery — Reduction of risks to health from hazardous substances emitted by
machinery — Part 2: Methodology leading to verification procedures.
EN 954-1:1996, Safety of machinery — Safety related parts of control systems. Part 1: General principles for
design.
prEN 1010-1:2003, Safety of machinery — Safety requirements for the design and construction of printing and
paper converting machines — Part 1: Common requirements.
prEN 1010-2:2003, Safety of machinery — Safety requirements for the design and construction of printing and
paper converting machines — Part 2: Printing and varnishing machines including pre-press machinery.
EN 1010-3:2002, Safety of machinery — Safety requirements for the design and construction of printing and
paper converting machines — Part 3: Cutting machines.
EN 1050:1996, Safety of machinery — Principles for risk assessment.
EN 1070 :1998, Safety of machinery — Terminology.
EN 1539:2000, Dryers and ovens in which flammable substances are released — Safety requirements.
prEN 13023, Noise measurement methods for printing, paper converting, paper making machines and
auxiliary equipment — Accuracy categories 2 and 3.
EN 61000-6-4:2002, Electromagnetic compatibility (EMC) — Generic standards — Part 6-4: Emission
standard for industrial environment (IEC 61000-6-4:1997).
EN ISO 4871, Acoustics — Declaration and verification of noise emission values of machinery and equipment
(ISO 4871:1996).
3 Terms and definitions
For the purposes of this European Standard, the definitions given in EN 1070:1998 and prEN 1010-1:2003
and the following apply.
3.1
stitching, riveting, eyeletting and attaching machines
powered machines using tools for
 connecting material by means of metallic items
or
 positively fixing metallic items to material
3.2
gang stitchers
machines for stitching folded sheets of paper where individual folded sheets are removed by feeding grippers
and the open sheets are stacked on top of each other on a transport chain for subsequent back stitching (see
Figure 1)
Key
A1 to A4 Feeding grippers
Figure 1 — Principle of a gang stitcher
3.3
gathering machines
machines for gathering folded sheets of paper where individual sheets are removed by feeding grippers and
are stacked in the correct order on a transport chain (see Figure 2)

Key
A1 to A4 Feeding grippers
Figure 2 — Principle of a gathering machine
3.4
perfect binders
machines for the automatic production of brochures (soft cover) or book signatures (hard cover) where
gathered folded sheets or single sheets are bound to form book or brochure signatures by applying glue on
the preprocessed book back and where book or brochure signatures are inserted into covers by gluing the
cover on the back and/or sides
3.5
paper drills
machines to drill holes into piles of paper
3.6
book signature presses
presses used for pressing book signatures: blocks are fed and aligned manually, pressing is power-operated
3.7
book presses
presses used for pressing books after manual binding in order to ensure dimensional stability
3.8
sheet folding machines
machines to apply single or multiple folds to single sheets of paper including cutting, perforating and creasing
3.9
book production lines
machines for the automatic production of books where book signatures consisting of gathered folded sheets
or single sheets are put together and trimmed and provided with hard or flexible book covers
3.10
back rounding and pressing machines
machines for rounding book signature backs and completing the forming process by pressing the back
3.11
backlining and head banding machines
machines for the automatic production of books with rounded or flat book back where book signatures are
glued, gauzed, backlined and head banded
3.12
casing-in machines
machines for the production of books (hard cover) where rounded or flat book signatures are cased into hard
or flexible book covers by gluing the end papers on the front and on the back of the book signatures to the
inner sides of the book covers
3.13
book cover crease forming machines (presses)
machines for the production of books (hard cover) where, following the process of gluing book signatures to
book covers, book cover creases are formed under heat and pressure and the books are pressed over the
entire surface
3.14
machines for the production of envelopes
machines for the production of envelopes and other kinds of paper bags
3.15
machines for the production of sanitary items
machines for the production of sanitary items from paper, tissue and non-woven fabric such as, for example,
paper handkerchiefs, paper napkins, tampons etc.
3.16
inserting machines
machines (for example attached to web-fed rotary printing presses) where printed matter such as leaflets and
magazines are inserted at a predetermined position into other printed products, for example newspapers or
magazines
Key
A feeder of main product,
B1 to B3 feeder of material to be inserted
Figure 3 — Principle of an inserting machine
3.17
counter-stackers
machines for cross-wise stacking of piles of leaflets, books, magazines or newspapers
3.18
paper embossing machines
machines for forming paper surfaces by using embossing cylinders
3.19
paper finishing machines
machines used for applying liquid or solid coating material on substrates made of paper or similar materials
such as board and corrugated boards, plastic film, tinfoil, metal sheets and photo paper. Examples of paper
finishing machines are coaters and laminators
3.19.1
coaters
type of paper finishing machine applying a liquid substance (for example glue, varnish, ink) of a predetermined
thickness onto a substrate. For dosing the substance applied, a doctor blade (scraper) or the gap between two
rollers (dosing gap) is used
3.19.2
laminators
type of paper finishing machine applying a solid material (for example foil, paper) onto a substrate
4 List of significant hazards
4.1 Insofar as they are dealt with in this standard, this clause contains all the significant hazards (noise is
dealt with basically in prEN 1010-1:2003), that have been identified by the risk assessment process as being
significant for this type of machinery and 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 user of this standard, i.e. the designer or manufacturer, takes into
account the following basic aspects in accordance with EN 1050:
 the intended use of the machine including setting up (making ready), cleaning and maintenance, including
foreseeable misuse;
 identification of all hazards existing on the machine.

Table 1 — Significant hazards, danger zones, safety measures
Significant hazards Danger zone Safety measures: reference to clauses in
EN 292-1: prEN 1010-1:
this standard
1991 2003
Machines with guards in open position 5.1.2
Mechanical hazards 4.2.1 5.2.2.3
crushing
Interfaces between individual machines 5.1.5, Annex A.1
shearing
cutting or severing
Stitching, riveting, eyeletting and attaching
entanglement
machines
drawing-in
- between tools 5.2.1.1 to 5.2.1.3
impacts 5.2.8
Gang stitchers
- feeder 5.2.2.1 to 5.2.2.3
5.3.4.8, 5.2.6.1.5
- stitching section 5.2.2.4
- drawing-in zone on thickness control 5.2.2.5

- transport chain 5.2.2.7
- starting with guards open 5.2.2.8, 7.1.7

- trimmer 5.2.2.10
Gathering machines
5.3.4.8
- feeder 5.2.3.1 to 5.2.3.3
5.2.10.2
- hand-feeder, transport chain 5.2.3.4

- gathering device (transport device) 5.2.3.5

- starting with guards open 5.2.3.7

Perfect binders
- book clamps 5.2.4.1
5.3.4.8
- gluing rollers 5.2.4.2
- cover feeder 5.2.4.8
- delivery unit 5.2.4.9
- starting with guards open 5.2.4.11, 7.1.2.2
- milling head cutters 5.2.4.12, 7.1.2.1

Paper drills
- drill 5.2.5.1
- drill/clamp jaws
5.2.5.2
Book signature presses
- clamping plate/material
5.2.6
Book presses
- pressing plates 5.2.7.1, 5.2.7.2
5.2.10.2
- pressing plates/machine enclosure 5.2.7.3

Sheet folding machines
- drawing-in zones of folding rollers 5.2.8.1

- cutting, creasing, perforating unit 5.2.8.2

- folding knife 5.2.8.3
- starting with guards open
5.2.8.4
Book production lines
- feed opening 5.2.9.1
- preheater, transport device 5.2.9.2

- pressing section
5.2.9.3
- glue section 5.2.9.4
- gauze section 5.2.9.6
5.2.1.1 b)
- head banding section 5.2.9.7
5.3.4.8
- book cover magazine 5.2.9.8
- cover bending section
5.2.9.9
- casing-in section
5.2.9.10
- starting with guards open 5.2.9.11, 7.1.7

Table 1 (continued)
Safety measures: reference to clauses in
Significant hazards Danger zone
this standard EN 292-1: prEN 1010-1:
Back rounding and pressing machines

- drawing-in zones of belts, transport
5.2.10.1
chains, feed opening
- tipping section 5.2.10.2
- preheater 5.2.10.3
- pre-forming, back rounding, pressing
5.2.10.5
sections
Backlining and head banding machines

- feed opening, belt feeding
5.2.11.1
- glue section, glue rollers
5.2.11.2
- gauze section
5.2.11.4
- head banding section
5.2.11.5
- pressing section 5.2.11.6
Casing-in machines
- transport finger
5.2.12.1
5.3.4.8
- book cover feeder 5.2.12.2
- cover bending section 5.2.12.3
- forming section 5.2.12.4
- casing-in, gluing section 5.2.12.6

- pressing section 5.2.12.7
- delivery unit, delivery opening 5.2.12.8

Book cover crease forming machine

- feed and delivery openings 5.2.13.1

- tipping section, transport devices 5.2.13.2

- pressing section 5.2.13.3
- starting with guards open
5.2.13.5, 7.1.7
Machines for the production of envelopes

- reel unwinding unit 5.3.1.1
5.3.5
- feeder
5.3.1.2
- printing unit 5.3.4.8
5.3.1.3.1, 5.3.1.3.2
5.2.1.1
- longitudinal and cross scoring 5.3.1.4.1, 5.3.1.4.2

- form cutting section 5.3.1.5 5.3.2.1

- guide rollers 5.3.1.6.1, 5.3.1.6.2

- window cutting section 5.3.1.7

- window material conveying section
5.3.1.8.1to 5.3.1.8.4
- scraper gluing unit 5.3.1.9.1, 5.3.1.9.2
5.2.1.1
- separating cutting unit 5.3.1.10.1 to
5.2.1.1
5.3.1.10.3
- bottom flap folding section 5.3.1.11.1, 5.3.1.11.2

- transport rolls
5.3.1.12.1, 5.3.1.12.2
5.2.1.1
- staggering wheel
5.3.1.13.1, 5.3.1.13.2,
5.2.1.1 b)
7.1.3.1
- roller gluing unit 5.3.1.14.1to
5.2.1.1
5.3.1.14.4, 7.1.3.3
- hot air dryers
5.3.1.15.1, 5.3.1.15.2
5.2.1.1
- separation roller before aligner section
5.3.1.16
5.2.1.1
- aligner section
5.3.1.17
- seal flap folding section
5.3.1.18
- separating disc delivery
5.3.1.19.1, 5.3.1.19.2
- starting with guards locked open
5.3.1.20.1, 7.1.7,
5.3.1.20.2, 7.1.4.1
5.2.3.4
Machines for the production of sanitary

items
5.3.5.1
- reel unwinding unit
5.3.2.1.1 to 5.3.2.1.4
5.2.1.1
- smoothing and embossing section
5.3.2.2.1, 5.3.2.2.2
5.3.2
- longitudinal cutting section
5.3.2.3
Table 1 (continued)
Safety measures: reference to clauses in
Significant hazards Danger zone
this standard EN 292-1: prEN 1010-1:
- longitudinal folding section 5.3.2.4

- waste suction devices on cutting devices 5.3.2.5
- counting and transfer section 5.3.2.6

- product checking section 5.3.2.7
5.2.1.1
- delivery unit 5.3.2.8.1, 7.1.4.2

- starting with guards open 5.3.2.9.1, 7.1.7,

5.3.2.9.2, 7.1.4.1
Inserting machines
- feeder 5.3.3.1, 5.3.3.2
5.3.4.8
- transport device/drive elements 5.3.3.3
- starting with guards open 5.3.3.5, 7.1.5

Counter-stackers
- drawing-in zones of belts 5.3.4.1

- waste separator 5.3.4.2
- turntable 5.3.4.3
- delivery units 5.3.4.4
- stored energy (pneumatic system) 5.3.4.5

Paper embossing machines
- danger zones of web threading device 5.3.5.2
5.2.3.5
- reel unwinding, rewinding units 5.3.5.3
5.3.5
- guide rollers 5.3.5.4
5.2.1.1
- stretch roller 5.3.5.5
- drawing-in zone of embossing

roller/counter roller 5.3.5.6
- movement of counter roller 5.3.5.7, 7.1.5
5.2.3.2 a) 2)
- rotary knives
5.3.5.9
Coaters
- danger zones of web threading device 5.4.1.2
- reel unwinding, rewinding units 5.4.1.3
5.3.5
- guide rollers 5.4.1.4
- dosing gap 5.4.1.5
- coating unit
5.4.1.8
- engagement and disengagement
5.4.1.9
of rollers
- drawing-in zones of belts 5.4.1.10

- continuous flow dryers 5.4.1.13.2,

- entire machine 5.4.1.13.5,
5.4.1.13.6, 7.1.6.3
Foil laminators
5.3.5
- reel unwinding, rewinding units 5.4.2.1.1

- manual feeding 5.4.2.1.2
5.2.1.1
- guide rollers 5.4.2.1.3, 5.4.2.1.4
- engagement and disengagement of 5.4.2.1.5
laminating rollers
- drawing-in zones of laminating rollers 5.4.2.1.6
5.2.1.1
- cutting unit 5.4.2.1.8
Laminators with glue application

- danger zones of web threading device 5.4.2.2.2
5.3.5
- reel unwinding, rewinding units 5.4.2.2.3
5.3.4
- feeder, delivery unit 5.4.2.2.4

- drawing-in zones of belts 5.4.2.2.5
- guide rollers 5.4.2.2.6 5.2.1.1
- tear-resistant material web 5.4.2.2.7
- rotary knife 5.4.2.2.8 5.3.2
- transport rolls 5.4.2.2.9
- glue unit 5.4.2.2.10
- laminating rollers 5.4.2.2.11, 5.4.2.2.12 5.2.3.2 a) 2)

Table 1 (continued)
Significant hazards Danger zone Safety measures: reference to clauses in
this standard EN 292-1: prEN 1010-1:
1991 2003
5.4.2.2.13
- sheeter
- pressing belt 5.4.2.2.14, 5.4.2.2.15 5.2.1.1 a)
- package stop, conveyor belt 5.4.2.2.16

5.4.2.2.17
- turning belt
Gang stitchers 5.2.2.6, 5.2.2.9 5.2.7.2
Avoiding direct or
Gathering machine 5.2.3.6, 5.2.3.8
pending hazardous 5.2.7.2
Perfect binders 5.2.4.10,5.2.4.13

situations
Sheet folding machines 5.2.8.6

Book production lines 5.2.9.12, 5.2.9.13
5.2.7.2
Back rounding and pressing machines 5.2.10.6

Backlining and head banding machines 5.2.11.7

Casing-in machines 5.2.12.9
Book cover crease forming machines 5.2.13.6
Machines for the production of 5.3.1.21, 5.3.1.23 5.2.7.2
envelopes
Machines for the production of sanitary 5.3.2.11, 5.3.2.12 5.2.7.2
items
Inserting machines 5.3.3.4, 5.3.3.6

Counter-stackers 5.3.4.6
5.2.7.2
Paper embossing machines 5.3.5.1, 5.3.5.10
Coaters 5.4.1.1, 5.4.1.15 5.2.7.2
Foil laminators 5.4.2.1.9
5.4.2.2.19
Laminators with glue application

Electrical equipment of all machines 5.1.3 4.3 5.2.5
Electrical hazards
Direct or indirect
contact
Perfect binders
Thermal hazards 4.4
- hotmelt glue reservoirs
5.2.4.6 5.2.14
Burns due to possible
contact
Book production lines
- preheating section 5.2.9.2, 7.1.8

Back rounding and pressing machines

5.2.10.4, 7.1.8
- preheater
Backlining and head banding machines

- hotmelt
5.2.11.3, 7.1.8
5.2.14
Casing-in machines
- heated forming section
5.2.12.5, 7.1.8
Book cover crease forming machines

(press)
- heated crease forming rails 5.2.13.4, 7.1.8
5.2.14
Machines for the production
of envelopes
- hot air nozzles, hot parts of machine 5.3.1.15.3
5.2.14
Paper embossing machines
- heated embossing roller
5.3.5.8, 7.1.8
Coaters
- hot liquid material 5.4.1.6
- continuous flow dryer 5.4.1.13.4 5.2.14

Foil laminators
- heated laminating rollers 5.4.2.1.7
5.2.14
Table 1 (concluded)
Significant hazards Danger zone Safety measures: reference to clauses in
this standard EN 292-1: prEN 1010-1:
Hazards generated by Sheet folding machines 5.2.8.5
4.5
noise
Machines for the production of 5.3.1.22
e. g. resulting in
envelopes
hearing loss (deafness)
Machines for the production of sanitary 5.3.2.10
items
Perfect binders
Hazards generated by 4.7
- radiation dryers (UV- HF-dryers)
radiation
5.2.4.7 5.2.16.2
UV radiation, laser
Machines for the production of sanitary 5.3.2.5
Hazards from fire and 4.8
items
explosion
Coaters 5.4.1.11, 5.4.1.13.1,

7.1.6.2,
5.4.1.13.3
Laminators with glue application
5.4.2.2.18
5.2.4
Hazards from Perfect binders
4.8
substances and - polyurethane hotmelt
5.2.4.3 to 5.2.4.5,
materials used for
7.1.2.3
processing, machine
operation or which are Book production lines

emitted during the - hotmelt
5.2.9.5
process
Coaters
Hazards resulting from
contact with or - hazardous substances
5.4.1.7, 7.1.6.1
inhalation of harmful
fluids, gases, fumes,
dusts
Hazards generated by Stitching, riveting, eyeletting and
4.9 8
neglect of ergonomic attaching machines
principles in machine - adjustments 5.2.1.2
design
Book production lines
unhealthy body
postures - glue replenishment 5.2.9.4

Control systems of all machines 5.1.4 5.2.6.1
Failure, malfunction of
control system
Stitching, riveting, eyeletting, attaching 5.2.1.1, 5.2.1.4 5.2.6
Faults or failures in
machines
safety circuits
Gathering machines 5.2.3.1, 5.2.3.4 5.2.6.1.5,
5.2.10.1
Perfect binders 5.2.4.8 5.2.6.1.5
Paper drills
5.2.5.2 5.2.8
Machines for the production of sanitary 5.3.2.8.2
5.2.6.2.1
items
Water jet knives
5.2.6.1.5
Inserting machines, residual pile 5.3.3.1
monitoring
5 Safety requirements and/or measures
5.1 General
5.1.1 Machinery shall comply with the safety requirements and/or protective measures of this clause. In
addition, the machine shall be designed according to the principles of EN 292 for hazards that are relevant but
not significant and that are not dealt with by this document (e. g. sharp edges of machine frame).
The common requirements of prEN 1010-1:2003 shall also be satisfied.
5.1.2 Guards that have to be removed frequently or for making ready shall be interlocked with the
hazardous movement in accordance with 5.2.2.3 of prEN 1010-1:2003.
5.1.3 The electrical equipment shall comply with the requirements of 5.2.5 of prEN 1010-1:2003.
5.1.4 The safety-related control circuits shall comply with the requirements of 5.2.6.1 of prEN 1010-1:2003.
5.1.5 Where machines are set up to form integrated lines (production lines) with one overall control system,
annex A.1 shall be applied.
5.2 Bookbinding machines
5.2.1 Stitching, riveting, eyeletting and attaching machines (with manual feeding)
5.2.1.1 Danger zones between tools on stitching, riveting, eyeletting and attaching machines (see
Figure 4) shall be avoided or safeguarded.
This requirement is satisfied by
 observing a maximum distance of 4 mm between the tools in the open position
or
 ensuring that the closing force of the movable tool is less than 50 N and a higher closing force is allowed
to become effective only after it has been ensured by means of a sensing device that there is no part of a
human body present between the two tools.
The sensing device may, for example, function on the basis of the difference in electrical resistance between
the workpiece and parts of the body or the difference in thickness. Control systems shall comply at least with
category B of EN 954-1:1996.
Danger zones are safeguarded if
 guards are provided with apertures and safety distances in accordance with Table 4 of EN 294:1992
or
 the machine can only be started by two-hand control. A device shall be provided for supporting and fixing
the product to be processed. Two-hand controls shall comply with the requirements specified in 5.2.8 of
prEN 1010-1:2003.
5.2.1.2 On flat and saddle stitching machines (see Figures 4 and 5) and on combined flat and saddle
stitching machines, adjustable guards are required for operational reasons. Where power-operated movable
guards are used, the requirements of 5.2.2.4 of prEN 1010-1:2003 shall be satisfied.
Adjustable guards shall extend to the product surface for flat stitching and to the upper edge of the lower tool
for saddle stitching. The upper tool shall be enclosed snugly by the guard.
Instructions that describe the safe adjustment of the guards in a clear and easily understandable form shall be
provided on the machine. This requirement is satisfied by labels provided with sketches and dimensional data,
for example, for identifying the guard adjustment required for a specific stitching thickness.
The required information on this in the instruction handbook is given in 7.1.1.

Key
1 Upper tool
2 Guard
Figure 4 — Flat stitching
Key
1 Upper edge of saddle 3 Workpiece
2 Guard
Figure 5 — Saddle stitching
5.2.1.3 For machines that can only be started by two-hand control, 5.2.8 of prEN 1010-1:2003 shall apply.
A workpiece support is required.
If the shape or size of the workpiece requires the operator to use both hands to hold the workpiece outside the
danger zone or if the workpiece needs to be held outside the danger zone with one hand, a hold-to-run control
shall be provided for starting the machine instead of the two-hand control.
5.2.1.4 Safety-related control circuits shall comply with 5.2.6 of prEN 1010-1:2003.
5.2.2 Gang stitchers
5.2.2.1 When gang stitcher feeding hoppers are fed manually, the danger zones of the separating
elements of the feeder shall be safeguarded in accordance with 5.3.4.8 of prEN 1010-1:2003 and the residual
risk monitoring device designed in accordance with 5.2.6.1.5 of prEN 1010-1:2003.
5.2.2.2 With automatic feeding of the feeding hopper, tunnel-type guards with a safety distance of 550 mm
from the nearest danger zone shall be provided instead of the measures specified in 5.2.2.1
5.2.2.3 The feeder shall be provided with fixed guards on all sides or with guards interlocked with the
hazardous movement.
In the sheet-feeding area (transport chain side), the feeder shall be guarded in order to prevent direct access
to the danger zones from the transport chain side. Where transport chains cannot be entirely enclosed for
functional reasons (e.g. where air vortexes are used) (see Figure 7), the lower edges of the guards on the
transport chain side shall be extended as low as technically feasible.
5.2.2.4 Danger zones of the stitching section shall be safeguarded by guards interlocked with the
hazardous movement on the operator side, otherwise by fixed guards or guards interlocked with the
hazardous movement. Guard apertures on the in-running side of the stitching unit may be adequately guarded
by elastic material (e.g. brushes).

Key
4 Stitching unit,
1 Transport chain 5 Trimmer (three-knife trimmer)
2 Feeder
3 Thickness control
Figure 6 — Gang stitcher
Key
1 Manual feeding 3 Transport chain
2 Bottom of feeder
Figure 7 — Feeder
5.2.2.5 Where a drawing-in zone exists in the calliper roll used for thickness control (see Figure 8), one of
the following requirements shall be applied:
 maximum clamping force of 50 N or
 displacement of at least 20 mm or
 guard.
5.2.2.6 Gang stitchers shall be provided with a start-up warning device according to 5.2.7.2 of
prEN 1010-1:2003.
Key
1 Folded sheets
2 Drawing-in zone of calliper roll
3 Gripper
Figure 8 — Calliper roll for thickness control

5.2.2.7 A safety distance of at least 25 mm is required between transport chain grippers and fixed
machine parts.
5.2.2.8 Starting the machine with the interlocking guards in the open position and with a hold-to-run
speed higher than 10 m/min shall be possible only by means of two-hand control and only if
 zones with restricted view and mutual interlocking as described in 5.2.3.4 of prEN 1010-1:2003 are
provided and
 a selector switch for this kind of operation is provided and
 the hold-to-run speed is the slowest speed possible under procedural requirements.
For further information in the instruction handbook, see 7.1.7.
5.2.2.9 An emergency stop system shall be provided with emergency stop buttons located on each main
control panel. In the area of the feeders, emergency stop buttons shall be provided at 5 m intervals.
5.2.2.10 The three-knife trimmer shall be safeguarded according to 5.5 of prEN 1010-3:2002.
When the interlocking guard is opened, it shall only be possible to start the trimmer by means of two-hand
controls. Operation of the two-hand control shall allow only a single stroke of the knives.
5.2.3 Gathering machines
5.2.3.1 With manual feeding of the feeders, the danger zones of the separating elements of the feeder
shall be safeguarded in accordance with 5.3.4.8 of prEN 1010-1:2003 and the residual pile monitoring device
shall be provided in accordance with 5.2.6.1.5 of prEN 1010-1:2003.
5.2.3.2 For feeding sections that are not used and cannot be stopped, blanking boards of maximum
format size shall be provided to safeguard the danger zones at the separating elements instead of the blanks.
Such boards shall ensure that the machine is not stopped by the residual pile monitoring system.
5.2.3.3 With automatic feeding of the feeding hopper, tunnel-type guards with a safety distance of
550 mm from the nearest danger zone shall be provided instead of the measures required in 5.2.2.1.

Key
1 Manual feeding 4 Gathering device (transport device)
2 Tunnel 5 Direction of following machine
3 Feeder
Figure 9 — Gathering machine (plan view)
5.2.3.4 For safeguarding the danger zones on the manual feeding unit, a minimum distance of 25 mm is
required between the transport chain and fixed machine parts.
Where the minimum distance cannot be adhered to, trip bars shall be used for safeguarding. The
requirements of 5.2.10.1 (category 3) and 5.2.10.2 of prEN 1010-1:2003 shall be met.
Danger zones that can be reached from the manual feeding section in the following feeder shall be
safeguarded by fixed or tunnel-type guards interlocked with the hazardous movement of a minimum length of
300 mm (see Figure 9, item 2).
5.2.3.5 Danger zones on the gathering device (transport device) (see Figure 9, item 4) shall be
safeguarded by fixed guards or by guards interlocked with the hazardous movement.
5.2.3.6 Gathering machines shall be provided with a start-up warning device in accordance with 5.2.7.2
of prEN 1010-1:2003.
5.2.3.7 Starting the machine with the interlocking guards in the open position and with a speed higher
than 10 m/min shall be possible only by means of two-hand control and only if
 zones with restricted view and mutual interlocking as described in 5.2.3.4 of prEN 1010-1:2003 are
provided and
 a selector switch for this kind of operation is provided and
 the hold-to-run speed is the slowest speed possible under procedural requirements.
For further information in the instruction handbook, see 7.1.7.
5.2.3.8 An emergency stop system shall be provided with emergency stop buttons located at least on
each main control panel. In the area of the feeders, emergency stop buttons shall be provided at 5 m intervals.
5.2.4 Perfect binders (Figure 11)
5.2.4.1 The danger zones existing between the book clamps and between book clamps and machine
frame as well as during cover pressing shall be safeguarded by fixed guards or by guards interlocked with the
hazardous movement. For guard apertures, the safety distances specified in Table 4 of EN 294:1992 shall be
applied.
Key
1 Book clamps open  3 Book signature
2 Book clamps closed
Figure 10 — Book clamps
5.2.4.2 The danger zones existing in the gluing unit (glue rollers, glue applicators) and the danger zones
between book backs and/or between book clamps and glue rollers and fixed machine parts shall be protected
by fixed guards or by guards interlocked with the hazardous movement.

Key
1 Milling unit 4 Pressing unit
2 Gluing unit 5 Book clamps
3 Cover feeder 6 Delivery
Figure 11 — Perfect binder (plan view)
5.2.4.3 The glue pans for hotmelt shall be provided with temperature control and with limit temperature
mon
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