1. This annex sets out specific safety requirements for the bakery and confectionery machines, i.e: kneaders, mixers, rollers, moulders, sheeters, bread slicers and breadcrumb mills.
2. Kneaders:
2.1 For the application of this Annex:
a) Class 1 kneaders: kneaders whose basins have a volume greater than 5 lt (five liters) and less than or equal to 90 lt (ninety liters) with a feeding capacity up to 25 kg (twenty-five kilograms) of flour per work cycle;
b) Class 2 kneaders: kneaders whose basins have a volume greater than 90 lt (ninety liters) and less than or equal to 270 lt (two hundred seventy liters) with a feeding capacity up to 100 kg (a hundred kilograms) of flour per work cycle;
c) Class 3 kneaders: kneaders whose basins have a volume greater than 270 lt (two hundred seventy liters) with a feeding capacity more than 100 kg (hundred kilogram) of flour per work cycle;
d) basin: container for receive the ingredients which turn into a dough after mixed by the beater, may also be termed pan or bowl;
e) basin volume: maximum volume of basin, usually measured in liters;
f) danger zone of basin: area between the basin and other machine elements, including its structure and drive systems that may pose a risk to the operator or to third parties;
g) beater: device for mixing the ingredients and producing the dough through rotational movement, may have various geometries and be called as fork or arm in case of kneading;
h) danger zone of beater: area in which the movement of the beater pose entrapment or crushing risks to the worker;
2.2. Access to the beater zone shall be prevented by means of a movable guard interlocked by at least one security key with dual-channel, monitored by safety relay – dual channel, according to items 12.38 to 12.55 and their sub-items and Table I, of item A in Annex I of this Standard.
2.3. Access to the danger zone of the basin shall be prevented by means of fixed or movable guards interlocked by at least one security key with dual-channel, monitored by safety relay – dual channel, according to items 12.38 to 12.55 and their sub-items and Table 1 of item A in Annex I of this Standard.
2.4. If electromechanical safety switches, i.e. with mechanical actuator, are used in interlocking of movable guards, two safety switches with positive break for protection shall be installed by double protection channel – door, both monitored by safety relay – in accordance with item 12.38 to 12.55 and their sub-items, meeting hygiene and vibration requirements as well.
2.5. Access to the beater zone and danger zones of basin shall only be possible when the movement of the beater and the basin has completely stopped.
2.6. The device responsible for stopping the movement and monitoring shall be reliable and secure in accordance with items 12.38 to 12.55 and their sub-items of NR12.
2.7. When the machine does not have a brake system, the provisions in paragraph “b” of item 12.44 shall be met.
2.8. The kneaders shall have at least two emergency stop buttons in accordance with items 12.56 to 12.63 and their sub-items.
2.9. The electrical control circuit for starting and stopping the kneaders’ electric motor shall have at least two contactors, positively driven and serially connected, monitored by safety interface.
3. Mixers
3.1. For the application of this Annex:
a) Class 1 mixer: mixers whose basins have a volume greater than 5 lt (five liters) and less than or equal to 18 lt (eighteen liters;
b) Class 2 mixer: mixers whose basins have a volume greater than 18 lt (eighteen liters) and less than or equal to 40 lt (forty liters);
c) Class 3 mixer: mixers whose basins have a volume greater than 40 lt (forty liters);
d) basin: container for receive the ingredients which turn into a dough after mixed by the beater, may also be termed pan or bowl;
e) basin volume: maximum volume of basin, usually measured in liters;
f) beater: device for mixing the ingredients and producing the dough through rotational movement, may have various geometries and be called as fork or arm in case of kneading;
h) danger zone of beater: area in which the movement of the beater pose entrapment or crushing risks to the worker;
3.2. Access to the beater zone shall be prevented by means of a movable guard interlocked by at least one security key with dual-channel, monitored by safety relay – dual channel, according to items 12.38 to 12.55 and their sub-items and Table I, of item A in Annex I of this Standard.
3.3. If electromechanical safety switches, i.e. with mechanical actuator, are used in interlocking of movable guards, two safety switches with positive break for protection shall be installed by double protection channel – door, both monitored by safety relay – in accordance with item 12.38 to 12.55 and their sub-items, meeting hygiene and vibration requirements as well.
3.4. Access to the danger zone of the beater shall only be possible when the movement of the beater and the basin has completely stopped.
3.5. The device responsible for stopping the movement and monitoring shall be reliable and secure in accordance with items 12.38 to 12.55 and their sub-items in this standard.
3.6. When the machine does not have a brake system, the provisions in paragraph “b” of item 12.44 shall be met.
3.7. It shall be ensured that the beater moves only when the basin is in its working position.
3.8. Class 2 and 3 mixers, which are defined in paragraphs “b” and “c” of sub-item 3.1, shall have a manual handling device for the displacement of the basin in order to reduce the physical effort of the operator.
3.9. The basins of the class 1 mixers defined in paragraph “a” of sub-item 3.1, which don’t have manual handling devices for the displacement, shall have ergonomically appropriate handles.
3.10. Class 1, 2 and 3 mixers, which are defined in paragraphs “a”, “b” and “c” of sub-item 3.1, shall have at least one emergency stop button in accordance with items 12.56 to 12.63 and their sub-items of NR12.
3.11. The mixers endowed with a combustible-burning heating system shall meet the provisions in item 12.108 of NR12 and the requirements of the current official technical standards.
3.12. The maximum temperature of the surfaces accessible to the workers shall meet the provisions in item 12.10.9 of NR12 and the requirements of the current official technical standards.
3.13. The device for vertical movement of the basin shall be strong enough to withstand the required effort and shall not pose any entrapment or compression risk to the body segments of the workers during the activity.
3.14. Class 2 mixers, which are defined in paragraph “b” of sub-item 3.1, shall have a mechanized vertical movement device that reduces the maximum effort and ensures appropriate ergonomic conditions.
3.15. Class 3 mixers, which are defined in paragraph “c” of sub-item 3.1, shall a motorized vertical movement device with actuation by a continuous action control device.
3.16. The electrical control circuit for starting and stopping the mixers’ electric motor shall have at least two contactors, positively driven and serially connected, monitored by safety interface.
4. Bakery cylinders
4.1. For the application of this Annex, bakery cylinders are non-household machines, regardless of the capacity, length and the diameter of cylindrical rollers, designed to knead the dough to make bread.
4.1.1. The cylinder consists of two parallel cylinders that revolve in reverse direction, low table, rear extension board, motor and pulleys.
4.1.1.1. The concepts and definitions used here takes into account the current technology applied in the segment, ie., manual feed.
4.2. For cylinders equipped with treadmill that leads the dough to the rolling zone, necessary protections and definitions are the same as for the bread molders, being understood that the access to the danger zone of the rollers, provided in sub-item 5.2.1.2 of this Annex, shall be free from inertial movement by means of mechanical braking system.
4.3. Definitions applicable to the cylinders:
a) low table: horizontal plank used by the operator as a support to handle the dough;
b) rear extension plank: plank inclined in relation to the base used for supporting and transporting the dough to the cylinders;
c) upper and lower cylinders: parallel tractioned cylinders that rotate in the reverse direction to compress the dough, making it uniform and in desired thickness, located between low table and rear extension plank;
d) safety distance: minimum distance required to impede access to the danger zone;
e) moving risk: movement of machine parts that may cause injury;
f) obstructive roller: cylinder roller not tractioned, free movement, positioned over the upper cylinder, to prevent the operator accessing to the danger zone;
g) plate closing the gap between the cylinders: interlocking movable guard that prevent the operator accessing the convergence zone between cylinders;
h) visual indicator: display with graduated ruler that indicates the distance between upper and lower cylinders, and determines the thickness of the dough, avoiding the act of placing the hands to check the opening of the cylinders;
i) side protection: fixed guard on the sides, especially on the rear extension plank, to eliminate the possibility of contact with the zone of moving risk.
j) emergency stop button: mushroom-type red push button, positioned on both sides of the cylinders, to stop the machine instantly in case of emergency, the mechanical braking system acting in such a way that eliminates the inertial movement of the cylinders;
k) cleaning blade for upper cylinder: blade parallel to the cylinder axis and the same length, kept tensioned to get contact with the lower surface of the cylinder, removing the waste dough;
l) plate closing the cleaning area: fixed guards that prevents the access to the gap between the lower cylinder and low table, providing cleaning of wastes on the lower cylinder.
Figure 1: Sectional drawing of the working area of the bakery cylinder.
Source: Fundacentro
4.4. The bakery cylinders shall keep a minimum safety distance according to Figure 2, respecting the ergonomic aspects providing in this Standard.
Figure 2: Schematic drawing of the bakery cylinder.
Legend – dimensions in millimeters with tolerance of 25,00mm B: 850 C: 840 D: 890 E: 1170 F: 900 G: 710 α: 50° to 55° – inclination angle of the rear extension plank (Rectified in DOU 10/01/11 – Section 1 – pg. 84)
4.5. Between the obstructive roller and upper cylinder there shall be a movable guard – plate closing the gap between the cylinders – interlocked by at least one safety switch with dual channel, monitored by safety relay, dual channel, according to items 12.38 to 12.55 and their sub-items and Table I of item A of Annex I of this Standard.
4.5.1. If electromechanical safety switches are used with mechanical actuator, in the interlocking of movable guards, two safety switches with positive break shall be installed, both monitored by safety relay, dual channel, in accordance with items 12.38 to 12.55 and their sub-items, meeting the hygiene and vibration requirements.
4.5.2. The access to the working zone between the obstructive roller and upper tractioned cylinder – plate closing the gap between the cylinders – shall only be possible when the movement of the upper tractioned cylinder has completely stopped by a mechanical braking system, which ensures immediate stop when the interlocking movable guard is open, or the emergency stop device is actuated.
4.6. The reversal of rotation direction of the tractioned cylinders shall be prevented by mechanical, electrical or electromechanical safety system, which cannot be manipulated, installed in the power transmissions of this cylinders.
4.7. The machinery shall have at least two emergency stop buttons installed on each sides, in accordance with items 12.56 to 12.63 and their sub-items.
4.8. The electrical circuits of the starting and stopping command of electric motors of the cylinders shall have at least two contactors with positively guided contacts, connected in series, monitored through a safety interface.
5. Molders
5.1. For the purposes of this annex:
a) moulder conveyor belt: belt that transport the dough into the winding process;
b) roller conveyor belt: belt that rolls the dough already flattened while passing through the roller set, by pressing the dough against the roller conveyor belt and by having different speeds;
c) stretcher conveyor belt: belt that stretches or shapes the dough already rolled, by pressing the dough against moulder conveyor belt;
d) roller set: set of cylindrical bodies that, when in operation, presents rotational movement along the axis of symmetry, observing that the relative positions of them can be changed by altering the distance between their axises of rotation, so as to change the thickness of the flattened dough while passing between them, which is then rolled and stretched; and
e) danger zone of the rollers: area in which the movement of the rollers pose risk of entrapment or crush.
5.2. Access to the danger zone of the rollers, as well as to the transmission elements of the conveyor belts, shall be prevented by all sides by means of guards, except for the input and output of the dough, where safety distances shall be complied so as to prevent danger zones being reached by hands and fingers of the workers, according to items 12.38 and 12.55 and their sub-items and Table I of item A of Annex I of NR12.
5.2.1. Access to the danger zone of the rollers for feeding through the moulder conveyor belt shall be prevented by means of a movable guard interlocked by at least one security key with dual-channel, monitored by safety relay – dual channel, according to items 12.38 to 12.55 and their sub-items and Table I, of item A in Annex I of NR12.
5.2.1.1. If electromechanical safety switches are used with mechanical actuator, in the interlocking of movable guards, two safety switches with positive break shall be installed, both monitored by safety relay, dual channel, in accordance with items 12.38 to 12.55 and their sub-items, meeting the hygiene and vibration requirements.
5.2.1.2. Access to the danger zone of the rollers shall only be possible when their movement has completely stopped.
5.2.1.3. The devices responsible for stopping the movement and for monitoring shall be reliable and secure in accordance with items 12.38 to 12.55 and their sub-items of NR12.
5.2.1.4. When the machine does not have a brake system, the provisions in paragraph “b” of item 12.44 of NR12 shall be met.
5.3. The moulders shall have at least one emergency stop button in accordance with items 12.56 to 12.63 and their sub-items of NR12.
5.4. The electrical control circuit for starting and stopping the moulders’ electric motor shall have at least two contactors, positively driven and serially connected, monitored by safety interface.
6. Sheeter
6.1. For the application of this Annex:
a) conveyor belt: belt that transport the dough into the forming process, having back and forth direction controlled by the operator and which extends from the front table to the rear table passing through the zone of tractioned rotating rollers responsible for forming the dough;
b) front table: conveyor belt on which the dough is placed at the beginning of the process;
c) rear table: conveyor belt on which the dough is shaped by the tractioned rotating rollers;
d) set of tractioned rotating rollers: set of cylindrical bodies that, when in operation, presents rotational movement along the axis of symmetry, being varied positions, altering the distance between their axises, so as to change the thickness of the dough, as well as for printing and cutting the dough;
e) danger zone of the rollers: area in which the movement of the rollers pose risk of entrapment or crush.
6.2. Access to the danger zone of the rollers, as well as to the transmission elements of the conveyor belts, shall be prevented by all sides by means of guards, except for the input and output of the dough, where safety distances shall be complied so as to prevent danger zones being reached by hands and fingers of the workers, according to items 12.38 and 12.55 and their sub-items and Table I of item A of Annex I of NR12.
6.2.1. Access to the danger zone of the rollers through conveyor belt on front and rear tables shall be prevented by means of a movable guard interlocked by at least one security key with dual-channel, monitored by safety relay – dual channel, according to items 12.38 to 12.55 and their sub-items of NR12.
6.2.1.1. If electromechanical safety switches are used with mechanical actuator, in the interlocking of movable guards, two safety switches with positive break shall be installed, both monitored by safety relay, dual channel, in accordance with items 12.38 to 12.55 and their sub-items, meeting the hygiene and vibration requirements.
6.2.1.2. Access to the danger zone of the rollers shall only be possible when their movement has completely stopped.
6.2.1.3. The devices responsible for stopping the movement and for monitoring shall be reliable and secure in accordance with items 12.38 to 12.55 and their sub-items of NR12.
6.2.1.4 When the machine does not have a brake system, the provisions in paragraph “b” of item 12.44 of NR12 shall be met.
6.3. The sheeters shall have at least one emergency stop button in accordance with items 12.56 to 12.63 and their sub-items of NR12.
6.4. The sheeters, including the movement of the conveyor belts, shall be actuated by means of a manual device, in view of item 12.24 of NR12, being the use of pedals prohibited.
6.5. The electrical control circuit for starting and stopping the sheeter’ electric motor shall have at least two contactors, positively driven and serially connected, monitored by safety interface.
7. Bread slicer
7.1. For the application of this Annex:
a) cutting device: set of parallel lined serrated knives, which cut by oscillatory movement or by one or more parallel continuous saw, which cut by the movement in one direction;
b) discharging area: area downstream of the cutting device, where the already sliced products are collected manually or automatically;
c) loading area: area upstream of the cutting device, where the products to be sliced are deposited manually or automatically;
d) feeding device: device that receives the products to be sliced and forwards them to the cutting location. An automatic operation can be used, for example, conveyor belt or being a manually operated device;
e) discharging device: device that receives the products already sliced and makes them available for the rest of the production process. An automatic operation can be used, for example, conveyor belt, or being a manually operated device, or just a flat metal plate that receives the product, which is removed manually.
7.2. Access to the cutting device shall be prevented by all sides by means of guards, except for the input and output of the breads, where safety distances shall be complied so as to prevent danger zones being reached by hands and fingers of the workers, according to items 12.38 and 12.55 and their sub-items and Table I of item A of Annex I of NR12.
7.2.1. Access to the cutting device through loading area shall be protected by a fixed guard combined with a movable guard interlocked, for input of the breads, by at least one security key with dual-channel, monitored by safety relay dual channel according to items 12.38 to 12.55 and their sub-items of NR12.
7.2.1.1. If electromechanical safety switches are used with mechanical actuator, in the interlocking of movable guards, two safety switches with positive break shall be installed, both monitored by safety relay, dual channel, in accordance with items 12.38 to 12.55 and their sub-items, meeting the hygiene and vibration requirements.
7.2.2. There shall be guards on loading area so as to prevent danger zones being reached by hands and fingers of the workers, according to items 12.38 and 12.55 and their sub-items and Table I of item A of Annex I of NR12, ensuring safety during the removal of sliced breads.
7.2.3. Access to the cutting zone shall only be possible when the movement of blades has completely stopped.
7.3. The automatic slicers shall have at least two emergency stop buttons in accordance with items 12.56 to 12.63 and their sub-items of NR12.
7.4. The electrical control circuit for starting and stopping the slicers’ electric motor shall have at least two contactors, positively driven and serially connected, monitored by safety interface.
8. Breadcrumbs Mill
8.1. For the application of this Annex:
a) grinding device: set of fins that mechanically reduce the toasted bread to the grained breadcrumbs;
b) discharging area: area downstream to the grinding device where the breadcrumbs are collected manually or automatically;
c) loading area: area upstream to the grinding device where the toasted bread is deposited manually or automatically.
8.2. Access to the grinding device shall be prevented by all sides by means of guards, except for the input and output of the breadcrumbs, where safety distances shall be complied so as to prevent danger zones being reached by hands and fingers of the workers, according to items 12.38 and 12.55 and their sub-items and Table I of item A of Annex I of NR12.
8.2.1. Access to the grinding device through loading area shall be prevented by a guard that prevents insertion of body parts through constructive geometry and distancing.
8.2.2. When movable guards are used, they shall be interlocked by at least one safety switch with dual channel, monitored by safety relay, dual channel.
8.2.2.1. If electromechanical safety switches are used with mechanical actuator, in the interlocking of movable guards, two safety switches with positive break shall be installed, both monitored by safety relay, dual channel, in accordance with items 12.38 to 12.55 and their sub-items, meeting the hygiene and vibration requirements.
8.2.3. Access to the grinding device through discharging area shall be prevented by a fixed guard in accordance with items 12.38 to 12.55 and their sub-items of NR12.
8.2.4. Access to the danger zone of the milling shall only be possible when the movement of fins has completely stopped.
8.3. The mouthpiece, if mobile, shall be interlocked on the base by at least one safety switch with double channel, monitored by safety relay, in accordance with items 12.38 to 12.55 and their sub-items of NR12, preventing the movement of the fins with the disassembled machine.
8.4. The electrical control circuit for starting and stopping the breadcrumb mills’ electric motor shall have at least two contactors, positively driven and serially connected, monitored by safety interface.
