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Machine Safety Standards

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Machine Safety Standards

There are two fundamental questions which Morello’s Technical Project Office always asks when designing a new machine:

  • Does the machine do exactly what the customer needs?

  • Is the machine safe?

Together with machine performance, Morello uses the safety factor as a fundamental design principle when studying and engineering a new machine.

When moving materials of different weights and sizes, it is an absolute priority to take all precautions necessary to ensure that a heavy-duty trolley, or its load, do not cause harm or damage to people or property.

For this reason, for each machine Morello designs, and as prescribed by the European Machinery Directive 2006/42/EC, a detailed Risk Analysis is prepared which aims to identify all possible risks which the machine may encounter, or risks created by the way in which the machine may be used.

In order to guarantee suitable safety standards, all Morello machines, regardless of the final country of destination, have the CE certification, in addition, of course, to complying with local directives and regulations.

During the machine design process, in addition to following the European Machinery Directive, Morello also follows all product-specific regulations, thus guaranteeing the highest safety standards.

Structural Safety

On a structural level, the machine’s load-bearing structure is calculated using a high safety factor, which goes beyond the limits and requirements prescribed by the regulations.

For structural calculations Morello uses advanced software for FEM analysis as well as traditional spreadsheet calculations, which allow for a more detailed analytical view.

The design of all structural welds is supervised by a skilled welding coordinator

In order to guarantee the safety of the machine’s structure, following the design phase, it is essential that Morello manages the production phase with maximum care and attention. Extreme importance is given to both the materials used and to the actual welds and the welding process. For all structural materials, the 3.1 certificate is requested and procedures are in place to guarantee the traceability of these materials at all times.

Every single weld is checked by a Morello qualified inspector. The non-destructive tests used are: visual method, penetrating liquids, magnetoscopic and, when requested by the customer, ultrasound or radiographic.



To ensure the above-mentioned processes are strictly adhered to, and are in accordance with international standards, Morello has attained the ISO 3834-2 certification, issued by DNV.

Electrical and Electronic Safety

Morello designs the electrical and electronic systems (as well as all other parts of the machine), following the Risk Analysis results and in accordance with the relevant product regulations. The Performance Level, or SIL, is then defined as required (or as requested by the Customer) and the entire system is designed accordingly.

Both for automatic machines and for operator controlled machines, Morello utilises all the necessary safety components required to minimise, if not eliminate, machine operator risk.

Safety laser scanners, safety PLCs, multiple safety sensors, safety communication networks (both cable and Wi-Fi) plus other components are used where required. All of this in accordance with the most stringent national and international safety standards.

Controls, Trials and Testing

To comply with the above requirements and standards, Morello has clearly defined internal procedures aimed at ensuring that, during the various design and production project phases, all activities are carried out effectively. At the conclusion of all key project phases, reviews and tests are carried out to verify that each task has been performed correctly.

Finally, when a machine has been completed, a strict acceptance test is carried out, to verify that every single aspect of the machine has been produced in line with, and as defined by, the original project design.