On January 20, 2027, the new EU Machinery Regulation (EU) 2023/1230 will take effect. While many companies are focusing on CE marking and new safety requirements, one crucial question often remains unanswered: How well do you understand the behavior of your existing machinery?
Many production systems have been running reliably for years—often with older control systems such as TwinCAT 2, Siemens S5, or S7. However, over the years, functions have been expanded, custom solutions added, and documentation only partially updated. The result: The machine works, but knowledge of its actual process logic is lost.
This is precisely where risks to safety and documentation can arise. The new Machinery Directive raises the bar, particularly with regard to software, digital documentation, and the assessment of significant changes. In our view, modern hardware alone is not sufficient—it is also crucial to understand the machine’s behavior.
In retrofit projects, therefore, the focus is no longer solely on the PLC code. Far more important is the technical reality of the machine: What states exist? Which safety functions are active? What interactions determine the process?
With its PTF (Process, Technology & Function) analysis, Selmo takes a different approach. Instead of migrating existing code, the actual machine behavior is analyzed and documented as a formal process model. This creates transparency, a robust foundation for modernization, and significantly better documentation throughout the entire lifecycle.
Use Case - Velox Werk GmbH
When Machine Knowledge Becomes a Business Risk
A mid-sized machine builder planned to modernize an automated plate-cutting system. Although the machine had been operating reliably for years, no one could fully explain its behavior anymore. Critical process knowledge was scattered across PLC code, documentation, and the experience of individual employees.
Instead of simply migrating the existing control system, the actual behavior of the machine was modeled first. This made it possible to identify previously unknown process dependencies and hidden issues before they became production or modernization risks. Only then was the retrofit carried out.
As a result, the project provided a reliable basis for decision-making, reduced project risk, and significantly decreased dependence on implicit expert knowledge. The retrofit became more than a technical upgrade—it became a strategic investment in the company's long-term resilience and future competitiveness.
The Machinery Directive is therefore far more than just a legal requirement. It demonstrates that anyone who wants to operate their machines safely in the long term should understand their actual behavior. Those who document the technical reality of their systems today lay the foundation for safe retrofit projects, better digitalization, and long-term competitiveness.
Find out how transparent your existing machines really are. Schedule a 30-minute initial consultation to assess your existing production system.
