EU Machinery Regulation 2027: Prepare for change

WITH THE EU Machinery Regulation coming into force in January 2027, machine builders face an imminent deadline  to review their compliance procedures, cybersecurity measures and engineering practices. Matthew Hallas, business development manager, OEM Drives at ABB opened the agenda by setting the scene in terms of the wider challenges currently faced by UK machine builders, from rising employment and energy costs to supply chain disruption and skills shortages. Against this backdrop, the speakers outlined how standardising machine architectures and reducing engineering complexity could help manufacturers meet regulatory requirements while bringing products to market more quickly.

Regulatory changes

Pekka Alasaari, senior global product manager, drive products at ABB presented on functional safety and the Machinery Regulation, highlighting the significance of the transition from the existing Machinery Directive to the new regulation. Unlike a directive, which allows some scope for national interpretation, the regulation establishes requirements that apply directly across the EU. For UK machine builders exporting to the EU, understanding the changes is therefore essential and manufacturers must ensure their machines meet the updated requirements when placing them on the market.

As Alasaari pointed out, cybersecurity is a particular focus. Under the new regulation, manufacturers must incorporate cybersecurity threats into their machine-level risk assessments, recognising that vulnerabilities can have implications for functional safety.

Another important change concerns software traceability. Alasaari explained that machines must maintain records of safety-related changes over a five-year period, with automatic logging providing digital evidence of modifications. This will help manufacturers investigate discrepancies between the machine’s actual configuration and its documented safety status.

Documentation requirements are also evolving. “In the machine directive era, it was mandatory to have paper documentation, now a QR code next to the machine is sufficient,” said Alasaari. However, he also emphasised that the responsibility for ensuring the complete machine complies remains with the OEM, rather than the individual component suppliers. “As a component provider, we do as much as we can to help the machine builder to comply with the standards, but still, at the end, it's the OEM that is responsible for ensuring the whole machine complies with the regulation."

Reducing engineering complexity

Beyond regulatory compliance, the webinar explored how machine builders can address the commercial pressures affecting their businesses. Hallas highlighted the importance of reducing time to market, particularly for UK manufacturers producing bespoke machinery that requires repeated engineering work. He noted that a significant proportion of machine costs sits outside the physical components themselves, with engineering, software development and assembly labour all contributing to the total.

“Half the cost of a machine is not in the cost of components,” he said, pointing to the potential savings available through better design decisions and more efficient engineering processes.

Umit Kahraman, global segment manager for machinery products at ABB, explained that combining drives, motors, PLCs and control functions within a common engineering environment could help reduce the complexity associated with configuring and commissioning machines.

Traditionally, machine builders may combine products from multiple suppliers, requiring engineers to work across different software packages and manage additional integration and verification tasks. Kahraman suggested that shifting towards configuration and reuse, rather than designing every machine from scratch, could help address these challenges.

ABB’s Automation Builder platform provides a common environment for configuring and programming drives alongside PLCs. According to Kahraman, this approach can simplify engineering workflows, accelerate commissioning and make better use of scarce technical expertise.

“Engineers can configure, programme, and manage drives directly within the PLC tool, so they don't need to learn multiple software packages or manage different database versions,” he said.

Standardisation also offers the opportunity to develop repeatable machine architectures and reusable software, helping manufacturers reduce engineering hours without compromising the functionality required by individual applications.

Efficiency, connectivity and cybersecurity

The webinar also examined the role of motor and drive selection in improving machine performance and energy efficiency. Richard Gee, UK sales manager for low voltage motors, outlined ABB’s comprehensive motor portfolio, including synchronous reluctance and liquid-cooled designs intended to deliver higher power density and more compact machine configurations. The range also includes solutions for applications requiring specific safety certifications or operation in hazardous environments.

Gee emphasised the importance of matching motor technology to the application, allowing machine builders to balance efficiency, available space and performance requirements.

“Whatever your application, I would say ABB has a package solution that we can offer, discuss, and adapt to your needs,” he said.

Lifecycle management was another consideration. Hallas highlighted ABB’s Go Select configuration tool and digital documentation resources as ways to support component selection and provide access to product information and certification.

Connectivity is also becoming increasingly important as end users seek better access to machine performance and condition data. Hallas discussed OPC UA as a means of connecting drive-level information with factory-level control systems, supporting more proactive maintenance and helping reduce unplanned downtime.

With cybersecurity remaining a growing priority as the regulatory landscape develops, Pekka Alasaari returned to the spotlight to discuss security features available in ABB drives, including user account management, firmware protection and parameter locking. He also highlighted the forthcoming Cyber Resilience Act as a further development that machine builders will need to consider.

Watch on-demand

This review provides just a taste of what was covered in the webinar, which also included an informative and wide-ranging roundtable discussion, including questions submitted by the audience on the day. If you would like to find out more, you can watch the webinar on-demand for free via the following link: