Safeguarding cutting machines in printing
The guidance in the following tables describes commonly accepted and practicable safeguards for the significant hazards on some cutting machines prior to the requirements of European Standard BS EN 1010 Safety of machinery –Safety requirements for the design and construction of printing and paper converting machines.
- Three-knife trimmers
- Label punching machines
- Round cornering machines
- Loose knife punching machines
- Flat-bed cutting and creasing machines
- Autoplatens
- Hand-fed platens
- Guillotines
For some machines, manufactured or refurbished after March 2002, the requirements of European Standard BS EN 1010-3:2002 Safety of machinery – Safety requirements for the design and construction of printing and paper converting machines: Cutting machines apply. See also general safeguarding guidance on machinery safety in the printing industry.
Manually fed three-knife trimmers
Hazards
Cutting/crushing/ trapping injuries from contact with knives on feed and delivery side
Safeguards
- Interlocking tunnel-type guards on delivery side
- Adjustable guards on feed side to reduce opening to minimum by combination of top flap and side guards with interlocking trip
- Actuation of trip guards should, with minimal deflection, instantly cut power and movement of hazardous parts
- Front table extension may also be required to keep operators away from feed opening
- Provide simultaneous actuation two-hand (hold-to-run) control on all manually fed machines where practicable
- If two-hand control is shown to be not practicable (eg older machines with mechanically integrated controls) employers should ensure robust systems provided for:
- effective maintenance and inspection, and
- information, instruction & training of operators on all safe systems of work (ssow) eg knife changing and setting
Label punching machines
Hazards
Access to punching knives at in-feed on manually fed machines
Safeguards
- Interlocking guard or electro-sensitive protective equipment (ESPE) at in-feed
- Openings/safety distances to comply with BS EN ISO 13857 Safety of machinery - Safety distances to prevent hazard zones being reached by upper and lower limbs
- If regular/ routine access required in feed area then safety devices should satisfy the requirements of Type 4 of BS EN 61496-1 and BS EN 61496-2 Safety of machinery – Electro-sensitive protective equipment
Discharge area access to danger zones
Safeguards
Guards with openings/ safety distances to comply with BS EN ISO 13857
Round cornering machines
Hazards
Access to trimming knife or saw
Safeguards
- Fixed or interlocking guards at the rear and on both sides.
- Adjustable transparent guard in front of the knife
- Cutter operation only starts after a pile has been fed using a presence sensing device
- Cutter operation by hold-to-run controls (hand or foot operated)
Loose knife punching machines
Hazards
Manually operated punching machines - Crush injuries from Stroking platen
Safeguards
- Sliding front feed table
- Simultaneous actuation two-hand controls, and
- Interlocking/ sliding screen front guards or self-adjusting tunnel/screen front guards, and
- Localised fixed guarding for the sides and rear, or perimeter-type fencing
- Cutter balancing springs to stop small cutters falling over
Automatic machines - Crush injuries from Stroking platen
Safeguards
- Simultaneous actuation two-hand controls, and
- Hinged interlock guard or an ESPE on feed side (two-hand controls only offer protection for the operator during the initial strike on)
- Fixed and interlocking guards for sides and rear
- Openings/safety distances designed to meet BS EN ISO
Flat-bed cutting and creasing machines
Hazards
Purpose-designed machines- Feed-end (similar to sheet-fed printing presses) crush injuries from descending pallets and in-running nips/ shear points
Safeguards
- Prevent foot-crushing risks from descending pallet tables by having a manual system for the final 100 mm, or alternatively, hinged flaps to raise operator's foot away from trapping point
- Adequately guard transfer mechanisms from the product pile or shear points as in-feed devices oscillate
Purpose-designed machines- Cutting /creasing and stripping areas - crush/shear
Safeguards
- Fixed or interlocking guards
- Pre-start audible warnings if limited movement possible with guards open, and
- Transport chains, which move intermittently, must be inaccessible with guards open
Purpose-designed machines- Delivery-end pallets - crush/shear
Safeguards
- People should not enter the pallet descent area during normal operation
- Isolation and lock off required to access the pallet descent area
- Provide ssow for pallet or carriage plate changeover
Converted printing presses – eg the Heidelberg Original Cylinder Access to forme (machines with infeed/delivery at same end) crush/shear
Safeguards
Interlocking guards provided over the forme to facilitate changeover of dies
Converted printing presses – Inking rollers in-running nips
Safeguards
Remove inking rollers from presses dedicated to cutting and creasing
Converted printing presses – Cylinder gap and machine fixed parts - shear trap
Safeguards
- Fixed guard - use U-bolts or similar devices round the cross tie bar' or
- interlocking guard
Converted printing presses – Oscillating delivery fingers - shear trap
Safeguards
- Ensure fingers are telescopic
- Replace jammed/damaged fingers
Autoplatens – original and converted machines
Hazards
Inking rollers – where still used - in-running nips
Safeguards
Inking rollers must be guarded
Access to moving parts eg reciprocating platen, piston, linkages, windmill or rotating grab bar – crush / shear
Safeguards
- Understanding of operator/machine interaction (eg by risk assessment) essential to provision of effective guards
- provide rear and side guards eg by machine position or with fixed panels, or
- provide specific guards for individual hazards such as exposed linkages, piston etc, and
- provide operator training and supervision
Converted machines eg to hot foil or similar
Safeguards
Cost of conversion combined with the increased life span of the machine may mean that it becomes reasonably practicable to install front interlocking gates/panels