Preface
The printing industry is a significant part of the manufacturing sector. While it provides a wide range of printing products, it also faces occupational safety challenges. According to data from the U.S. Bureau of Labor Statistics, in 2021, the non-fatal occupational injury and illness incidence rate in the printing industry was 2.2 cases per 100 full-time employees, higher than the all-industry average of 1.8 cases. This highlights the potential dangers, especially during the mechanical operations in the post-press stage.
Establishing and strictly adhering to safety operating regulations is not only essential for protecting the safety of every employee but also serves as the foundation for long-term business development. Proper safety management can reduce accidents, ensure stable production processes, and improve product quality, ultimately benefiting businesses, employees, and customers alike.
SBL Machinery has been deeply involved in the post-press packaging equipment industry for over fifty years (Die Cutting Machines, Folder Gluer Machines, Hot Stamping Machines). Through this article, we aim to provide a detailed introduction to the safety rules for operating post-press equipment, covering everything from basic equipment knowledge and safety guidelines to emergency response procedures. We hope that this systematic introduction will offer the industry a practical safety guide, creating a safer, more efficient, and reliable working environment, and promoting the continued healthy development of the printing industry.
1. Understanding Post-Press Equipment and Potential Risks
During the operation of post-press equipment, the characteristics of the mechanical structure directly affect the safety risks for operators. The following details the structural aspects of Die Cutting Machines, Folder Gluer Machines, and Hot Stamping Machines, and analyzes their potential hazards:
1-1. Die Cutting Machine
- Structural Details:
The core components of a Die Cutting Machine are the high-pressure die and platen, which cut paper or cardboard into the desired shape using immense pressure. The machine typically utilizes hydraulic or pneumatic systems to drive the die’s movement and performs cutting operations at high speed. In addition, the machine is equipped with a feeding system and a waste management system. - Potential Risks:
The die and platen are the primary sources of danger. If an operator’s hand or another part of the body accidentally enters the working area, they may be pinched or cut. High-speed cutting can generate offcuts or debris that may fly off, leading to cuts or impact injuries. Additionally, if the hydraulic or pneumatic system fails, the die could suddenly drop, causing an accidental injury.
1-2. Folder Gluer Machine
- Structural Details:
The Folder Gluer Machine consists of multiple rollers, conveyor belts, a glue application system, and folding units. The rollers and conveyor belts move the cardboard, the glue system applies adhesive evenly to the cardboard, and the folding unit folds the cardboard into box shapes. The entire process is highly automated, with mechanical components operating continuously at high speed. - Potential Risks:
The gaps between the rollers and conveyor belts can easily trap an operator’s fingers, especially during equipment adjustments or when clearing blockages. If the machine is not turned off or operated improperly, it may lead to pinching or pulling accidents. The glue system poses a risk of chemical exposure to the skin or eyes, and when the glue is processed at high temperatures, it may cause burns.
1-3. Hot Stamping Machine
- Structural Details:
The key components of the Hot Stamping Machine are the stamping head and heating plate. The stamping head heats the metallic foil at high temperatures and applies pressure to emboss the foil onto the material’s surface. The machine is also equipped with an automatic feeding and positioning system to ensure printing accuracy. - Potential Risks:
The high-temperature stamping head and heating plate are major sources of danger. If an operator accidentally touches these heated components while changing foil or performing maintenance, severe burns could occur. Additionally, if the pressure system is accidentally triggered or malfunctions during operation, it may crush the operator’s hand or fingers.
2. Safety Guidelines for Operating Post-Press Equipment
In post-press equipment operations, ensuring safety is not only crucial to the health of the operators but also directly impacts production efficiency and product quality. The following sections outline how to ensure workplace safety in three stages: preparation before operation, safety regulations during operation, and emergency response.
2-1. Preparation Before Operation
Preparing properly before starting post-press equipment is essential. This not only helps prevent accidents but also improves production efficiency. Preparation before operation can be divided into the following steps:
2-1-1. Adequate Training
Ensure that operators are familiar with the equipment’s working principles and operating procedures. Provide professional safety training for new employees, helping them understand potential risks and how to respond.
2-1-2. Appropriate Clothing and Accessories
- Proper Clothing:
Wear snug-fitting clothing to prevent long sleeves or loose clothing from being caught in the machine. Operators with long hair should tie it up or use a hairnet or hat. - Safety Accessories:
Wear gloves, safety goggles, safety shoes, and a safety lanyard with a breakaway design. Gloves, goggles, and safety shoes protect against mechanical injury. The lanyard should have a quick-release feature so that if it gets caught or pulled, it can quickly detach, preventing the technician from being dragged into the machine. In areas with machine operation, the lanyard should be tucked inside the clothing to prevent it from being caught.
2-1-3. Equipment Inspection
- Before operation, check whether all equipment is functioning properly, including indicator lights, emergency stop devices, etc.
- Inspect the machine for any unusual noises, loose or worn parts, and contact maintenance personnel for repairs if necessary.
2-1-4. Confirm your own environmental conditions
Clear the work area of debris to prevent paper scraps or tools from jamming the machine. Maintaining a clean and tidy environment reduces the risk of slipping or tripping.
2-2. Safety Regulations During Operation
During the operation of post-press equipment, operators must remain vigilant and follow safety guidelines. Here are some important safety measures:
- Stay Away from Moving Mechanical Parts:
Never touch dangerous areas like the die, rollers, or heating plates while the equipment is running. Use tools for adjustments or cleaning instead of handling machinery directly. - Monitor Equipment Status at All Times:
Continuously observe the equipment for abnormalities such as unusual noises, vibrations, or jams. If an issue is detected, stop the operation immediately and inspect the equipment. - Avoid Multiple Operators at Once:
Ideally, only one person should operate the machine at a time. If maintenance or testing requires multiple people, maintain good communication to prevent accidental operations or switching on the machine. No other individuals should be present in the operation area while the machine is running to avoid accidents. - Maintenance and Cleaning of Equipment:
Only perform maintenance or cleaning when the machine is completely shut down and powered off. Regularly maintain the machine to ensure stable operation.
2-3. Emergency Response
- Emergency Stop Devices:
Each machine should be equipped with an emergency stop button, and operators must know its location. In cases of machine jams or material blockages, immediately press the emergency stop button. - Handling Equipment Failures:
If a machine malfunctions during operation, quickly cut off the power and wait for the equipment to fully stop before conducting inspections or repairs. Do not attempt repairs while the machine is running to avoid further damage or injury to operators. - Emergency Injury Treatment:
If an operator is injured, immediately notify the supervisor and seek medical assistance. The workplace should have a first aid kit available, and employees should undergo regular first aid training.
3. Key Maintenance Items
3-1. Die Cutting Machine Maintenance
- Maintenance of Cutting Dies:
Regularly check the sharpness of the cutting dies, sharpening or replacing them as needed to ensure cutting quality. - Pressure System Check:
Inspect the pressure settings of the die cutting machine, ensuring even pressure to avoid deforming or damaging paper boxes due to uneven pressure. - Positioning Device Adjustment:
Regularly adjust the machine’s positioning system to maintain cutting accuracy.
3-2. Folder Gluer Machine Maintenance
- Glue Supply System Cleaning:
Clean the glue supply system daily to prevent dried glue from clogging the pipes or causing uneven application. - Conveyor Belt Maintenance:
Regularly inspect the conveyor belt of the folder gluer machine to ensure it is free from cracks or deformation, replacing it when necessary. - Glue Nozzle Check:
Inspect the condition of the glue nozzles to ensure precise glue supply, preventing wastage and ensuring product adhesion.
3-3. Hot Stamping Machine Maintenance
- Temperature Control System Check:
Regularly inspect the temperature control system of the hot stamping machine to ensure stable temperatures and avoid issues from excessive or insufficient heat affecting the stamping effect. - Cleaning of Stamping Molds:
After each operation, clean the hot stamping molds to prevent residual foil from affecting subsequent operations. - Pressure Adjustment:
Regularly check the stamping pressure to ensure it is evenly distributed, ensuring clear and defect-free stamped patterns.
4. Conclusion
The world’s largest mobile phone manufacturer, APPLE, CEO Tim Cook once said: “The health and safety of our employees is our top priority”. I believe that everyone also places great importance on the health and safety of employees in the enterprise, and operating post-press equipment is like driving on the road. No matter how powerful your car is or how skilled your technique may be, safe driving is the most basic and important thing. You can have extremely high speeds and perfect routes, but if you don’t fasten your seatbelt or follow traffic rules, a small mistake could lead to a serious accident.
In post-press equipment operation, safety is like the seatbelt. Even if the equipment operates efficiently and the product is flawless, if the operator neglects basic safety protocols, it’s like driving without a seatbelt—danger could strike at any time. Take a moment to check the equipment and wear protective gear, just like fastening your seatbelt before driving, to ensure safety all along the way.
Absolutely! Safety should always be the top priority because it’s the only way to truly protect the well-being of employees. When safety is prioritized, not only does it safeguard lives, but it also ensures smoother operations and long-term success for the business. Wouldn’t you agree?