A plastic packaging factory usually includes film blowing machines, bag cutting machines with a high level of automation and operating speed, high operating voltage, which easily leads to a significant risk of injury. This makes it necessary for factories to be equipped with safety systems and equipment designed to minimize operating hazards.
1. Possible risks when working in a plastic packaging factory
Mechanical risks of machines
Machines in the plastic packaging factory, including blow molding machines, cutters and bag bottom presses all have rotary or reciprocating motors. When the machine starts up, when adjusting parameters or during cleaning and maintenance activities, there are times when occupational accidents can occur. For example, clothes, hair or limbs get entangled in motors, conveyors, transmission lines, etc. These types of machines often perform very fast operating cycles and can cause scratches, tears, and even crushing of body parts if accidentally entangled.
In companies specializing in the production of plastic packaging, packaging workshops, machines often operate continuously to reduce energy costs for starting the system. As a result, operators of packaging machines or automatic packaging machines often have to work long hours and sometimes even at night. Such working frequency also easily leads to distraction, the risk of occupational accidents is also higher.
In addition, the risks of falling from height or falling on slippery floors, electric shocks due to open lines or faulty equipment are always possible. These hazards are not unique to the manufacturing and packaging factory, but are common to any industrial operation.
Mechanical parts on plastic bag cutters are always potentially dangerous for the operator
Physical risks of manual handling operations
The task of packing or cutting plastic bags, punching plastic bags is usually done in a standing or sitting position for a long time. And handling these operations on machines or tools requires more or less physical effort. Minimizing possible risks such as crushing fingers, cutting hands, etc. depends largely on the safety and design of the machines or tools used. However, constant attention and skill, stable working speed are also important factors to ensure occupational safety.
For both semi-automatic and automatic plastic bag bottom cutting and pressing equipment, sorting the bags and packing them also causes the operator to make repetitive gestures over and over again, which can lead to musculoskeletal disorders, or even the gradual aging of skeletal structures.
Chemical and radioactive risks
There are chemical risks specific to the plastic packaging industry when chemicals are used, especially for printing inks. In addition, machine cleaning detergents or special additives also need safe and appropriate use procedures.
Food packaging factories that use UV or Gamma-ray sterilization processes also have a small probability of creating radiation risks.
Other risks
Finally, it is necessary to take into account the rarer occupational risks for the plastic packaging industry, such as noise pollution, temperature and working time differences (alternating day and night shifts).
Noise in packaging factorys and packaging workshops is emitted by operating machinery, the external environment or various other sound sources. Sound pressure levels up to 85 dB are considered to be harmful to the auditory system (hearing loss, tinnitus), cause discomfort or stress affecting workers' health and concentration.
In addition to emitting sound, nylon film, roll blowing machines also emit a huge amount of heat in the process of melting plastic beads. If the workshop does not have an effective ventilation or cooling system, the workplace will quickly become overheated. Workers are more likely to be dehydrated and less alert, easily posing risks to occupational safety.
The way of arranging alternate working schedules between day and night shifts for a long time in some packaging factories is also considered unreasonable, causing biological imbalance and long-term impacts on the health of the workers.
2. Occupational risk prevention measures in plastic packaging factory
Although the risks in industrial production are many and unpredictable. However, the application of safety standards in production can reduce them to a very low level, in order to create a safe and comfortable working environment for workers, so that productivity can also be improved to better.
Installation of a safe electrical system
Fires or explosions are mostly caused by failures of electrical systems and equipment, check for equipotentiality and proper grounding of all metal mechanical systems, and replace faulty sockets. Avoid static electricity build-up, sparks and overheating caused by motor and heating resistors
The electrical safety system needs to be implemented in parallel with the fire protection system, the ventilation system, reasonably and effectively.
Adequate ventilation for the workplace
Workplace ventilation systems play an essential role in limiting the concentration of all harmful gases, dusts and vapors in the air, diffusing them to the outside to minimize the effects on people's health. Sufficient ventilation and air provision are also essential to prevent the accumulation of flammable mixtures.
Reasonable workshop design can create natural ventilation by wind or air pressure. Mechanical ventilation is created by suction and blowing: the air is transported by the ventilation fan into the workplace, forming a ventilated airflow, and finally being sucked out of the room by the exhaust fan.
Every device requires warning lights and an emergency stop button
Automated and mechanized plastic packaging production machinery but still ensures safety in operation
Today, the processes of most packaging companies have been greatly modernized, making machine operations lighter and also significantly reducing physical and chemical risks. The operation of setting and changing parameters of current, motor speed or heating temperature are all controlled by a central computer, limiting direct intervention into mechanical parts. However, failures during automation will still create hazards without the right safety devices in place. A high-performance safety system must both not interfere with the production process and constantly ensure the physical integrity of the operator under all circumstances.
All machines must have necessary warnings and signals to ensure the safety of workers, in order to eliminate or minimize to a minimum the risks of cutting, rolling, crushing, cutting due to factors affecting directly or indirectly directly or indirectly. These warning signs or lights must be made with pictograms and standardized colors (in particular, the color symbolizing danger is red and of note, yellow). Machines must be located, protected and controlled so that the operator cannot access the hazardous area even during adjustment or maintenance. Or, if access to a hazardous area is required, a sensor or body temperature or presence or motion detection device is required, which will lock the movement of components in the presence of the operator. Each machine shall be fitted with one or more clearly identifiable and easily accessible emergency stopping devices.
Plastic film blowing machines need a temperature sensor and adjustment to avoid overheating, causing plastic decomposition to produce dangerous gases. Sensors measure pressure and adjust devices to avoid internal overpressure.
Maintain and check regularly that guards, locking or interlocking devices and emergency stopping devices are in place and in good working order. Use and maintenance of the machine must be carried out by qualified, professionally trained personnel. Pneumatic hoses must be periodically inspected and replaced when worn or impacted, or according to the specified service life.
Safe working process
Personal precaution by following safety procedures, wearing protective equipment is the last line of defense when unforeseen events occur. They clearly reduce the severity of accidents if any, and therefore safety regulations should be considered mandatory at all stages of production. Information on occupational safety should be posted on notice boards in the factory, accompanied by training sessions on safety for workers.
Specialized packaging production workshops with complex machines need in-depth risk analysis to prepare occupational safety documents. Evaluate all physical and technical environment (tools, machinery used) and effectiveness of protective facilities and equipment. There should be a procedure for the movement of personnel out of the hazard area in the event of an incident, guided by signs or permanent obstructions such as fences, railings or nets.
Production workshops can also research and improve equipment in the direction of ergonomics to reduce the drudgery of work. For example, bring the operating point on the machine closer to the worker's sitting position to avoid leaning, using accessories such as ergonomically designed seats or anti-fatigue mats. There are also tools to support manual work such as pallet wrapping equipment, trolleys, hand or electric forklifts, ...
