Thermoforming Machines

Thermoforming machines take rolls of plastic sheeting, heat them, and form them into parts. Although much of the process is automated and requires little operator interaction, there are portions of the process during setup and production that need human involvement, and therefore present potential hazards that need to be addressed.

Setup

• Hazards (Roll Handling): Moving/falling rolls and equipment, as well as broken equipment, put the operator at risk. There are also pinch points on the frame of the machine.
• Potential Safeguards (Roll Handling): Whenever possible, workers should avoid working under suspended material or equipment.
• Hazards (Feed End Handling): Crushing, pinching, or other injuries are possible when hands are placed in feed mechanisms. There are also rotating shafts and nip points in several places on the machine.
• Potential Safeguards (Feed End Handling): Utilizing fixed or interlocked guards over pinch points will minimize this risk. The use of presence-sensing devices for danger zones and fixed guards on other moving pieces provide the best protection.

Production - Form Station

• Hazards: Burns from hot surfaces are possible, as is electric shock from exposed wires. Because of the numerous parts in this machine, crushing, pinching, or other injuries may occur.
• Potential Safeguards: Fixed or interlocked guards may be implemented to prevent employee access to danger zones. Presence-sensing devices may be used as well. It is important for workers to always wear appropriate protective clothing and safety equipment.

Production - Trim Station

• Hazards: Workers are subject to cuts from sharp edges and burns from hot surfaces. Moving chains can also trap clothing and body parts while in operation.
• Potential Safeguards: Proper lockout/tagout procedures will prevent the machine from activating while preparations are being made. Workers should utilize protective clothing and equipment during repairs. Fixed barrier guards, interlocked gates, or adjustable barrier guards can be installed to prevent employee access to danger zones and moving chains.

Production - Stacker

• Hazards: The stacker implements a variety of moving machine parts, and there can be unguarded platforms where employees perform work.
• Potential Safeguards: Installing a top fixed guard on low-profile machines will prevent objects and body parts from being lodged in the moving parts. Adjustable guards and a correctly positioned operator station can prevent employees from encountering danger zones. Finally, installing guardrails on platforms is one of the easiest, most effective methods of preventing falls.

Production - Manual Packing and Inspecting

• Hazards: Unguarded platforms can lead to trips, slips, and falls. Workers are also exposed to sharp objects, and sometimes must work through awkward body positions.
• Potential Safeguards: Guardrails and stable platforms and steps will prevent slips, trips, and falls. Utilizing appropriate protective clothing and equipment will help minimize the risk from sharp objects. Building a workstation that is the appropriate height will go far in helping with body position.

Production - Scrap Rewinder

• Hazards: Pinch points and nip points are present, and workers may have to work in awkward body positions.
• Potential Safeguards (Scrap Rewinder): Protective clothing and equipment for employees are key when working with unavoidable hazards. A workstation platform that is constructed at an appropriate height will allow for more comfort while working.

Production - Guillotine Cutter

• Hazards: Nip points, and a large moving knife blade, present hazards to workers. Additionally, dust exposure can be a problem for workers exposed over a long period of time.
• Potential Safeguards: Barriers and light curtains can be installed to prevent work from being done while employees are in the danger zone. Ensuring the workspace is properly ventilated will help to clear dust.

Production - Web Grinder

• Hazards: Rotary and stationary knives present cutting hazards.
• Potential Safeguards: Energy control procedures during maintenance will prevent the blades from moving while being repaired. Barriers and light curtains can prevent the machine from operating while employees are near hazardous parts. Another method of protection is proximity guarding to create distance between the area where stick is fed and the sharp blades inside.

Production - Chain Rail

• Hazards: Moving chains and sprockets can catch clothing or body parts.
• Potential Safeguards: Avoiding loose clothing and personal items can prevent an employee from being caught by the chains. Proper lockout/tagout procedures will ensure that the chains do not move during maintenance. Additional barriers can be implemented to prevent chain access.

Production - Heating Oven

• Hazards: In the oven, burns from hot surfaces and electric shock from exposed wires are possibilities. There are also pinch points where the door opens.
• Potential Safeguards: Proper lockout/tagout procedures will alert other employees that repairs are being made. Workers should also utilize the proper tools and protective clothing and equipment.

To learn more about Machine Guarding visit our Machine Guarding Safety Online Training web page.