Title Page
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Site conducted
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Conducted on
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Prepared by
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Location
Section 1 - 9
Section:1 Reel Preparation Area
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1) There should be a safe area away from lift truck movement where an operator can safely prepare the paper reels for production. NB: this area should be clear of falling paper reels and where necessary protected with “A safe barriers” to prevent collisions with operators.
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2) Has a job task risk assessment been completed for this task? If so, does it capture all the known hazards? Has the risk assessment been communicated to all affected operators and is there a record of this communication?
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3) Has this safe working area been communicated to the operators highlighting the safety control measures? (this can be done via the site safety rules or operational SOP or via a toolbox talk). Is there a record of this training/ communication/ toolbox talk?
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4) Have the residual risks been communicated in this area via warning signage such as danger lift trucks and danger risk of falling paper reels?
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5) Have the mandatory requirements been communicated in this area via signage such as ‘high visibility clothing/safety footwear or eye protection’ must be worn?
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6) Is the reel warehouse a pedestrian free zone with a formal documented entry procedure and adequate safety signage and if so, have all site personnel received information, instruction and training on this procedure, including records of training?
Section:2 Reel Handling Conveyors/Tracks
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1) The reel trolley tracks should be seated into the ground (to prevent a tripping and falling hazard) and the reel trolley should be highlighted in yellow paint with black stripes.
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2) Where a conveyor belt is fitted or caterpillar track, there shall be no gaps in the conveyor larger than 5mm to prevent hand and fingers injuries.
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3) Have all electrical control cabinets been securely locked to prevent unauthorised access?
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4) There should be some emergency stop buttons located at this area of the machine?
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5) Has this equipment been fitted with lockable energy isolation devices (electrical, Pneumatic or hydraulic)? If so, have these devices been identified?
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6) Has a risk assessment been completed for this area? If so, has it captured all hazards, been communicated and recorded to all relevant operators?
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7) Has the site prepared an SOP for safely operating the reel handling conveyors or tracks. If so, have all affected operators been trained in this SOP and is there a record of this training?
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8) Is it possible to release & open the roll stand arms when the machine has a full or part roll in operation, or standing ready to go into production.?
Section:3 Reel Stands (Auto/Manual)
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1) Reel stands fitted with automatic reel loading shall be fitted with ESPE light guards that stop movement of the conveyor & reel stand arms if a person enters the area when the automatic process is activating or stationary.
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2) The ESPE light guard shall be fitted with a safety reset button located outside of the danger zone (so an operator cant reset it whilst stood inside the ESPE guarding) but close enough to see that all persons are clear before rearming the guard.
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3) Manually operated reel stands should be fitted with a 2handed hold to run control to keep the operators hands clear of the reel clamps when fitting a reel. This control will be located a safe distance from the hazard, but close enough to check the reel is safely clamped into position before attempting to lift the reel into a run position.
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4) Have all electrical control cabinets been securely locked to prevent unauthorised access?
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5) Has this equipment been fitted with lockable energy isolation devices (electrical, Pneumatic or hydraulic)? If so, have these devices been identified?
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6) Have the reel stands been fitted with mirrors at the drive side of the reel stands to help the operator have good vision that the paper reel stand is clamped correctly?
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7) Has a job task risk assessment been completed for this task? If so, does it capture all the known hazards? Has the risk assessment been communicated to all affected operators and is there a record of this communication?
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8) Has the site prepared an SOP for safely operating the reel stands? If so, have all affected operators been trained in this SOP and is there a record of this training?
Section:4 Splicers (Auto & Manual)
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1) Have automatic splicers been protected with ESPE light guards that stop the movement of the splicer when a person gets close to this equipment?
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2) Is the ESPE light guarding fitted with a safety reset button located outside of the danger zone (enabling only a reset outside the ESPE area whilst still retaining a clear line of sight within).
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3) If a manually operated splicer, are they fitted with a 2handed hold to run control keeping the operators clear of the moving splicer (or the control should be a safe distance from the splicer)?
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4) Have all dangerous gears, rollers and cutting devices been fitted with suitable guards (where necessary) to prevent a person trapping/injuring their hands and fingers?
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5) Has the splicer been fitted with an emergency stop control wire that will immediately stop the splicer in the event it is activated?
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6) Have all electrical control cabinets been securely locked to prevent unauthorised access?
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7) Has this equipment been fitted with lockable energy isolation devices (electrical, Pneumatic or hydraulic)? If so, have these devices been identified?
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8) Has a risk assessment been completed for this task? If so, does it capture all the known hazards? Has the risk assessment been communicated to all affected operators and is there a record of this communication?
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9) Has the site prepared an SOP for safely operating the splicer? If so, have all affected operators been trained in this SOP and is there a record of this training?
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10) Has appropriate warning signage been installed to warn operators of the risk of crushing and automatic equipment?
Section:5 Single Facers
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1) Have the corrugator roll and press rolls been protected with fixed or interlocked guarding to prevent immediate access to dangerous moving machinery?
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2) Has access to the moving preheater wrap arms been protected with fixed or interlocked guarding to prevent immediate access to this dangerous moving machinery?
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3) Have the moving drive shafts (usually located at the drive side of the single facers) been protected with fixed or interlocked guarding?
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4) Have all inward nips (sandwich belts) been protected with fixed guarding?
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5) There should be some emergency stop buttons located at this area of the machine?
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6) Have all electrical control cabinets been securely locked to prevent unauthorised access?
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7) Are there satellite starch holding tanks in this area and if so is there a fixed access platform with access stairs (not ladders) to assist the safe access and egress to and from this area and have the tanks access point been fitted with grates to prevent a person falling into the tanks.
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8) Has a suitable noise reducing enclosure been fitted around the single facer machine?
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9) Have all exposed hot steam pipes been protected with thermal resistant cladding up to a height of 2.7metres?
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10) Has a suitable work platform with a hand rail been provided to safely access the single facer machine (where necessary)?
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11) Has this equipment been fitted with lockable energy isolation devices (electrical, Pneumatic, steam or hydraulic)? If so, have these devices been identified?
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12) Has a job task risk assessment been completed for this task? If so, does it capture all the known hazards? Has the risk assessment been communicated to all affected operators and is there a record of this communication?
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13) Has the site prepared an SOP for safely operating the single facer? If so, have all affected operators been trained in this SOP and is there a record of this training?
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14) Has suitable warning signage been posted in and around the machine covering the following hazards, Hot surfaces hazard, automatic machinery hazard, crushing hazard and noise hazard?
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15) Has mandatory safety signage been posted at the area for the following; Hearing protection worn, thermal gloves and sleeves worn when threading up the machine, bump caps worn when threading up the machine, Stop and isolate machinery before attempting to remove jam ups or making technical adjustments.
Section:6 Double Facer/Hot Plate Section
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1) Has appropriate guarding been fitted to the glue rolls to prevent immediate access to dangerous moving machinery? (A mix of fixed or interlocked guarding).
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2) Has access to the moving preheater wrap arms been protected with fixed or interlocked guarding to prevent immediate access to this dangerous moving machinery? (Also check the triple stack wrap arm area).
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3) Have access gates been fitted between the double backer glue unit and the entrance to the short press section (to prevent an operator reaching dangerous parts of moving machinery) of the machine that when open, will only allow the machine to run in crawl speed?
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4) Have all dangerous moving rollers, belts and pulleys been protected with a mix of fixed or interlocked guarding?
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5) There should be some emergency stop buttons located at this area of the machine and an emergency stop trip wire including a reset button on the trip wire control?
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6) Has this equipment been fitted with lockable energy isolation devices (electrical, Pneumatic, steam or hydraulic)? If so, have these devices been identified?
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7) Are there satellite starch holding tanks in this area and if so, is there a fixed access platform with access stairs (not ladders) to assist the safe access and egress to and from this area and have the tanks access point been fitted with grates to prevent a person falling into the tanks?
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8) Have all exposed hot steam pipes been protected with thermal resistant cladding?
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9) Has a job task risk assessment been completed for this task? If so, does it capture all the known hazards? Has the risk assessment been communicated to all affected operators and is there a record of this communication?
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10) Has the site prepared an SOP for safely operating the double backer? If so, have all affected operators been trained in this SOP and is there a record of this training?
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11) Has suitable warning signage been posted in and around the machine covering the following hazards, Hot surfaces hazard, automatic machinery hazard, crushing hazard and noise hazard?
Section:7 Bridge Section
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1) Have suitable access stairs been fitted to allow a safe access to & from the bridge area? (the stairs should have hand rails at both sides of the stairs). Are the stairs in good condition?
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2) Has the top area of the working platform near to the stairs been fitted with a self closing gate(s)? Do these gates immediately self close after being released?
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3) Has the top of the bridge working platform been fitted with hand rails 1100mm high, a 500mm intermediate rail and a 100mm toe board (Ops & drive side of machine)?
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4) Has the top section of the bridge (web support area) been fitted with hand rails 1100mm high, a 500mm intermediate rail and a 100mm toe board? Has a stairway or ladder been provided to allow the safe access and egress to this area?
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5) Have the triple stack wrap arms been fitted with appropriate guarding? (Interlocked access gates/ guarding or ESPE guarding)?
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6) Have all steam pipes around the triple stack been lagged with thermal protection to prevent contact with hot surfaces & all hot surfaces been identified with warning signage such as “danger hot surfaces”?
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7) Have all nip points been guarded on the bridge brake guidance system? (ESPE or interlocked access gates)
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8) Does the bridge have trap doors to allow the safe removal of waste from this area and if yes, can this trap door be locked to prevent a person falling from height?
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9) Is there a formal written SOP for the safe removal of waste from the bridge area and if so, have all affected persons been trained in the standard operating procedure for the safe removal of waste from the bridge area including records of this training?
Section:8 Rotary Shear
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1) Has suitable guarding been fitted to and around the rotary shear to prevent an operator touching or reaching the moving shear blade or other dangerous moving parts of equipment? (A mix of fixed and interlocked guarding is required).
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2) Has a suitable interlocked access gate been installed on the waste bin area that will stop all the movement of the rotary shear when the interlocked access door has been opened?
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3) Has a safety gate reset button located outside of the danger zone (so an operator cant reset it whilst stood inside the guarding) but close enough to see that all persons are clear before rearming the guard? Please note the reset button should only reset the one gate.
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4) Is the waste bin easy to remove from the machine? Are all the wheels working correctly and is the waste bin in good condition?
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5) There should be some emergency stop buttons located at this area of the machine?
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6) Has this equipment been fitted with lockable energy isolation devices (electrical, Pneumatic, or hydraulic)? If so, have these devices been identified?
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7) Has a job task risk assessment been completed for this task? If so, does it capture all the known hazards? Has the risk assessment been communicated to all affected operators and is there a record of this communication?
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8) Has the site prepared an SOP for safely operating the rotary shear? If so, have all affected operators been trained in this SOP and is there a record of this training?
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9) Has suitable warning signage been posted in and around the machine covering the following hazards, automatic machinery hazard, cutting hazard, crushing hazard and noise hazard?
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10) Has mandatory safety signage been posted at the rotary shear machine area for the following, Hearing protection must be worn, cut resistant gloves and sleeves to be worn when handling blades or entering the machine, bump caps must be worn when entering the machine, Stop and isolate machinery before attempting to remove jam ups or making technical adjustments.
Section:9 Cross over bridge/platform
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1) Has suitable guarding been fitted to and around the rotary shear to prevent an operator touching or reaching the moving shear blade or other dangerous moving parts of equipment? (A mix of fixed and interlocked guarding is required).
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2) Has a suitable interlocked access gate been installed on the waste bin area that will stop all the movement of the rotary shear when the interlocked access door has been opened?
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3) Has a safety gate reset button located outside of the danger zone (so an operator cant reset it whilst stood inside the guarding) but close enough to see that all persons are clear before rearming the guard? Please note the reset button should only reset the one gate.
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4) Does the machine have a ripper tape stand and if yes, has a suitable work platform with access stairs (operator and drive side) been provided and a support bar fitted to the ripper tape heads area to prevent a person falling into the machine when they are working in this area?
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5) Does the platform have an access gate into the rotary shear and if so has the access gate been fitted with an electronic interlock that will fully stop and isolate the machine if a person has to enter this area and has the access gate been fitted with a safety reset button that is located outside of the danger zone (not reachable from inside this area) but close enough to see if all personnel are clear of this area before resetting the gate switch? 6) Are the ripper tape heads protected with ESPE light guards to prevent a crushing injury and if so, has a safety reset button been fitted to reset the ESPE light curtains outside of the danger zone (not reachable from inside this area) but close enough to see if all personnel are clear of this area before resetting the light curtain?
Section 10 - 16
Section:10 Slitter Scorer unit
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1) Has suitable guarding been fitted to and around the slitter scorer to prevent an operator touching or reaching the moving cutting blades or other dangerous moving parts of equipment? (A mix of fixed and interlocked guarding is required).
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2) Has a suitable interlocked access gate been installed on the operators side and drive side of the machine that will stop and isolate the machine when the interlocked access door has been opened?
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3) Has a safety gate reset button located outside of the danger zone (so an operator cant reset it whilst stood inside the guarding) but close enough to see that all persons are clear before rearming the guard? Please note the reset button should only reset the one gate.
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4) There should be some emergency stop buttons located at this area of the machine?
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5) Has this equipment been fitted with lockable energy isolation devices (electrical, Pneumatic, or hydraulic)? If so, have these devices been identified?
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6) Has a job task risk assessment been completed for this task? If so, does it capture all the known hazards? Has the risk assessment been communicated to all affected operators and is there a record of this communication?
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7) Has the site prepared an SOP for safely operating the slitter scorer? If so, have all affected operators been trained in this SOP and is there a record of this training?
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8) Has suitable warning signage been posted in and around the machine covering the following hazards, automatic machinery hazard, cutting hazard, crushing hazard and noise hazard?
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9) Has mandatory safety signage been posted at this area of the machine for the following, Hearing protection must be worn, cut resistant gloves and sleeves to be worn when handling slitting knives or entering the machine, bump caps must be worn when entering the machine, Stop and isolate machinery before attempting to remove jam ups or making technical adjustments.
Section:11 Chop Unit
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1) Has suitable guarding been fitted to and around the chop unit to prevent an operator touching or reaching the moving cutting blades or other dangerous moving parts of equipment? (A mix of fixed and interlocked guarding is required).
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2) Has a suitable interlocked access gate been installed on the operators side and drive side of the machine that will stop and isolate the machine when the interlocked access door has been opened?
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3) Has a safety gate reset button located outside of the danger zone (so an operator cant reset it whilst stood inside the guarding) but close enough to see that all persons are clear before rearming the guard? Please note the reset button should only reset the one gate.
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4) There should be some emergency stop buttons located at this area of the machine?
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5) Has this equipment been fitted with lockable energy isolation devices (electrical, Pneumatic, or hydraulic)? If so, have these devices been identified?
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6) Has a job task risk assessment been completed for this task? If so, does it capture all the known hazards? Has the risk assessment been communicated to all affected operators and is there a record of this communication?
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7) Has the site prepared an SOP for safely operating the chop unit? If so, have all affected operators been trained in this SOP and is there a record of this training?
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8) Has suitable warning signage been posted in and around the machine covering the following hazards, automatic machinery hazard, cutting hazard, crushing hazard and noise hazard?
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9) Has mandatory safety signage been posted at this area of the machine for the following, Hearing protection must be worn, cut resistant gloves and sleeves to be worn when handling slitting knives or entering the machine, bump caps must be worn when entering the machine, Stop and isolate machinery before attempting to remove jam ups or making technical adjustments.
Section:12 Up & Down Stackers
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1) Has suitable guarding been fitted to and around the stackers to prevent an operator touching or reaching the dangerous moving parts of equipment? (A mix of fixed and interlocked guarding is required).
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2) Has a safety gate been fitted across the web conveyor (top stacker) that will stop and isolate the machine if this device has been activated? (Please note check the safety gate is not too close to the pressure roller)
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3) Has a safety trip wire been installed across the web (bottom stacker) that will stop and isolate the machine when this device has been activated?
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4) Has the safety trip wire been fitted with a reset switch?
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5) Does the machine have an audible and visible warning when the upper stacker conveyor is about to speed up on order changes?
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6) Have suitable ESPE light curtains been fitted to the outfeed conveyors to stop and isolate the machine if a person enters the lift area with the machinery running.
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7) Have suitable ESPE light curtains been fitted below the stacker lifts that can detect a person if they are stood under the lift and do these light guards stop and isolate the equipment?
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8) The ESPE light curtains should be fitted with a safety reset buttons located outside of the danger zone (so an operator cant reset it whilst stood inside the ESPE guarding) but close enough to see that all persons are clear before rearming the guard?
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9) Have the stacker lifts been fitted with securing pins that can support the weight of the lift during maintenance and cleaning activities?
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10) Do these stacker securing pins stop and isolate the machine when they are inserted into position? (Are the pins fitted with an interlock switch that stops and isolates the machine when they have been removed from the storage position?).
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11) There should be some emergency stop buttons located at this area of the machine?
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12) Has this equipment been fitted with lockable energy isolation devices (electrical, Pneumatic, or hydraulic)? If so, have these devices been identified?
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13) Has a job task risk assessment been completed for this task? If so, does it capture all the known hazards? Has the risk assessment been communicated to all affected operators and is there a record of this communication?
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14) Has the site prepared an SOP for safely operating the stackers? If so, have all affected operators been trained in this SOP and is there a record of this training?
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15) Has suitable warning signage been posted in and around the machine covering the following hazards, automatic machinery hazard, crushing hazard and noise hazard?
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16) Has mandatory safety signage been posted at this area of the machine for the following, Hearing protection must be worn, stop and isolate machinery before attempting to remove jam ups or making technical adjustments.
Section:13 Outfeed Conveyors
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1) Have the outfeed conveyors been fitted with slip resistant access steps and a working platform between the conveyors?
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2) The gaps between the conveyors should not exceed the required 5mm? (There shall be no gaps in the conveyor larger than 5mm to prevent hand and fingers injuries). If they do, are they fitted with nip guards?
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3) Have roller conveyors been fitted with crossing points?
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4) Have roller conveyors (free running rollers) been identified with red paint to prevent a person slipping and falling on them.
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5) There should be some emergency stop buttons located at this area of the machine?
Section:14 Bulk Starch Silo
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1) If a bulk starch silo is installed, does it have an access ladder to the top of the silo and if so, has the ladder been securely locked to prevent unauthorised access?
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2) Has the silo been fitted with an earth lead that needs attaching to the bulk LGV tanker and if so, is this earth lead in good condition?
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3) Is the access door under the silo locked to prevent unauthorised access?
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4) Is there an SOP present at the starch silo showing the starch transfer procedure?
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5) Is there hazard warning signage present warning of the risk of explosion?
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6) Has the top of the silo been fitted with an explosion vent?
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7) Is the starch silo in good condition/ good state of repair?
Section:15 Starch Kitchen
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1) Is there a working platform installed around the starch mixing and holding tanks?
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2) Is the working platform fitted with access stairs with hand rails on both sides?
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3) Is the working platform fitted with hand rails 1100mm high, with a 500mm intermediate rail and a 100mm toe board?
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4) Has secure grating been fitted to the access points into the mixing and holding tanks that will prevent a person falling into the tanks?
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5) Where a static caustic soda tank is fitted, has the access hatch been securely locked?
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6) Is caustic soda mechanically pumped into the mixing tank?
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7) Has the caustic soda tank been fitted inside a bund that will easily capture the full contents of the tank (one and a half times the contents) should the tank start leaking?
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8) If caustic soda IBCs are used to pump it into the mixing tanks, has a chemical risk assessment been completed and have the required control measures been implemented?
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9) Is the IBC tank sat on top of an appropriate bund pallet or located in a bunded area?
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10) Has the starch kitchen been fitted with an emergency shower? If so, is this emergency shower flushed and checked on a regular basis (at least once per week)
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11) Has an eye wash station been installed into the starch kitchen area that is easily accessible?
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12) Are biocides mechanically pumped from an IBC tank into the starch missing process?
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13) If biocides are manually (in sacks) put into the mixing tanks, has a chemical risk assessment been completed and have the required control measures been implemented?
Section:16 Other Safety Items
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1) Has the machine been CE marked to comply with the Machinery Directive 2006/42/EC and has the machine been issued with a Declaration of Conformity?
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2) Has the machine been fitted with CE making plates?
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3) Does the emergency stop, control stop all the machine up and down stream? (The emergency stop must stop the machine from the reel stands down to the stacker area).
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4) Has the machine been fitted with an audible start up/ jogging alarm that is loud enough to be heard from all areas of the machine?
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5) Does the start up/ jogging alarm sound for 3 seconds before attempting to start the machine?
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6) Have all electrical control cabinets been securely locked to prevent unauthorised access?
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7) Have all persons running and maintaining the machine received appropriate training? Look for training records from the OEMs and from other sources.
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8) Have all controls been labelled in the country language?
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9) Has the machine been supplied with operator and maintenance hand books that are translated into the country language?
Sign Off
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Completed by (Name, Signature & Sign Date)
