Plastics Manufacturing Safety Manual

Plastics Manufacturing OSHA Requirements

Federal OSHA does not maintain one comprehensive standard specifically regulating all plastics manufacturing operations.

Instead, plastics manufacturers may be subject to applicable General Industry requirements addressing hazards such as:

• Machine guarding.
• Control of hazardous energy.
• Electrical safety.
• Personal Protective Equipment.
• Hazard Communication.
• Respiratory protection.
• Walking-working surfaces.
• Powered Industrial Trucks.
• Flammable liquids.
• Fire prevention.
• Noise exposure.
• Other workplace hazards.

The safety manual should therefore be based on the company’s actual processes and employee exposures rather than treating plastics manufacturing as though it were governed by a single OSHA plastics standard.

Types of Plastics Manufacturing Operations

Plastics processing can involve substantially different equipment and hazards.

Operations may include:

• Injection molding.
• Extrusion.
• Sheet extrusion.
• Film extrusion.
• Thermoforming.
• Blow molding.
• Injection blow molding.
• Rotational molding.
• Compression molding.
• Plastic grinding.
• Granulation.
• Pellet handling.
• Compounding.
• Mixing and blending.
• Plastic welding.
• Assembly.
• Printing or decorating.
• Finishing.
• Packaging.

The programs included in the manual should reflect the operations actually performed.

What Should a Plastics Manufacturing Safety Manual Include?

Depending on operations, a Plastics Manufacturing Safety Manual may address:

• Plastics manufacturing safety responsibilities.
• Hazard assessments.
• Job Safety Analysis.
• Machine guarding.
• Injection molding safety.
• Extrusion safety.
• Thermoforming safety.
• Blow molding safety.
• Robots and automation.
• Grinders and granulators.
• Conveyors.
• Lockout/Tagout.
• Mold changes.
• Machine setup.
• Preventive maintenance.
• Hydraulic systems.
• Pneumatic systems.
• Hot surfaces and molten plastic.
• Chemicals and additives.
• Hazard Communication.
• Ventilation.
• Respiratory protection.
• Personal Protective Equipment.
• Hearing Conservation.
• Forklift safety.
• Ergonomics.
• Material handling.
• Fire prevention.
• Emergency procedures.

Programs should be selected according to the company’s equipment, resins, production methods, chemicals, material-handling operations, and employee exposures.

Plastics Manufacturing Safety Program

An effective Plastics Manufacturing Safety Program establishes responsibilities and procedures for controlling machinery, hazardous energy, heat, chemicals, material handling, automation, and other plastics-processing hazards.

Management should provide employees with properly guarded machinery, appropriate ventilation, PPE, training, supervision, maintenance resources, and safe work procedures.

Managers, supervisors, and designated safety personnel should:

• Identify and evaluate workplace hazards.
• Maintain applicable written safety programs.
• Verify machine guards and interlocks are maintained.
• Establish safe operating procedures.
• Establish Lockout/Tagout procedures.
• Evaluate chemical and process exposures.
• Maintain ventilation systems.
• Provide appropriate PPE.
• Maintain mobile equipment.
• Correct unsafe conditions.
• Investigate incidents.
• Provide employee training.
• Maintain applicable records.

Employees should follow established procedures, inspect equipment, use guards and safety devices, wear required PPE, follow hazardous-energy controls, handle chemicals safely, and promptly report unsafe equipment, damaged guards, bypassed interlocks, leaks, spills, injuries, and other hazards.

Plastics Manufacturing Hazard Assessments

Hazard assessments should consider each stage of production.

Potential areas include:

• Material receiving.
• Resin storage.
• Pellet transfer.
• Blending.
• Machine setup.
• Processing.
• Mold or die changing.
• Part removal.
• Trimming.
• Grinding.
• Regrind handling.
• Packaging.
• Maintenance.
• Shipping.

Potential hazards may include:

• Crushing.
• Pinching.
• Amputation.
• Entanglement.
• Burns.
• Hot plastic.
• High pressure.
• Hydraulic injection.
• Unexpected startup.
• Electrical hazards.
• Chemical exposure.
• Fumes and vapors.
• Noise.
• Ergonomic stress.
• Fire.

Assessments should be reviewed when machinery, materials, chemicals, automation, or processes change.

Job Safety Analysis (JSA/JHA)

A JSA/JHA may be used to evaluate higher-risk plastics-manufacturing tasks.

Potential JSAs/JHAs may address:

• Injection molding machine operation.
• Mold changes.
• Thermoforming machine operation.
• Extruder startup.
• Die changes.
• Grinder or granulator operation.
• Clearing jams.
• Robot cell entry.
• Machine maintenance.
• Resin handling.
• Chemical mixing.
• Forklift operation.
• Loading and unloading.

The analysis should identify job steps, hazards, controls, PPE, and employee responsibilities.

Machine Guarding

Machine guarding is one of the most important elements of plastics-manufacturing safety.

Plastics-processing machinery can expose employees to:

• Nip points.
• Clamping areas.
• Rotating screws.
• Moving platens.
• Cutting systems.
• Chains.
• Sprockets.
• Belts.
• Rollers.
• Feed mechanisms.
• Robots.
• Automated equipment.

Machines should be equipped with guards and safety devices appropriate to the hazards.

Employees should not operate equipment when required guards or interlocks are missing, damaged, or bypassed.

Fixed Guards

Fixed guards may be used where employee access to the hazardous area is not normally required.

Fixed guards should:

• Prevent access to hazards.
• Be securely installed.
• Require appropriate means for removal where intended.
• Be maintained in serviceable condition.

Employees should not remove fixed guards during normal production unless the machine has been placed in an appropriate safe condition.

Interlocked Guards

Interlocked gates and guards can prevent machine movement when access points are opened.

Interlocks should not be:

• Removed.
• Bypassed.
• Defeated.
• Manipulated.
• Altered.

Machines should not be operated when required interlocks are not functioning properly.

Presence-Sensing Devices

Certain machines or automated systems may use:

• Light curtains.
• Safety mats.
• Laser scanners.
• Other presence-sensing devices.

These systems should be installed and maintained so hazardous motion is stopped or prevented when employees enter protected areas.

Employees should not defeat these systems to increase production speed.

Emergency Stops

Emergency-stop devices should be readily accessible where provided.

Employees should understand:

• Their location.
• Their purpose.
• How to activate them.
• Their limitations.

An emergency stop is not a substitute for Lockout/Tagout when hazardous-energy control is required.

Injection Molding

Injection molding converts plastic material into molded parts by heating resin and injecting the molten material into a mold held between machine platens.

Potential hazards may involve:

• Moving platens.
• Mold-closing areas.
• Clamping mechanisms.
• Ejectors.
• Rotating screws.
• Hot plastic.
• High pressure.
• Hydraulic systems.
• Robots.
• Electrical equipment.

Employees should receive machine-specific training before operating injection molding equipment.

Injection Molding Operator Gate

The operator gate should prevent employee access to hazardous mold-closing and moving-machine areas during normal production.

Applicable gate interlocks should prevent hazardous clamp motion while the gate is open.

Employees should not:

• Reach over a gate.
• Reach under a guard.
• Reach around guarding.
• Bypass an interlock.

When additional access is needed, the machine should be placed in the appropriate safe condition.

Mold Area

The mold area can expose employees to severe crushing or amputation hazards.

Employees should not place any part of the body between mold halves or platens while unexpected movement is possible.

Access should occur only through established procedures.

Injection Unit

The injection unit may contain:

• Heated barrel surfaces.
• Rotating screw components.
• High-pressure molten plastic.
• Feed-throat hazards.
• Hydraulic systems.

Guards and covers should remain in place.

Employees should not access the feed throat or screw area while hazardous movement is possible.

Feed Throat

The hopper and feed-throat guarding should prevent access to rotating screw components.

Employees should not reach into the feed throat.

If maintenance or cleaning requires access, applicable hazardous-energy procedures should be followed.

Hot Plastic

Molten plastic may be ejected or splatter unexpectedly.

Potential exposure may occur during:

• Purging.
• Startup.
• Nozzle clearing.
• Material changes.
• Troubleshooting.
• Equipment malfunction.

Appropriate PPE and shields should be used where necessary.

Purging Operations

Purging may expose employees to hot resin and process fumes.

Employees should:

• Stand clear of the expected discharge path.
• Use designated tools.
• Wear required eye and face protection.
• Wear appropriate heat-resistant protection.
• Control ignition sources where relevant.
• Maintain ventilation.

Employees should never attempt to catch or manipulate hot purged resin with unprotected hands.

Nozzle Hazards

Injection molding nozzles can contain hot plastic under pressure.

Employees should be alert to sudden discharge during:

• Startup.
• Blockage clearing.
• Material changes.
• Maintenance.

Pressure should be relieved and required energy controls applied before servicing.

Mold Changes

Molds can be extremely heavy and may create:

• Crushing.
• Pinch points.
• Suspended-load hazards.
• Rigging hazards.
• Hydraulic hazards.
• Ergonomic hazards.

Mold-changing procedures should address:

• Machine shutdown.
• Hazardous energy.
• Rigging.
• Hoists.
• Lifting devices.
• Employee positioning.
• Mold securement.

Mold Handling

Molds should be moved using equipment appropriate to their weight and configuration.

Potential equipment may include:

• Overhead cranes.
• Hoists.
• Mold carts.
• Forklifts.
• Specialized mold-changing systems.

Employees should remain clear of suspended molds.

Mold Securement

Molds should be properly secured before the machine is returned to operation.

Clamps, fasteners, mounting systems, and connections should be installed according to machine and mold requirements.

Ejector Systems

Ejector systems can create pinch and crushing hazards.

Employees should not place hands into the mold area to remove stuck parts while unexpected movement is possible.

Safe tools or energy-control procedures should be used as appropriate.

Robots at Injection Molding Machines

Robots may be used to:

• Remove parts.
• Place inserts.
• Trim products.
• Package components.
• Perform repetitive tasks.

Robot work envelopes should be guarded.

Employees should not enter a robot’s operating area while uncontrolled motion is possible.

Robot Cell Entry

Before entering a guarded robot cell for servicing, maintenance, jam clearing, adjustment, or other covered activities, hazardous energy should be controlled according to applicable procedures.

Employees should understand that stopping normal production does not necessarily remove all robot or machine energy.

Thermoforming

Thermoforming heats thermoplastic sheet or film and forms it into a desired shape.

A thermoforming line may contain:

• Roll stands.
• Feed rollers.
• Heating ovens.
• Form stations.
• Trim stations.
• Chain rails.
• Stackers.
• Scrap rewinders.
• Guillotine cutters.
• Grinders or granulators.

Employees should understand the hazards associated with each section of the machine.

Thermoforming Roll Handling

Plastic sheet rolls may be large and heavy.

Employees should use suitable roll-handling devices where appropriate.

Procedures should address:

• Roll stability.
• Lifting.
• Pinch points.
• Shafts.
• Chucks.
• Employee positioning.

Thermoforming Feed End

The feed end may contain:

• Roll shafts.
• Roll stands.
• Nip points.
• Feed mechanisms.
• Pinch points.

Required guarding should prevent employee access during hazardous movement.

Thermoforming Oven

Heating ovens can expose employees to:

• Hot surfaces.
• Electrical hazards.
• Plastic decomposition fumes.
• Moving machinery.
• Burns.

Guards and access doors should remain in place.

Appropriate ventilation should control process smoke or irritating vapors where necessary.

Form Station

Thermoforming form stations may involve moving molds, platens, vacuum systems, and compressed air.

Employees should remain outside hazardous areas during machine cycling.

Appropriate guarding and interlocks should be maintained.

Trim Station

Trim stations may contain cutting dies operated by:

• Hydraulic systems.
• Pneumatic systems.
• Mechanical systems.

Employees should not place hands beneath cutting assemblies or between moving components.

Thermoforming Chain Rails

Chain rails may contain moving chains, sprockets, and sharp pins.

These components should be guarded to prevent employee access.

Employees should keep loose clothing, jewelry, and unsecured hair away from moving machinery.

Thermoforming Stacker

Automatic stackers can create crushing, pinch, and struck-by hazards.

Employees should remain outside guarded operating areas.

Access for troubleshooting should follow appropriate safe procedures.

Scrap Rewinder

Scrap web may be automatically wound after thermoforming.

Potential hazards include:

• Rotating rolls.
• Nip points.
• Entanglement.
• Tensioned material.

Employees should keep hands and clothing clear.

Guillotine Cutters

Guillotine cutters can cause severe amputations.

Cutting areas should be appropriately guarded.

Employees should not reach beneath or around guards to remove scrap or material while hazardous motion is possible.

Extrusion

Plastic extrusion generally involves forcing heated plastic through a die to create continuous products such as:

• Sheet.
• Film.
• Pipe.
• Profiles.
• Tubing.

Depending on the operation, hazards may involve:

• Heated barrels.
• Rotating screws.
• Dies.
• Rollers.
• Nip points.
• Pullers.
• Cutters.
• High pressure.
• Hot plastic.

Extrusion procedures should reflect the specific line and equipment used.

Extruder Feed Areas

Employees should be protected from access to rotating screws and other hazardous feed components.

Hoppers, feed throats, and related guarding should remain in place.

Employees should not reach into operating feed equipment.

Extruder Barrel and Die

Barrels and dies may operate at high temperatures.

Employees should avoid contact with hot surfaces and use appropriate protective equipment during:

• Setup.
• Die changes.
• Cleaning.
• Maintenance.

Hot-surface warnings should be provided where appropriate.

Die Changes

Extrusion dies may be heavy and hot.

Die-changing procedures should address:

• Shutdown.
• Hazardous-energy control.
• Cooling.
• Lifting.
• Rigging.
• Employee positioning.
• Sharp edges.
• Residual pressure.

Employees should verify the system is in a safe condition before loosening components.

Extrusion Pressure

Material may remain under pressure within an extruder.

Employees should not loosen dies, screens, breaker plates, or other components until pressure has been relieved and required procedures completed.

Unexpected release can eject hot plastic.

Film and Sheet Lines

Film and sheet extrusion equipment may contain:

• Rolls.
• Nip points.
• Winders.
• Pullers.
• Cutting equipment.
• Tensioned web.

Employees should remain clear of operating rollers and winders.

Winders

Winders can create entanglement and crushing hazards.

Employees should not attempt to manually control or correct moving rolls where doing so places them near hazardous nip points or rotating material.

Blow Molding

Blow molding may involve:

• Extrusion blow molding.
• Injection blow molding.
• Stretch blow molding.

Potential hazards include:

• Moving molds.
• Clamping.
• Hot plastic.
• High-pressure air.
• Cutting systems.
• Automated equipment.

Machines should be guarded according to their specific hazards.

High-Pressure Air

Blow molding may use compressed air at substantial pressures.

Employees should inspect applicable:

• Hoses.
• Fittings.
• Valves.
• Connections.
• Pressure systems.

Damaged equipment should be removed from service.

Rotational Molding

Rotational molding can involve:

• Heated ovens.
• Large rotating machinery.
• Mold handling.
• Hot molds.
• Material loading.
• Elevated work.

Employees should remain clear of rotating equipment and use appropriate procedures for mold handling and unloading.

Compression Molding

Compression molding can expose employees to:

• Moving platens.
• Heated molds.
• Crushing.
• Pinch points.
• Hydraulic systems.
• Material exposure.

Machine guarding and safe setup procedures should prevent employee access during hazardous movement.

Grinders and Granulators

Plastic scrap may be processed through grinders or granulators.

These machines can expose employees to:

• Rotating knives.
• Feed-throat hazards.
• Flying material.
• Noise.
• Entanglement.
• Amputation.

Feed openings and machine components should be guarded.

Feeding Grinders

Employees should keep hands away from grinder feed throats.

Appropriate:

• Feed chutes.
• Push tools.
• Anti-kickback devices.
• Proximity guards.

should be used where necessary.

Clearing Grinder Jams

Employees should not reach into grinders or granulators to clear jams while hazardous movement is possible.

Applicable energy-control procedures should be followed before access.

Employees should recognize that rotating components may continue moving after power is shut off.

Grinder Blade Changes

Grinder knives and blades can be extremely sharp and heavy.

Blade-changing procedures should address:

• Lockout/Tagout.
• Blade handling.
• Appropriate hand protection.
• Lifting.
• Secure installation.

Conveyors

Plastics facilities may use conveyors for:

• Resin.
• Parts.
• Scrap.
• Finished products.
• Packaging.

Potential hazards include:

• Nip points.
• Pulleys.
• Belts.
• Chains.
• Sprockets.
• Entanglement.

Required guards should remain in place.

Conveyor Jam Clearing

Employees should not reach into hazardous conveyor areas to clear jams unless the equipment has been placed in the required safe condition.

Stop buttons alone should not be relied upon when Lockout/Tagout is required.

Automation

Modern plastics manufacturing may include highly automated:

• Robots.
• Pick-and-place systems.
• Conveyors.
• Packaging systems.
• Vision systems.
• Material-handling equipment.

Automation can reduce some exposures while introducing hazards from unexpected machine movement.

Guarded systems should be evaluated as an integrated production cell.

Lockout/Tagout

Plastics-processing machinery may contain multiple forms of hazardous energy.

Potential energy sources include:

• Electrical.
• Mechanical.
• Hydraulic.
• Pneumatic.
• Thermal.
• Gravity.
• Stored pressure.

Applicable Lockout/Tagout procedures should be followed during covered servicing and maintenance.

Machine-Specific Energy Control

Complex plastics equipment may require machine-specific hazardous-energy procedures.

Procedures should identify:

• Energy-isolation devices.
• Shutdown steps.
• Stored-energy controls.
• Verification methods.
• Restart procedures.

Employees should not rely solely on control-panel shutdown.

Stored Hydraulic Energy

Hydraulic accumulators, cylinders, hoses, and other components may retain pressure after machine shutdown.

Stored pressure should be:

• Relieved.
• Blocked.
• Restrained.
• Otherwise controlled.

before employees perform covered servicing.

Hydraulic Systems

Hydraulic systems can expose employees to:

• High-pressure fluid.
• Hot oil.
• Hose failure.
• Unexpected movement.
• Stored energy.

Hoses, fittings, and connections should be inspected.

Employees should never use bare hands to search for high-pressure hydraulic leaks.

Hydraulic Injection Injuries

High-pressure fluid can penetrate the skin and cause severe internal injury even when the external wound appears small.

Suspected hydraulic injection injuries require prompt medical evaluation.

Pneumatic Systems

Pneumatic systems may retain compressed energy after normal shutdown.

Air pressure should be isolated and relieved before covered maintenance.

Employees should verify moving machine parts cannot cycle unexpectedly.

Blocking and Pinning

Raised or movable machine components should be mechanically blocked, pinned, restrained, or otherwise secured where necessary before employees work beneath or between them.

Hydraulic or pneumatic pressure alone should not be relied upon to support equipment during servicing.

Preventive Maintenance

Preventive maintenance should identify conditions that can contribute to employee injury or process failure.

Inspections may address:

• Guards.
• Interlocks.
• Hydraulic hoses.
• Pneumatic lines.
• Electrical systems.
• Heaters.
• Controls.
• Safety devices.
• Ventilation.
• Cooling systems.

Deficiencies should be corrected promptly.

Machine Setup and Adjustment

Some plastics-processing tasks require setup, adjustment, or troubleshooting close to machinery.

The employer should determine whether the work requires full hazardous-energy control or whether a specific applicable exception and effective alternative protective measures apply.

Employees should not assume routine production status makes access to hazardous areas safe.

Hot Surfaces

Plastics equipment can contain hot:

• Barrels.
• Dies.
• Molds.
• Nozzles.
• Heaters.
• Ovens.
• Plastic material.

Engineering controls, guarding, warnings, and PPE should be used where appropriate.

Burn Prevention

Employees exposed to hot plastic or equipment may require:

• Heat-resistant gloves.
• Face protection.
• Eye protection.
• Long sleeves.
• Other protective clothing.

PPE should be selected according to the actual task and material.

Plastic Decomposition

Plastic can degrade or decompose when overheated.

Decomposition may release smoke, gases, or vapors that can irritate the eyes or respiratory system or present other hazards depending on the polymer and additives involved.

Employees should follow procedures for overheated or burning material.

Process Fumes

The potential for process fumes depends on factors including:

• Polymer type.
• Additives.
• Processing temperature.
• Residence time.
• Contamination.
• Equipment malfunction.

The company should evaluate actual process conditions rather than assuming all plastic-processing fumes present the same hazards.

Ventilation

Ventilation may be necessary to control:

• Process fumes.
• Smoke.
• Vapors.
• Dust.
• Chemical contaminants.

Ventilation should be located and maintained according to the source and process.

Employees should report ventilation failures.

Local Exhaust Ventilation

Local exhaust may be appropriate near:

• Purging areas.
• Extruder dies.
• Thermoforming ovens.
• Mixing operations.
• Chemical processes.
• Printing or coating stations.

The system should capture contaminants as close to the source as practical.

Resins and Plastic Pellets

Raw plastic materials may include:

• Pellets.
• Powders.
• Flakes.
• Regrind.
• Liquid resins.

Employees should understand the hazards associated with the specific materials used.

Plastic pellets spilled on walking surfaces can create significant slip hazards and should be cleaned promptly.

Additives

Plastics processing may involve additives such as:

• Colorants.
• Fillers.
• Plasticizers.
• Stabilizers.
• Flame retardants.
• Reinforcing materials.
• Release agents.
• Other processing aids.

The hazards depend on the specific formulation.

Safety Data Sheets and supplier information should be reviewed.

Powdered Materials

Some plastics facilities handle powdered resins, pigments, fillers, or additives.

Potential hazards may include:

• Inhalation.
• Dust accumulation.
• Combustibility.
• Static electricity.
• Skin contact.

Dust hazards should be evaluated according to the particular material.

Combustible Dust — When Applicable

Some powdered plastic resins and additives may present combustible-dust hazards.

Facilities handling combustible particulate materials should evaluate:

• Dust generation.
• Dust accumulation.
• Ignition sources.
• Dust collection.
• Electrical equipment.
• Housekeeping.

Combustible dust should not be assumed to be present at every plastics facility.

Static Electricity

Static electricity may be generated during handling of:

• Plastic film.
• Powders.
• Pellets.
• Solvents.
• Other materials.

Where static discharge could ignite a flammable atmosphere or combustible dust, appropriate bonding, grounding, or other controls should be implemented.

Hazard Communication

A Hazard Communication Program should address hazardous chemicals used in plastics manufacturing.

Applicable elements may include:

• Chemical inventory.
• Labels.
• Safety Data Sheets.
• Employee training.
• Non-routine tasks.
• Chemical storage.

Employees should know how to obtain hazard information before using a material or chemical.

Cleaning Chemicals

Machine cleaning may involve:

• Solvents.
• Purging compounds.
• Degreasers.
• Mold cleaners.
• Release agents.
• Other specialty products.

Employees should follow product labels, Safety Data Sheets, ventilation requirements, and PPE procedures.

Solvents — When Applicable

Some facilities use solvents for:

• Cleaning.
• Printing.
• Coating.
• Bonding.
• Maintenance.

Potential hazards may include:

• Inhalation.
• Skin absorption.
• Eye irritation.
• Fire.
• Toxic effects.

Controls should reflect the actual solvent used.

Adhesives — When Applicable

Plastic assembly operations may use adhesives containing:

• Solvents.
• Epoxies.
• Cyanoacrylates.
• Other reactive chemicals.

Employee exposure should be evaluated according to the products and application methods.

Printing and Decorating — When Applicable

Plastic products may be printed, painted, coated, or decorated after molding.

These operations may introduce additional hazards involving:

• Inks.
• Solvents.
• Coatings.
• UV-curing equipment.
• Flammable materials.
• Ventilation.

Applicable specialized programs should be added where needed.

Respiratory Protection

Respiratory protection may be required for certain process, chemical, dust, or maintenance exposures.

Where respirators are required, the company should maintain an appropriate Respiratory Protection Program.

Applicable elements may include:

• Hazard evaluation.
• Respirator selection.
• Medical evaluation.
• Fit testing.
• Training.
• Inspection.
• Maintenance.
• Program evaluation.

Respirators should not substitute for required feasible engineering controls.

Personal Protective Equipment

PPE should be selected based on the hazard assessment.

Depending on work performed, PPE may include:

• Safety glasses.
• Goggles.
• Face shields.
• Heat-resistant gloves.
• Chemical-resistant gloves.
• Protective footwear.
• Hearing protection.
• Respiratory protection.
• Protective clothing.

Employees should understand PPE use and limitations.

Eye and Face Protection

Eye and face protection may be necessary during:

• Purging.
• Nozzle clearing.
• Chemical handling.
• Grinding.
• Maintenance.
• Hot-plastic operations.

Face shields should normally be used with appropriate primary eye protection when both are needed.

Hand Protection

Hand protection should be selected for the specific task.

Potential hazards include:

• Hot plastic.
• Hot molds.
• Sharp trim.
• Chemicals.
• Rough material.

Gloves should not be used where they create an entanglement hazard around exposed rotating machinery.

Protective Footwear

Protective footwear may be required where employees are exposed to:

• Heavy molds.
• Resin containers.
• Material-handling equipment.
• Falling components.
• Sharp scrap.

Footwear should also provide suitable traction on production floors.

Noise

Potential noise sources may include:

• Grinders.
• Granulators.
• Compressors.
• Pumps.
• Blowers.
• Molding machines.
• Conveyors.
• Material-handling systems.

Employee noise exposure should be evaluated where hazardous levels may be present.

Hearing Conservation

Where employee exposure reaches applicable thresholds, required Hearing Conservation measures should be implemented.

These may include:

• Noise monitoring.
• Audiometric testing.
• Hearing protection.
• Training.
• Recordkeeping.

Electrical Safety

Plastics-processing equipment may use:

• High-voltage electrical systems.
• Electric heaters.
• Motors.
• Control panels.
• Robotic systems.

Electrical equipment should be maintained in safe condition.

Electrical work should be performed only by appropriately qualified employees.

Damaged Electrical Equipment

Employees should report:

• Exposed wiring.
• Damaged cords.
• Open electrical enclosures.
• Defective controls.
• Overheated equipment.
• Damaged heater wiring.

Unsafe equipment should be repaired before continued use where necessary.

Material Handling

Plastics facilities may handle:

• Resin bags.
• Gaylords.
• Drums.
• Sheet rolls.
• Film rolls.
• Molds.
• Finished parts.
• Pallets.

Mechanical assistance should be used where appropriate.

Resin Bags

Employees manually handling resin or additive bags may be exposed to repetitive lifting and awkward postures.

Controls may include:

• Lift tables.
• Bag-handling equipment.
• Vacuum lifts.
• Reduced lift heights.
• Team handling.

Gaylords and Bulk Containers

Bulk resin containers should be stored and moved using appropriate equipment.

Employees should not climb onto unstable containers or pallets.

Damaged containers should be addressed before handling.

Roll Handling

Sheet and film operations may involve large rolls.

Roll-handling procedures should address:

• Roll weight.
• Rolling movement.
• Shafts.
• Lifting.
• Storage.
• Employee positioning.

Suitable roll-handling equipment should be used where appropriate.

Mold Storage

Molds should be stored in stable racks or designated storage areas capable of supporting their weight.

Storage should prevent:

• Falling.
• Shifting.
• Rack overloading.
• Unsafe manual access.

Overhead Cranes and Hoists

Facilities may use cranes or hoists for mold, die, and equipment handling.

Only appropriately trained and authorized employees should perform assigned lifting operations.

Loads should remain within equipment capacity.

Employees should not stand beneath suspended loads.

Rigging

Rigging equipment used for mold and die handling should be selected, inspected, and used appropriately.

Potential equipment may include:

• Slings.
• Shackles.
• Hooks.
• Eyebolts.
• Lifting beams.

Damaged rigging should be removed from service.

Powered Industrial Trucks

Forklifts may be used to move:

• Resins.
• Molds.
• Pallets.
• Chemicals.
• Finished products.

Only trained and authorized employees should operate powered industrial trucks.

Forklift and Pedestrian Safety

Facilities should reduce interactions between pedestrians and mobile equipment.

Potential controls may include:

• Designated aisles.
• Marked walkways.
• Barriers.
• Mirrors.
• Speed controls.
• Restricted areas.

Employees should not assume equipment operators can see them.

Loading and Unloading

Shipping and receiving may involve:

• Trucks.
• Trailers.
• Forklifts.
• Pallet jacks.
• Resin deliveries.
• Finished-product shipments.

Procedures should address vehicle movement, load stability, trailer condition, dock hazards, and employee positioning.

Ergonomics

Plastics manufacturing may involve repetitive:

• Part removal.
• Trimming.
• Inspection.
• Packing.
• Assembly.
• Material feeding.

Workstations should be evaluated for:

• Reach distance.
• Work height.
• Repetition.
• Force.
• Posture.
• Lift frequency.

Part Trimming

Manual trimming can involve repetitive hand exertion and sharp tools.

Controls may include:

• Improved fixtures.
• Ergonomic hand tools.
• Automation.
• Appropriate work heights.
• Task variation.

Cut-resistant hand protection may be appropriate depending on the task.

Packing Operations

Employees packing molded or thermoformed parts may perform repetitive reaching and lifting.

Workstations should be arranged to minimize excessive bending and extended reach.

Manual Lifting

Employees should evaluate the weight, size, shape, and stability of loads before lifting.

Mechanical assistance or team handling should be used where appropriate.

Housekeeping

Good housekeeping is important throughout plastics operations.

Floors and aisles should be kept free of:

• Plastic pellets.
• Resin.
• Scrap.
• Oil.
• Water.
• Packaging.
• Strapping.
• Tools.

Plastic pellets can be particularly slippery and should be cleaned promptly.

Plastic Scrap

Scrap should be collected and stored so it does not create:

• Trip hazards.
• Sharp-edge hazards.
• Fire hazards.
• Blocked aisles.
• Machine interference.

Regrind material should be handled according to facility procedures.

Slips, Trips and Falls

Common hazards may involve:

• Resin pellets.
• Hydraulic oil.
• Cooling water.
• Scrap.
• Cords.
• Packaging.

Employees should promptly report and address unsafe walking surfaces.

Walking-Working Surfaces

Platforms, stairs, ladders, mezzanines, and machine-access areas should be maintained in safe condition.

Fall protection should be provided where required.

Machine Platforms

Some plastics equipment includes elevated operating or maintenance platforms.

Platforms should have appropriate:

• Guardrails.
• Access.
• Walking surfaces.
• Fall protection.

Employees should not climb machine structures in place of designated access systems.

Ladders

Portable and fixed ladders should be selected, inspected, and used safely.

Employees should not stand on machine frames, pallets, or improvised objects to gain elevation.

Compressed Air

Compressed air may be used for machine operation, cleaning, or part handling.

Employees should use compressed air according to applicable requirements.

Compressed air should not be directed at employees.

Fire Prevention

Plastics manufacturing can involve combustible:

• Plastic materials.
• Packaging.
• Solvents.
• Oils.
• Chemicals.

Fire-prevention procedures should address:

• Ignition sources.
• Hot equipment.
• Electrical hazards.
• Chemical storage.
• Housekeeping.
• Hot Work.

Hot Work

Welding, cutting, brazing, and grinding may be performed during machine or facility maintenance.

Applicable Hot Work procedures should control:

• Plastic materials.
• Flammable chemicals.
• Dust.
• Packaging.
• Nearby equipment.

Fire protection should be available as required.

Flammable and Combustible Liquids

Where flammable or combustible liquids are used, they should be stored, transferred, and handled in accordance with applicable requirements.

Potential materials may include:

• Solvents.
• Cleaning products.
• Coatings.
• Adhesives.
• Fuels.

Ignition sources should be controlled.

Emergency Action Plan

The company should maintain emergency procedures appropriate to the facility.

Potential emergencies may include:

• Fire.
• Chemical release.
• Machine injury.
• Hot-plastic burn.
• Hydraulic injury.
• Medical emergency.
• Severe weather.

Employees should understand applicable alarms, evacuation routes, assembly areas, and reporting procedures.

Machine Injury Response

Following a serious machinery injury:

• Stop equipment safely.
• Control hazardous energy where necessary.
• Obtain emergency medical assistance.
• Prevent additional employee exposure.
• Preserve the scene where appropriate.

Employees should not expose themselves to uncontrolled machinery while attempting a rescue.

Thermal Burn Response

Burns may result from:

• Molten plastic.
• Hot molds.
• Barrels.
• Dies.
• Ovens.

Employees should receive prompt first aid and medical evaluation appropriate to the injury.

Material stuck to a burn should not be forcibly removed unless directed by appropriate medical procedures.

Chemical Emergency

Employees should understand procedures for chemical spills or releases.

Response should reflect:

• Chemical identity.
• Quantity.
• Fire hazard.
• Toxicity.
• PPE.
• Available response capability.

Employees should not perform emergency response beyond their training and assigned duties.

First Aid

Appropriate first-aid resources should be available.

Potential plastics-manufacturing injuries may include:

• Burns.
• Cuts.
• Crushing.
• Amputations.
• Eye injuries.
• Chemical exposure.
• Strains.
• Hydraulic injection injuries.

Employees should promptly report injuries and obtain appropriate medical evaluation.

Incident Reporting

Employees should promptly report:

• Injuries.
• Near misses.
• Guard failures.
• Bypassed interlocks.
• Machine contacts.
• Hot-plastic releases.
• Hydraulic leaks.
• Chemical exposures.
• Fires.
• Forklift incidents.
• Equipment damage.

Prompt reporting allows hazards to be identified and corrected.

Incident Investigation

Significant incidents should be investigated to identify:

• Immediate causes.
• Contributing factors.
• Root causes.
• Corrective actions.

Investigations may consider:

• Machine guarding.
• Interlocks.
• Lockout/Tagout.
• Machine setup.
• Process conditions.
• Maintenance.
• Training.
• Supervision.
• Chemical controls.
• Work procedures.

Root Cause Analysis

Root Cause Analysis may identify underlying factors involving:

• Machine design.
• Guarding.
• Interlock reliability.
• Preventive maintenance.
• Hazardous-energy procedures.
• Training.
• Production pressure.
• Staffing.
• Process changes.
• Corrective-action systems.

Corrective actions should address identified causes rather than simply assigning blame.

Plastics Manufacturing Safety Inspections

Periodic safety inspections should evaluate:

• Machine guards.
• Interlocks.
• Emergency stops.
• Hydraulic systems.
• Electrical equipment.
• Robots.
• Grinders.
• Conveyors.
• Chemical storage.
• Ventilation.
• PPE.
• Forklifts.
• Walking-working surfaces.

Identified deficiencies should be corrected in a timely manner.

Plastics Manufacturing Safety Training

Employee training should reflect assigned duties and equipment.

Depending on responsibilities, training may address:

• Machine hazards.
• Guards and interlocks.
• Injection molding.
• Thermoforming.
• Extrusion.
• Robots.
• Lockout/Tagout.
• Hot plastic.
• Chemicals.
• PPE.
• Forklifts.
• Emergency procedures.

Employees should not independently operate specialized equipment until they have received appropriate instruction.

Machine-Specific Training

Employees should receive training for each type of plastics-processing machine they are authorized to operate.

Training should address:

• Machine controls.
• Guarding.
• Interlocks.
• Hazardous areas.
• Safe setup.
• Emergency stopping.
• Jam clearing.
• Prohibited practices.

Training on one machine should not automatically be considered adequate for substantially different equipment.

New Employee Orientation

New employees should receive safety orientation before independently performing assigned work.

Orientation may address:

• Machine hazards.
• Hot surfaces.
• Chemicals.
• PPE.
• Forklift traffic.
• Housekeeping.
• Emergency procedures.
• Incident reporting.

Refresher Training

Refresher or remedial training may be appropriate following:

• Unsafe machine operation.
• Interlock bypassing.
• Lockout/Tagout violations.
• Equipment changes.
• Process changes.
• Incidents or near misses.
• Identified knowledge gaps.

Safety Meetings

Periodic safety meetings may reinforce safe work practices.

Potential topics include:

• Machine guarding.
• Injection molding.
• Hot plastic.
• Lockout/Tagout.
• Robots.
• Grinder safety.
• Chemical handling.
• Forklift traffic.
• Housekeeping.
• Recent incidents.

Recordkeeping

Plastics manufacturers should maintain occupational safety and health records required for their operations.

Records may include:

• Employee training.
• Injury and illness records.
• Machine inspections.
• Preventive maintenance.
• Lockout/Tagout inspections.
• Exposure monitoring.
• Respiratory Protection records.
• Hearing Conservation records.
• Forklift training.
• Incident investigations.
• Chemical records.

Records should be retained according to applicable requirements.

Additional Safety Programs

Depending on plastics-manufacturing operations and employee exposures, additional programs may be necessary for:

• Plastics Processing Safety.
• Injection Molding Safety.
• Thermoforming Safety.
• Extrusion Safety.
• Blow Molding Safety.
• Machine Guarding.
• Lockout/Tagout.
• Robotics & Automation Safety.
• Grinder & Granulator Safety.
• Conveyor Safety.
• Preventive Maintenance.
• Hydraulic Systems Safety.
• Pneumatic Systems Safety.
• Hot Work.
• Fire Prevention.
• Hazard Communication.
• Chemical Safety.
• Flammable & Combustible Liquids.
• Combustible Dust.
• Respiratory Protection.
• Personal Protective Equipment.
• Eye & Face Protection.
• Hand Protection.
• Hearing Conservation.
• Electrical Safety.
• Overhead Crane & Hoist Safety.
• Rigging & Material Handling.
• Powered Industrial Trucks.
• Loading & Unloading.
• Ergonomics.
• Manual Lifting.
• Housekeeping.
• Slips, Trips & Falls.
• Walking-Working Surfaces.
• Ladder Safety.
• Emergency Action Plan.
• First Aid.
• Incident Reporting & Investigation.
• Root Cause Analysis.

Programs should be included when the company’s machinery, polymers, additives, chemicals, automation, maintenance activities, and employee exposures make them applicable.

Building a Plastics Manufacturing Safety Manual

A useful Plastics Manufacturing Safety Manual should reflect the company’s actual manufacturing processes.

An injection molding company may require extensive procedures for molding-machine guarding, operator gates and interlocks, mold changes, hot plastic, purging, robots, hydraulic systems, Lockout/Tagout, grinders, material handling, and PPE.

An extrusion company may require greater emphasis on heated barrels and dies, high pressure, roll and winder hazards, line guarding, die changes, material handling, ventilation, and hazardous-energy control.

A thermoforming operation may require programs covering roll handling, feed systems, heating ovens, form stations, trim presses, chain rails, stackers, grinders, machine guarding, and Lockout/Tagout.

A blow molding company may require additional emphasis on mold-closing hazards, high-pressure air, hot plastic, automated part handling, trimming equipment, and maintenance.

A plastics facility using large quantities of powders or combustible additives may require additional combustible-dust controls that would not be appropriate for a facility handling only non-dust-generating pellets.

A company performing printing, coating, adhesive bonding, or chemical finishing may require additional Hazard Communication, ventilation, flammable-liquid, respiratory, and PPE programs.

The safety manual should therefore be based on the plastics-manufacturing operations actually performed rather than automatically assigning every plastics-related program to every employer.

Customized Plastics Manufacturing Safety Manuals

A Plastics Manufacturing Safety Manual can be developed around the company’s injection molding machines, extruders, thermoforming equipment, blow molding machines, grinders, granulators, robots, molds, dies, resins, additives, chemicals, forklifts, material-handling systems, maintenance activities, employees, and other occupational hazards.

The finished manual may incorporate applicable programs for Machine Guarding, Lockout/Tagout, Injection Molding, Thermoforming, Extrusion, Robotics, Hydraulic Systems, Hot Work, Hazard Communication, PPE, Respiratory Protection, Hearing Conservation, Powered Industrial Trucks, Rigging, Ergonomics, Emergency Action Planning, Incident Investigation, and other hazards associated with plastics processing.

This provides injection molders, extruders, thermoformers, blow molders, plastic-product manufacturers, and other plastics-processing employers with a practical safety manual organized around the work their employees actually perform.