Printing Company Safety Manual

Types of Printing Operations

Printing operations can vary substantially depending on the process used.

A safety manual may need to address:

• Lithography and offset printing.
• Sheetfed printing.
• Webfed printing.
• Flexographic printing.
• Gravure printing.
• Screen printing.
• Digital printing.
• Label printing.
• Packaging printing.
• Large-format printing.
• Prepress operations.
• Platemaking.
• Press operations.
• Finishing.
• Binding.
• Cutting.
• Folding.
• Packaging and shipping.

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

What Should a Printing Company Safety Manual Include?

Depending on operations, a Printing Company Safety Manual may address:

• Printing safety responsibilities.
• Hazard assessments.
• Job Safety Analysis (JSA/JHA).
• Printing press safety.
• Machine guarding.
• Nip-point hazards.
• Rollers and cylinders.
• Paper cutters.
• Bindery equipment.
• Conveyors.
• Lockout/Tagout.
• Machine maintenance.
• Inks.
• Solvents.
• Cleaning chemicals.
• Coatings.
• Adhesives.
• Hazard Communication.
• Flammable and combustible liquids.
• Fire prevention.
• Ventilation.
• Personal Protective Equipment.
• Respiratory protection where applicable.
• Hearing Conservation.
• Ergonomics.
• Material handling.
• Forklift safety.
• Emergency procedures.

Programs should be selected according to the company’s presses, machinery, printing methods, chemicals, finishing processes, and employee exposures.

Printing Company Safety Program

An effective Printing Safety Program establishes responsibilities and procedures for controlling machinery, hazardous energy, chemicals, fire hazards, material handling, ergonomics, and other printing-industry hazards.

Management should provide employees with properly guarded equipment, 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.
• Establish safe press-operating procedures.
• Maintain machine guards and safety devices.
• Establish Lockout/Tagout procedures.
• Evaluate chemical exposures.
• Maintain ventilation systems.
• Control flammable materials and ignition sources.
• Provide appropriate PPE.
• Maintain material-handling equipment.
• Correct unsafe conditions.
• Investigate workplace incidents.
• Provide employee training.
• Maintain applicable records.

Employees should follow established procedures, inspect equipment before use, use guards and safety devices, wear required PPE, follow hazardous-energy controls, handle chemicals safely, and promptly report unsafe conditions, missing guards, equipment defects, chemical releases, injuries, and other hazards.

Printing Hazard Assessments

Hazard assessments should consider each stage of production.

Potential areas include:

• Prepress.
• Platemaking.
• Press setup.
• Press operation.
• Ink preparation.
• Roll handling.
• Sheet handling.
• Press cleaning.
• Finishing.
• Cutting.
• Folding.
• Binding.
• Packaging.
• Shipping.
• Maintenance.

Potential hazards may include:

• Nip points.
• Crushing.
• Entanglement.
• Cutting.
• Amputation.
• Unexpected startup.
• Chemical exposure.
• Flammable vapors.
• Fire.
• Noise.
• Ergonomic stress.
• Forklift traffic.

Assessments should be reviewed when equipment, chemicals, substrates, or processes change.

Job Safety Analysis (JSA/JHA)

A JSA/JHA may be used to evaluate higher-risk printing activities.

Potential JSAs/JHAs may address:

• Printing press setup.
• Plate changing.
• Roll changing.
• Press cleaning.
• Ink preparation.
• Paper cutting.
• Bindery equipment.
• Screen reclamation.
• Machine jam clearing.
• Blade replacement.
• Maintenance.
• Forklift operation.
• Loading and unloading.

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

Prepress Operations

Prepress work may include:

• Computer-based design.
• Image preparation.
• Platemaking.
• Film or plate handling.
• Chemical processes.
• Material preparation.

Modern prepress operations may involve fewer traditional photographic chemicals than older processes, but hazards should be evaluated according to the equipment and products actually used.

Computer Workstations

Employees performing design and prepress work may spend substantial time at computer workstations.

Workstations should be arranged to reduce:

• Awkward neck posture.
• Excessive reaching.
• Raised shoulders.
• Wrist deviation.
• Contact stress.
• Prolonged static posture.

Employees should be encouraged to adjust workstations and vary tasks where practical.

Platemaking

Platemaking may involve:

• Photopolymer plates.
• Digital plate systems.
• Exposure units.
• Plate processors.
• Cutting tools.
• Cleaning chemicals.

Employees should follow safe procedures for handling plates, chemicals, and processing equipment.

Plate Handling

Printing plates may be large, awkward, or heavy.

Employees should avoid excessive reaching and awkward carrying.

Where appropriate, use:

• Carts.
• Transfer tables.
• Mechanical assistance.
• Appropriate storage racks.

Sharp plate edges should also be considered when selecting handling methods and PPE.

Printing Press Safety

Printing presses contain numerous moving components capable of causing serious injury.

Potential hazards include:

• In-running nip points.
• Rollers.
• Cylinders.
• Gears.
• Chains.
• Belts.
• Webs.
• Sheet feeders.
• Delivery systems.
• Automated movement.

Employees should operate presses only when required guards and safety devices are in place.

Press Machine Guarding

Presses should be guarded to prevent employee contact with hazardous moving components.

Potential guarding methods may include:

• Fixed guards.
• Interlocked guards.
• Barriers.
• Enclosures.
• Presence-sensing systems.
• Other appropriate protective devices.

Employees should not bypass guards or interlocks.

Nip Points

Printing presses frequently contain in-running nip points where rollers or cylinders rotate toward one another.

Employees should keep hands, clothing, tools, and other objects away from operating nip points.

Nip-point hazards should be guarded wherever required.

Rollers and Cylinders

Employees should remain clear of rotating rollers and cylinders.

Employees should not:

• Reach between operating rollers.
• Attempt to retrieve dropped material from moving equipment.
• Wipe operating rollers unless specifically permitted under a safe procedure.
• Bypass guards to improve access.

Press Controls

Press controls should be readily identifiable.

Employees should understand:

• Normal start controls.
• Stop controls.
• Emergency stops.
• Jog controls.
• Inch controls.
• Safe access procedures.

Only authorized employees should operate press controls.

Press Startup

Before starting a press, the operator should determine that employees are clear of hazardous areas.

Where warning systems or startup signals are provided, employees should understand their meaning.

Employees should not assume equipment will remain stopped unless hazardous energy has been appropriately controlled for the work being performed.

Press Setup

Press setup may involve:

• Plates.
• Blankets.
• Cylinders.
• Rollers.
• Ink systems.
• Doctor blades.
• Web threading.
• Substrate loading.

Setup procedures should identify tasks requiring machine shutdown or hazardous-energy control.

Plate Changing

Employees changing printing plates should use procedures appropriate to the press.

Potential hazards include:

• Pinch points.
• Sharp plate edges.
• Cylinder movement.
• Awkward lifting.
• Unexpected startup.

Equipment should be placed in a safe condition before employees enter hazardous areas.

Blanket Changing

Offset presses may require employees to replace or adjust blankets.

Employees should not enter hazardous roller or cylinder areas while uncontrolled movement is possible.

Applicable hazardous-energy procedures should be followed.

Web Presses

Webfed presses use continuous rolls of paper, film, foil, or other substrate.

Potential hazards include:

• Heavy rolls.
• Roll stands.
• Web tension.
• Nip points.
• Web breaks.
• Automatic splicing equipment.
• High-speed machinery.

Employees should receive press-specific training.

Web Threading

Threading a web through a press can place employees near rollers, cylinders, dryers, and nip points.

Safe threading procedures should identify:

• Required machine condition.
• Permitted controls.
• Employee positions.
• Communication.
• Prohibited areas.

Employees should not improvise unsafe methods to speed web threading.

Sheetfed Presses

Sheetfed presses may expose employees to hazards involving:

• Feeders.
• Delivery systems.
• Grippers.
• Rollers.
• Sheet piles.
• Pallets.

Employees should keep hands away from operating feed and delivery mechanisms.

Paper and Substrate Loading

Paper, film, board, and other substrates may be:

• Heavy.
• Bulky.
• Awkward.
• Difficult to grip.

Mechanical assistance should be used where practical.

Employees should avoid excessive lifting and awkward postures.

Flexographic Printing

Flexographic printing commonly uses flexible printing plates mounted on cylinders and liquid inks transferred through anilox rolls.

Potential hazards may involve:

• Anilox rolls.
• Plate cylinders.
• Doctor blades.
• Ink systems.
• Solvents.
• Heavy material rolls.
• Nip points.
• Automated equipment.

Procedures should reflect the specific flexographic press and ink system.

Anilox Rolls

Anilox rolls can be heavy and difficult to handle.

Employees should use appropriate lifting or handling equipment where necessary.

Storage systems should reduce the need for:

• Excessive reaching.
• Overhead lifting.
• Awkward carrying.

Rolls should be secured against unintended movement.

Doctor Blades

Doctor blades may have sharp edges capable of causing serious cuts.

Employees should use appropriate procedures and hand protection when:

• Installing.
• Removing.
• Cleaning.
• Disposing of blades.

Used blades should be stored or discarded so they do not create a laceration hazard.

Ink Preparation

Ink preparation may involve:

• Mixing.
• Dispensing.
• Pouring.
• Color matching.
• Solvent addition.
• Drum or container handling.

Employees should review applicable labels and Safety Data Sheets before handling ink products.

Gravure Printing

Gravure printing uses engraved cylinders and typically liquid inks.

Depending on the products used, hazards may involve:

• Rotating cylinders.
• Doctor blades.
• Solvents.
• Flammable vapors.
• Dryers.
• Material rolls.
• Heavy cylinders.

Ventilation and fire prevention may be particularly important where solvent-based inks are used.

Screen Printing

Screen printing may involve:

• Manual presses.
• Automatic presses.
• Screens.
• Squeegees.
• Inks.
• Emulsions.
• Screen-cleaning products.
• Reclaiming chemicals.
• Dryers.

Safety procedures should reflect the products and equipment actually used.

Manual Screen Printing

Manual screen printing can involve repetitive:

• Reaching.
• Pulling.
• Pushing.
• Wrist movement.
• Shoulder exertion.
• Bending.

Workstation height, squeegee design, job rotation where appropriate, and work methods should be evaluated to reduce ergonomic stress.

Automatic Screen Printing

Automatic screen-printing equipment can expose employees to:

• Moving print heads.
• Conveyors.
• Indexing tables.
• Pinch points.
• Automated movement.

Required guards and interlocks should remain in place.

Screen Reclamation

Screen reclamation may involve:

• Pressure washing.
• Degreasers.
• Emulsion removers.
• Ink removers.
• Other cleaning chemicals.

Potential hazards include chemical exposure, high-pressure spray, awkward posture, and repetitive work.

Appropriate ventilation and PPE should be used according to the products and processes involved.

Printing Ink

Printing inks vary substantially in composition.

Depending on the process, inks may be:

• Oil based.
• Water based.
• Solvent based.
• UV curable.
• Energy curable.
• Specialty formulations.

The company should evaluate the actual ink products used rather than assuming all printing inks present the same hazards.

Ink Handling

Employees should:

• Keep containers labeled.
• Close containers when not in use where appropriate.
• Prevent unnecessary skin contact.
• Control spills.
• Follow Safety Data Sheet precautions.
• Use appropriate PPE.

Ink should not be transferred into unlabeled containers except as permitted under applicable workplace-labeling requirements.

Solvents

Printing operations may use solvents for:

• Press cleaning.
• Ink adjustment.
• Screen reclamation.
• Equipment cleaning.
• Maintenance.

Potential hazards may include:

• Inhalation.
• Skin absorption.
• Eye contact.
• Fire.
• Central nervous system effects.

The company should evaluate the specific solvents used.

Cleaning Solvents

Cleaning methods should minimize unnecessary employee exposure.

Potential controls may include:

• Lower-hazard substitute products.
• Closed containers.
• Controlled dispensing.
• Local ventilation.
• Appropriate gloves.
• Eye protection.

Employees should not use unidentified or unauthorized cleaning products.

Press Cleaning

Press cleaning can place employees close to rollers and other moving components while also exposing them to cleaning chemicals.

Procedures should address both:

• Machine hazards.
• Chemical hazards.

Employees should not sacrifice machine protection to make cleaning faster.

Automatic Wash Systems

Automatic press-washing systems can reduce some manual chemical and machine exposure.

Employees should nevertheless understand:

• Chemical hazards.
• System limitations.
• Maintenance requirements.
• Spill procedures.

Employees should not enter hazardous press areas during an automatic wash cycle.

Hazard Communication

A Hazard Communication Program should address hazardous chemicals used in printing operations.

Applicable elements may include:

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

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

Chemical Substitution

Where practical, employers should evaluate whether higher-hazard products can be replaced with lower-hazard alternatives.

Substitution should consider the full hazard profile rather than assuming a product is safer based solely on a marketing description.

Flammable and Combustible Liquids

Printing facilities may use flammable or combustible:

• Inks.
• Solvents.
• Coatings.
• Cleaning products.
• Adhesives.

These materials should be stored, handled, transferred, and used according to applicable requirements.

Ignition sources should be controlled.

Flammable-Liquid Storage

Flammable liquids should be stored in appropriate containers and locations.

Where required, storage may include:

• Approved cabinets.
• Designated storage rooms.
• Approved safety containers.

Quantities in production areas should be appropriately controlled.

Chemical Dispensing

Chemical dispensing should minimize:

• Spills.
• Splashing.
• Vapor release.
• Uncontrolled container transfer.

Employees should use appropriate containers, pumps, funnels, or dispensing equipment.

Chemical Spill Response

Employees should understand procedures for spills involving:

• Ink.
• Solvents.
• Cleaning products.
• Coatings.
• Adhesives.

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

Ventilation

Ventilation may be necessary to control airborne contaminants generated during:

• Printing.
• Ink preparation.
• Press cleaning.
• Screen reclamation.
• Coating.
• Drying.
• Adhesive use.

Ventilation systems should be maintained so they continue to operate effectively.

Local Exhaust Ventilation

Local exhaust ventilation may be appropriate where contaminants are generated at identifiable sources.

Employees should not disconnect, obstruct, or disable required ventilation.

Ventilation failures should be reported.

Dryers and Ovens

Printing operations may use dryers, ovens, curing units, or other systems to dry inks and coatings.

Potential hazards may include:

• Heat.
• Fire.
• Flammable vapors.
• Moving webs.
• Electrical systems.
• Gas-fired equipment.

Equipment should be operated and maintained according to applicable procedures.

UV-Curing Systems — When Applicable

Some printing operations use ultraviolet-curing equipment.

Potential hazards may include:

• Ultraviolet radiation.
• Electrical energy.
• Heat.
• Ozone where generated.
• Chemical exposure from UV-curable products.

Guards and shielding should be maintained.

Employees should not bypass protective enclosures or interlocks.

Finishing and Bindery Operations

Printed products may undergo:

• Cutting.
• Folding.
• Collating.
• Stitching.
• Binding.
• Trimming.
• Laminating.
• Die cutting.
• Packaging.

Each operation should be evaluated for machinery and ergonomic hazards.

Paper Cutters

Powered paper cutters can cause severe amputations and lacerations.

Appropriate safeguarding should prevent employees from reaching the cutting area during hazardous machine movement.

Employees should not bypass safety devices.

Guillotine Cutters

Guillotine-style paper cutters should have appropriate point-of-operation protection.

Potential safeguards may include:

• Two-hand controls.
• Presence-sensing devices.
• Barriers.
• Other appropriate safeguarding systems.

Employees should follow machine-specific operating procedures.

Cutter Blade Changes

Blade changes can expose employees to extremely sharp and heavy blades.

Appropriate procedures should address:

• Lockout/Tagout.
• Blade handling.
• Mechanical lifting where necessary.
• Blade guards or carriers.
• Hand protection.
• Safe blade storage.

Employees should not handle large cutter blades without appropriate controls.

Folding Machines

Folders may expose employees to:

• Nip points.
• Rollers.
• Belts.
• Feed mechanisms.
• Delivery systems.

Required guards should remain in place.

Employees should not reach into operating folding equipment to clear jams.

Binding Equipment

Bindery equipment may include:

• Perfect binders.
• Saddle stitchers.
• Collators.
• Drills.
• Punches.
• Staplers.
• Gluing equipment.

Employees should receive equipment-specific training.

Stitchers and Staplers

Powered stitching and stapling equipment can cause puncture or crushing injuries.

Point-of-operation hazards should be guarded.

Employees should keep hands outside fastening areas.

Die Cutting

Die-cutting equipment may expose employees to:

• Crushing.
• Cutting.
• Pinch points.
• Automated movement.

Appropriate guarding and safe operating procedures should be maintained.

Laminating

Laminators may create:

• Heated-surface hazards.
• Nip points.
• Chemical exposure.
• Roll-handling hazards.

Employees should remain clear of operating rollers and use appropriate controls when clearing jams.

Machine Guarding

All printing and finishing machinery should be evaluated for machine hazards.

Potential hazards include:

• Rotating components.
• Reciprocating components.
• Nip points.
• Cutting.
• Shearing.
• Crushing.
• Entanglement.

Appropriate guarding should be provided and maintained.

Lockout/Tagout

Printing machinery may contain hazardous:

• Electrical energy.
• Mechanical energy.
• Pneumatic energy.
• Hydraulic energy.
• Gravity.
• Stored tension.

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

Jam Clearing

Employees should not reach into hazardous machine areas to clear jams while unexpected startup or movement is possible.

Applicable hazardous energy should be controlled before employees enter danger areas.

Setup and Adjustment

Not every routine production adjustment necessarily requires full Lockout/Tagout.

The employer should evaluate whether the activity qualifies for an applicable exception and whether alternative measures provide effective protection.

Employees should not assume that calling an activity “setup” makes uncontrolled machine access acceptable.

Machine Maintenance

Maintenance procedures should address:

• Lockout/Tagout.
• Guards.
• Electrical hazards.
• Pneumatic pressure.
• Hydraulic energy.
• Heavy components.
• Chemical exposure.
• Hot surfaces.

Only appropriately trained and authorized employees should perform specialized maintenance.

Preventive Maintenance

Preventive maintenance can help identify:

• Damaged guards.
• Worn controls.
• Leaking chemical systems.
• Defective interlocks.
• Bearing problems.
• Electrical damage.
• Ventilation deficiencies.

Maintenance schedules should reflect equipment use and manufacturer recommendations.

Compressed Air

Compressed air may be used for equipment or cleaning.

Employees should use compressed air according to applicable requirements.

Compressed air should not be directed toward employees or used in a manner that unnecessarily disperses hazardous contaminants.

Ergonomics

Ergonomic hazards are common throughout printing operations.

Employees may perform repetitive:

• Lifting.
• Reaching.
• Bending.
• Gripping.
• Pushing.
• Pulling.
• Standing.
• Material feeding.

Workstations and material-handling methods should be evaluated to reduce unnecessary physical stress.

Roll Handling

Large paper, film, foil, and substrate rolls can be extremely heavy.

Employees should use appropriate:

• Roll-handling equipment.
• Hoists.
• Carts.
• Lifting devices.
• Mechanical assists.

Employees should not manually attempt to control rolls beyond their physical capability.

Cylinder Handling

Printing cylinders, anilox rolls, and similar components may be heavy and awkward.

Mechanical handling should be used where appropriate.

Storage systems should prevent rolling or falling.

Repetitive Feeding

Employees feeding presses, bindery equipment, or finishing machines may perform highly repetitive motions.

Potential controls may include:

• Adjustable workstations.
• Improved material positioning.
• Mechanical feeding.
• Task variation.
• Reduced reach distances.

Manual Material Handling

Employees should evaluate the weight, dimensions, stability, and grip of loads before handling them.

Mechanical assistance or team lifting should be used when appropriate.

Palletizing

Finished printed materials may be manually palletized.

Palletizing should be arranged to reduce:

• Excessive bending.
• Extended reaching.
• Repetitive heavy lifting.
• Twisting.

Adjustable pallet positions or mechanical assistance may be appropriate for higher-volume operations.

Powered Industrial Trucks

Printing facilities may use forklifts to move:

• Paper.
• Rolls.
• Pallets.
• Chemicals.
• Finished products.

Only trained and authorized employees should operate powered industrial trucks.

Forklift Traffic

Facilities should reduce interaction between pedestrians and forklifts.

Potential controls may include:

• Designated aisles.
• Pedestrian walkways.
• Mirrors.
• Barriers.
• Warning signs.
• Traffic rules.

Employees should remain alert around mobile equipment.

Loading and Unloading

Shipping and receiving operations may involve:

• Trucks.
• Trailers.
• Loading docks.
• Forklifts.
• Pallet jacks.
• Heavy paper rolls.

Procedures should address vehicle movement, trailer condition, dock hazards, and material stability.

Loading Docks

Dock areas should be maintained to prevent:

• Falls.
• Trailer movement.
• Forklift incidents.
• Pedestrian collisions.

Dock plates and related equipment should be inspected and used within rated capacities.

Paper and Material Storage

Paper, rolls, substrates, and finished products should be stored securely.

Storage procedures should prevent:

• Unstable stacks.
• Falling materials.
• Rolling material.
• Blocked aisles.
• Overloaded racks.

Roll Storage

Rolls should be stored to prevent uncontrolled movement.

Chocks, racks, cradles, or other suitable means should be used as appropriate.

Employees should not stand downhill or directly in the anticipated movement path of an unsecured roll.

Personal Protective Equipment

PPE should be selected according to the hazard assessment.

Depending on duties, PPE may include:

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

Employees should understand PPE limitations.

Eye and Face Protection

Eye protection may be necessary for:

• Chemical handling.
• Press cleaning.
• Screen reclamation.
• Maintenance.
• Cutting.
• Flying material.

Face protection may be required where splash or impact hazards warrant additional protection.

Hand Protection

Hand protection should be selected according to the task.

Potential hazards include:

• Solvents.
• Inks.
• Cleaning chemicals.
• Sharp plates.
• Doctor blades.
• Cutter blades.
• Paper edges.

Chemical-resistant gloves should be selected for compatibility with the products used.

Gloves and Machinery

Employees should not wear gloves around exposed rotating equipment when the glove itself could create an entanglement hazard.

Task-specific evaluation is necessary.

Protective Footwear

Protective footwear may be necessary where employees handle:

• Heavy rolls.
• Pallets.
• Cylinders.
• Machine components.

Footwear should also provide suitable traction for production areas.

Respiratory Hazards

Depending on processes and products, printing employees may be exposed to:

• Solvent vapors.
• Mists.
• Cleaning chemicals.
• Dust.
• Aerosols.
• Coating components.
• Other contaminants.

Potential exposure should be evaluated according to the actual products and processes used.

Respiratory Protection — When Applicable

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

Applicable elements may include:

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

Respirators should not substitute for required feasible engineering controls.

Noise Exposure

Potential printing-industry noise sources include:

• Printing presses.
• Folders.
• Cutters.
• Compressors.
• Bindery equipment.
• Material-handling equipment.

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:

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

Fire Prevention

Printing facilities may contain significant quantities of:

• Paper.
• Cardboard.
• Ink.
• Solvents.
• Coatings.
• Adhesives.
• Packaging.

Fire-prevention procedures should address both combustible materials and ignition sources.

Ignition Sources

Potential ignition sources may include:

• Electrical faults.
• Dryers.
• Ovens.
• Hot surfaces.
• Static electricity.
• Welding.
• Cutting.
• Smoking.
• Open flames.

Ignition sources should be controlled where flammable liquids or vapors may be present.

Static Electricity

Certain web-printing and solvent-handling operations may generate static electricity.

Where static discharge can create an ignition hazard, appropriate bonding, grounding, equipment design, or other controls should be used.

Hot Work

Welding, cutting, brazing, and grinding should be controlled when performed near:

• Paper.
• Ink.
• Solvents.
• Coatings.
• Dust.
• Packaging.
• Other combustible materials.

Applicable Hot Work procedures should be followed.

Housekeeping

Good housekeeping is important throughout printing operations.

Floors and aisles should be kept free of:

• Paper.
• Strapping.
• Ink.
• Solvent.
• Packaging.
• Pallets.
• Cords.
• Other debris.

Waste should not be allowed to interfere with machinery or emergency exits.

Ink and Solvent Spills

Ink or solvent spills can create:

• Slip hazards.
• Chemical exposure.
• Fire hazards.

Spills should be cleaned promptly using appropriate procedures.

Employees should use required PPE and appropriate waste containers.

Waste Handling

Printing operations may generate waste including:

• Used ink.
• Solvents.
• Cleaning materials.
• Chemical containers.
• Used wipes.
• Plates.
• Used blades.

Waste should be evaluated and managed according to its characteristics and applicable requirements.

Printing waste should not automatically be classified as hazardous waste solely because it comes from a printing process.

Electrical Safety

Printing facilities contain numerous electrically powered machines.

Electrical equipment should be maintained in safe condition.

Employees should report:

• Damaged cords.
• Missing covers.
• Exposed wiring.
• Defective switches.
• Overheated equipment.

Electrical work should be performed by appropriately qualified employees.

Slips, Trips and Falls

Printing facilities may have slip and trip hazards involving:

• Ink.
• Solvents.
• Paper.
• Strapping.
• Pallets.
• Cords.
• Uneven surfaces.

Employees should maintain clear aisles and promptly address spills.

Ladders and Elevated Work

Employees may use ladders for:

• Maintenance.
• Storage.
• Lighting.
• Ventilation equipment.
• Press access.

Ladders should be selected, inspected, and used appropriately.

Fall protection should be provided where required.

Emergency Action Plan

The company should maintain emergency procedures appropriate to the facility.

Potential emergencies may include:

• Fire.
• Chemical release.
• Machine injury.
• Medical emergency.
• Severe weather.
• Workplace violence.

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

Fire Emergency

Employees should know how to:

• Report a fire.
• Activate alarms.
• Evacuate.
• Proceed to assembly areas.
• Account for personnel as required.

Only employees trained and authorized under company procedures should use portable fire extinguishers.

Chemical Emergency

Employees should understand procedures for significant releases involving inks, solvents, coatings, cleaners, or other chemicals.

Employees should not perform emergency response beyond their training and available protection.

First Aid

Appropriate first-aid resources should be available.

Potential printing-industry injuries may include:

• Cuts.
• Crushing.
• Amputations.
• Chemical exposures.
• Eye injuries.
• Burns.
• Strains.

Employees should promptly report injuries and obtain appropriate medical evaluation.

Incident Reporting

Employees should promptly report:

• Injuries.
• Near misses.
• Machine contacts.
• Missing guards.
• Chemical exposures.
• Fires.
• Forklift incidents.
• Equipment damage.
• Unsafe conditions.

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.
• Press setup.
• Lockout/Tagout.
• Chemical handling.
• Ventilation.
• Maintenance.
• Ergonomics.
• Training.
• Supervision.
• Work procedures.

Root Cause Analysis

Root Cause Analysis may identify underlying factors involving:

• Equipment design.
• Guarding.
• Preventive maintenance.
• Chemical selection.
• Employee training.
• Procedures.
• Production pressure.
• Staffing.
• Hazard assessments.
• Corrective-action systems.

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

Printing Safety Inspections

Periodic safety inspections should evaluate:

• Printing presses.
• Machine guards.
• Interlocks.
• Emergency stops.
• Cutters.
• Bindery equipment.
• Chemical storage.
• Ventilation.
• Forklifts.
• Fire protection.
• PPE.
• Walking-working surfaces.

Identified deficiencies should be corrected in a timely manner.

Printing Safety Training

Employee training should reflect assigned duties and equipment.

Depending on responsibilities, training may address:

• Press hazards.
• Machine guarding.
• Lockout/Tagout.
• Chemical hazards.
• Flammable liquids.
• Ink and solvent handling.
• PPE.
• Forklift safety.
• Ergonomics.
• Emergency procedures.

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

Machine-Specific Training

Employees should receive instruction for the printing and finishing equipment they are authorized to operate.

Training should address:

• Machine controls.
• Guarding.
• Nip points.
• Safe setup.
• Emergency stopping.
• Jam clearing.
• Cleaning.
• Prohibited practices.

Training on one press should not automatically be considered sufficient for substantially different equipment.

New Employee Orientation

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

Orientation may address:

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

Refresher Training

Refresher or remedial training may be appropriate following:

• Unsafe equipment operation.
• Guard bypassing.
• Lockout/Tagout violations.
• Chemical-handling incidents.
• 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.
• Nip points.
• Lockout/Tagout.
• Chemical handling.
• Solvents.
• Ergonomics.
• Material handling.
• Forklift safety.
• Fire prevention.
• Recent incidents.

Recordkeeping

Printing employers 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 printing operations and employee exposures, additional programs may be necessary for:

• Printing Press Safety.
• Machine Guarding.
• Lockout/Tagout.
• Preventive Maintenance.
• Hand & Power Tools.
• Paper Cutter Safety.
• Conveyor Safety.
• Hazard Communication.
• Chemical Safety.
• Flammable & Combustible Liquids.
• Spray Finishing.
• Respiratory Protection.
• Personal Protective Equipment.
• Eye & Face Protection.
• Hand Protection.
• Hearing Conservation.
• Electrical Safety.
• Powered Industrial Trucks.
• Material Handling.
• Loading & Unloading.
• Ergonomics.
• Manual Lifting.
• Housekeeping.
• Slips, Trips & Falls.
• Walking-Working Surfaces.
• Ladder Safety.
• Hot Work.
• Fire Prevention.
• Emergency Action Plan.
• First Aid.
• Hazardous Waste Management where applicable.
• Incident Reporting & Investigation.
• Root Cause Analysis.

Programs should be included when the company’s printing methods, presses, finishing equipment, chemicals, material-handling operations, and employee exposures make them applicable.

Building a Printing Company Safety Manual

A useful Printing Company Safety Manual should reflect the company’s actual printing processes.

An offset or lithographic printing company may require extensive procedures for sheetfed or webfed presses, plate and blanket changing, rollers and cylinders, paper handling, press cleaning, inks, solvents, bindery equipment, Machine Guarding, and Lockout/Tagout.

A flexographic printer may require greater emphasis on anilox rolls, plate cylinders, doctor blades, material rolls, ink preparation, solvent or water-based ink systems, web handling, dryers, ergonomics, and material handling.

A screen-printing company may require programs covering manual or automatic presses, ink preparation, screen reclamation, cleaning chemicals, dryers, repetitive work, ventilation, and PPE.

A gravure printer may require substantial procedures for heavy cylinders, doctor blades, liquid inks, solvent vapor control, dryers, flammable liquids, material rolls, and fire prevention.

A printing and bindery company may require greater emphasis on cutters, folders, collators, stitchers, binders, laminators, material handling, ergonomics, and finished-product packaging.

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

Customized Printing Company Safety Manuals

A Printing Company Safety Manual can be developed around the company’s printing presses, prepress operations, inks, solvents, plates, rollers, cylinders, cutters, bindery equipment, finishing operations, forklifts, material handling, maintenance activities, employees, and other occupational hazards.

The finished manual may incorporate applicable programs for Printing Press Safety, Machine Guarding, Lockout/Tagout, Chemical Safety, Hazard Communication, Flammable Liquids, PPE, Respiratory Protection, Hearing Conservation, Ergonomics, Powered Industrial Trucks, Fire Prevention, Emergency Action Planning, Incident Investigation, and other hazards associated with printing operations.

This provides commercial printers, offset printers, flexographic printers, screen printers, gravure printers, label and packaging printers, bindery operations, and other printing employers with a practical safety manual organized around the work their employees actually perform.