Machine Guarding

for Plastic Sheet

and Roll Stock
Extrusion
OSHA 10-Hour Outreach Training Program for the
Plastics Processing Industry
A Presentation of the SPI-OSHA Alliance

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Course Objectives
Identify the types of injuries that can occur
while operating plastics sheet and roll stock
extrusion equipment
Describe the possible causes of these injuries
Identify ways to safely operate plastic
extrusion equipment
Recognize the importance of a total safety
and health approach

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Reasons to Focus on Injuries in

the Extrusion Process
High injury/illness rates
OSHA citations
National Emphasis Program on
Amputations
Site-Specific Targeting
High workers compensation costs

Types of Injuries
Fatalities

Cuts and bruises

Amputations

Sprains and strains

Avulsions

Electric shock

Fractures
Burns

Some Causes of Injuries

Reaching around, under, over or through
guards into hazardous areas
Removing or bypassing guards
Inadequate temperature monitoring during
cleanup
Not using LOTO procedures
Machine/equipment malfunctions

Causes of Injuries

(contd)

Lack of recognition of hazards of the job

Lack of familiarity with the equipment
Inadequate training, comprehension, or both
Operating machines with missing or inoperable
guards and improper or inadequate machine
maintenance
Lack of proper PPE
Loose clothing around winding equipment

Schematic of Extruder

Schematic of Extrusion Process

Risk Areas
Feed Tubes

Shear

Roll Stack

Winder

Trim Knives

Grinder

Pull/Nip Rolls

Feed Tubes

Accident #1
Third-Degree Skin Burns
Two employees were cleaning the feed pipe for
a line extruder
Resin in the feed pipe hardened during
shutdown
Employee heated the feed pipe to soften the
plastic for 30 minutes
The employee pulled plastic plug at bottom of
feed pipe
Hot plastic sprayed out causing 2nd & 3rd
degree burns

Roll Stack

Accident # 2
Fatality
Machine operator was threading plastic film
through rolls of film extruder line when he got
caught between top and bottom rolls
Skull fracture and head trauma resulted in his
death

Trim Knives

trim knife

pivoting blade guard

Trim Knives

Trim Knives

Trim Knife Guarding

Trim Knife Blade Disposal

Pull-Roll Nips
Sturdy metal mesh in guard

Emergency stop pull cord

Shear

Shear

Winder

Accident #3
Fatality
Employee was splicing plastic on new extruder
winder rolls to get it started
drawstring on hooded sweatshirt got
caught in roll
employee died by asphyxia

Grinder Guarding
Guarding by:
Enclosure over moving
components
Anti-kickback flaps in
feed throat
Proximity guarding
distance from feed chute
to rotating knives

Proximity
Guarding

Abrasive Wheel Machinery

Work rests on offhand grinding machines must be kept
adjusted closely to the wheel with a maximum opening
of 1/8-inch to prevent the work piece or tool from
being jammed between the wheel and the rest, which
may result in wheel breakage or wheel explosion.

Abrasive Wheel Machinery

The distance between the wheel periphery and the
adjustable tongue must never exceed 1/4-inch.

Power-Transmission Apparatus
Power-transmission
apparatus (shafting,
flywheels, pulleys, belts,
chain drives, etc.) less
than 7 feet from the floor
or working platform must
be guarded.

Unguarded belt
and pulley

Safety Guards and Devices

Types of guards and devices
Movable guards with interlocks
Fixed barrier or proximity guards
Presence-sensing device
Locations of guards
Over/around moving equipment
Around electrical hazards
Around thermal hazards
Around cut hazards

Movable Guards with Interlocks

Allows the electrical
system to operate
Actuated when the
interlocked guard is
closed or opened
Prevents machine
from operating when
the guard is open

Electrical Interlock Switch

Interlocked Guard
Emergency stop pull cable

Electrical interlock switch

Electrical Interlock Operation

Fixed Barrier Guards

Prevent
contact with
the hazard

Yellow fixed guard

Fixed Barrier Guards

Wing guards

Guard over moving

machine components

Fixed Barrier Guards

Presence Sensing Devices

Safety mat

Light curtain

Presence Sensing Devices

Safety Mat

Safety Guards and Devices

Light Curtain

How to Protect Yourself

Recognize the hazards in the job you are
doing
Understand the requirements for
guarding machines
Implement guarding solutions

Emergency Stop Button

Know:
Where they are
located
What they control
When to use them

Emergency Stop Cable

Know:
Where they
are located
What they
control
When to use
them

Signs and Warnings

Colors used with Safety Signs

have meaning!
DANGER
White Lettering/Red Background

WARNING
Black Lettering/Orange
Background

CAUTION
Black Lettering/Yellow
Background

High Voltage

Rotating Screw

High Temperature

High Pressure

Crushing Fingers

Amputated Fingers

References for Extrusion Safety

ANSI B11.TR3-2000 Risk Assessment and Risk Reduction - A Guide to
Estimate, Evaluate and Reduce Risks Associated with Machine Tools
ANSI B11.19-2003 Performance Criteria for Safeguarding
ANSI/SPI B151.7-1996 Plastics Machinery - Plastics Extrusion Machines
- Requirements for the Manufacture, Care and Use
ANSI/SPI B151.5-2000 Plastic Film and Sheet Winding Machinery Manufacture, Care, and Use
ANSI/SPI B151.20-1999 Plastic Sheet Production Machinery Manufacture, Care and Use
ANSI Standards are available at the following web site: www.ansi.org
SPI Guide to Extruded Plastic Sheet Products,
www.plasticsheet.org/Guide/index.htm

OSHA's Site-Specific Targeting (SST) Program

OSHA's Site-Specific Targeting (SST) program selects for inspection
individual worksites with the nation's highest Days Away from Work Injury
and Illness (DAFWII) Case Rate and Days Away, Restricted, or
Transferred (DART) Rates. It is based on data reported by more than
80,000 employers surveyed by the agency.
See the OSHA Web site for the
most current directive and the
rates used to target inspections.
In order to verify the reliability of
claims by establishments that
they have achieved low DART
rates, OSHA inspects a certain
percentage of employers with low
rates.

OSHA National Emphasis Program on Amputations

On October 27, 2006, the Occupational Safety and Health Administration (OSHA)
revised its national emphasis program aimed at reducing amputations in general
industry workplaces. The National Emphasis Program on Amputations targets
all types of machinery and equipment that are considered a high risk for causing
amputations. The plastics processing industry is among the industries under
scrutiny for workplace amputations.
The twenty-four states and two territories which operate their own OSHA programs
are encouraged, but not required, to adopt a similar emphasis program. State Plan
State information is available on OSHAs Web site. The OSHA directive on this
emphasis program is available on OSHA's Web site under Regulations and
Compliance, subcategory Compliance Directives, No. CPL 03-00-003.
Under this initiative, regional and area OSHA offices will continue to conduct
outreach; targeting and selection; and inspections. Area offices will obtain and use
additional data to identify and add establishments where serious injuries or fatalities
related to these machines have occurred.

The Job Safety Analysis Process

The Job Safety Analysis (JSA) process is a very
effective means of helping reduce incidents,
accidents, and injuries in the workplace. It is a
multi-step process.
Basic Job Steps
Potential Hazards
Recommended Safe Job Procedures

Summary
Injuries can occur while operating plastics
sheet and roll stock extrusion equipment
Risk areas can be protected by safety guards
and devices
Protect yourself and operate plastic extrusion
equipment safely
Recognize the importance of a total safety
and health approach

Do you have any

Questions?