Worker safety isn’t just a legal requirement—it’s a moral obligation and a business priority. On a fast-paced packaging line, the risk of accidents is real, but it is preventable. From finger pinches to serious machinery-related injuries, it’s critical to prioritize packaging line safety through smarter designs and technologies.
In this post, we’ll examine common risks, actionable tips, and how Wayne Automation makes production plants safer.
Common Accidents on the Packaging Line (and How to Avoid Them)
Packaging lines drive production, but keeping workers safe must always be a priority. Still, preventable accidents continue to disrupt operations, causing downtime, injuries, and extra costs.
In 2020 alone, the private manufacturing industry reported 373,300 total recordable cases (TRC) of nonfatal injuries and illnesses, with an incidence rate of 3.1 per 100 full-time workers.
Let’s examine the most common risks and practical steps to prevent them.
Caught-In or Caught-Between Incidents
The moving parts of packaging machinery—belts, gears, rollers—are like traps waiting to snag hands, sleeves, or worse. These accidents can lead to crushed limbs or even amputations.
- How to Prevent: Fully enclosed machines provide the best protection, with guards and interlocks that immediately stop the machinery if tampered with, keeping workers safe from harm.
Slips, Trips, and Falls
Packaging lines are fast-paced, and a spill or stray piece of material can turn your production floor into a hazard zone. Workers moving quickly to keep up with production can easily lose footing, leading to twisted ankles, sprains, or fractures.
- How to Prevent: A clean and organized floor is a safe floor. Sweep frequently, clean up spills immediately, and organize stray materials to maintain clear walkways. Secure cables, cords, and hoses or route them away from walkways, as these can be tripping hazards. For extra grip in slick areas, install anti-slip mats.
Ergonomic Injuries
Repetitive tasks often go unnoticed until staff experience back pain or shoulder injuries. Heavy lifting, awkward postures, and long hours at the same task can take a serious toll on their well-being.
- How to Prevent: Don’t let your team suffer through preventable pain. Adjustable workstations, mechanical lifts for heavy loads, and job rotation keep work-related injuries to a minimum and morale high.
Electrical and Chemical Hazards
Faulty wiring, improper packaging machinery maintenance, or exposure to harsh cleaning agents can lead to burns, shocks, or respiratory issues for workers. These are accidents that can spiral into long-term damage if overlooked.
- How to Prevent: Regularly inspect equipment, follow lockout/tagout protocols during maintenance, and stock up on the right PPE for your team. Gloves, masks, and goggles aren’t just extras—they’re lifesavers.
Wayne Automation’s Safety Innovations
1. Polycarbonate Lexan Doors for Maximum Protection
- Fully encased machines shield operators from moving parts while maintaining clear visibility of operations.
- The design eliminates the need to remove guards, minimizing downtime and reducing risks.
2. Safety Interlocked Guarding
- Integrated safety systems stop the machine instantly if guards are opened, and low-inertia parts ensure all movement halts quickly for maximum safety.
- This critical feature prevents accidents and adds a layer of operational security.
3. Cat 3 PLd Option for Advanced Monitoring
- Tracks the status of safety mechanisms to meet or exceed strict regulatory standards.
- Scalable for all operations, the Cat 3 PLd option supports both small-scale production lines and high-performance industrial systems, ensuring safety without compromising efficiency.
- Equipment can be modified to fit any category or performance level, allowing manufacturers to adapt safety systems to their production needs.
- Reliable monitoring and adaptability instill trust in the safety and compliance of the equipment.
4. Proven Track Record of Safety
- Wayne Automation’s innovative safety packaging equipment designs have resulted in an exceptional safety record. Trusted by manufacturers across glass and plastic, beverage, chemical equipment, and food industries, our equipment leads the pack in keeping workers safe.
5. Training
- We offer our clients recurring OEM-level training as part of our maintenance agreement to ensure your operators and maintenance staff are well-versed in safe and proper equipment use.
Additional Tips for Enhancing Packaging Line Safety
While advanced machinery design is crucial, these steps can further improve safety:
- Conduct Regular Training: Ensure all workers are familiar with the equipment and trained in emergency procedures.
- Perform Routine Inspections: Check packaging machinery and safety systems regularly to catch issues before they become hazards.
- Implement Lockout/Tagout (LOTO) Procedures: Prevent accidental machine startups during maintenance.
- Provide Proper PPE: Require gloves, goggles, and other protective gear as appropriate.
How Safety Drives Efficiency and Profitability
Investing in packaging line safety isn’t just about avoiding fines or lawsuits. A safer workplace leads to:
- Fewer Downtime Incidents: Machines designed with safety in mind, like Wayne Automation’s, reduce the likelihood of accidents that disrupt production.
- Higher Employee Morale: Workers who feel safe are more engaged and productive.
- Lower Insurance Costs: Safer practices and equipment can lead to lower premiums and fewer claims.
Keep Your Packaging Line Safe with Wayne Automation
Don’t wait for accidents to happen—be proactive about packaging line safety. Wayne Automation’s industry-leading equipment delivers superior protection without compromising efficiency.
Learn how our designs and safety packaging features can safeguard your team while boosting your bottom line. Contact Wayne Automation today for a safer, smarter solution to your packaging needs!