Automated Packaging Line — Risk Reduction & compliance
Packaging
Client
Regional Food Packaging Facility
Industry
Packaging
Equipment
High-speed automated packaging line with robotic case packing
Project Duration
3 months
The Challenge
A regional food packaging facility was operating a high-speed packaging line installed in 2008 that had never undergone a formal risk assessment. Following a near-miss incident and an internal safety audit, management recognized significant gaps in machine safeguarding and a lack of documentation to demonstrate compliance with current ANSI/PMMI standards.
Key Issues Identified:
- No documented risk assessment or safety analysis for the packaging line
- Inadequate safeguarding at multiple access points during routine operations
- High-risk pinch points and entanglement hazards during changeover procedures
- Lack of proper lockout/tagout procedures and unclear energy isolation points
- Non-compliant emergency stop coverage and safety distances
- Production pressure to maintain uptime while addressing safety concerns
The Solution
Safe‑T‑Sense conducted a comprehensive risk assessment to identify and evaluate all hazards associated with the packaging line across all modes of operation. We then developed a prioritized safety concept that addressed high-risk hazards first while balancing safety improvements with production requirements.
1
Comprehensive Risk Assessment
Conducted on-site task analysis covering production, changeover, cleaning, and maintenance operations. Identified and evaluated 47 distinct hazards using ISO 12100 and ANSI B155.1 methodologies.
2
Prioritized Safety Concept
Developed a practical safety concept that categorized improvements into immediate, near-term, and long-term actions based on risk levels and operational impact.
3
Engineering & Implementation Support
Designed new guard interlocking systems, revised emergency stop coverage, specified proper safety distances, and created detailed electrical and mechanical specifications for new safeguarding devices.
4
Validation & Documentation
Validated all implemented safety measures through functional testing and provided complete documentation including risk assessment reports, safety concept specifications, and validation records.
Services Provided
Risk Assessment
Safety Concept Development
Engineering
Validation
Results & Outcomes
- Eliminated all high-risk hazards identified in the risk assessment
- Implemented guard interlocking on 12 access points with proper safety distances
- Achieved compliance with ANSI B155.1 and ISO 12100 requirements
- Provided training for 24 operators and maintenance personnel
- Reduced medium-risk hazards by 85% through engineering controls
- Established clear lockout/tagout procedures with labeled energy isolation points
- Zero unplanned downtime during implementation through phased approach
- Delivered complete documentation package for regulatory and audit purposes
Ready to Address your Machine Safety Challenges?
Let’s discuss how Safe-T-Sense can help you reduce risk and improve safety on your equipment.