Paper bag machine safety operating procedures: ensuring the safety of personnel and equipment

Release time：2025-08-22 Classification：Knowledge

In the paper packaging industry, paper bag machines are core production equipment. Their high speeds, combined with sharp blades, high-temperature components, and complex transmission mechanisms, present significant safety risks during operation. Every misuse of the machine can lead to serious damage to the equipment or personal injury. The lesson of Mr. Zhang at a factory last year is still fresh in our minds. Despite his experience, Mr. Zhang neglected to lock the power supply as required. While clearing a paper jam, the machine suddenly started, severely crushing three fingers on his right hand. This serves as a reminder that strict adherence to safety regulations is not a constraint; it is the cornerstone of protecting lives and productivity . The following comprehensive procedures are an essential guide to ensuring a safe and efficient daily workday.

1. Preparation before operation: Safety starts with details

  1. Wear all personal protective equipment (PPE):
    • Head protection:  Wear a standard safety helmet (long hair must be completely tied inside the hat).
    • Eye protection:  When operating or approaching the machine, you must wear impact-resistant goggles to prevent injury from paper scraps, dust or accidental splashes.
    • Hand protection:  Wear appropriate protective gloves (such as cut-resistant gloves or heat-resistant gloves) when cleaning, adjusting, handling sharp parts (such as blades), or working on hot surfaces. Do not operate the core transmission parts of a running machine (such as rollers and gears) while wearing gloves to prevent entanglement.
    • Foot protection:  Wear anti-smash and non-slip safety shoes.
    • Hearing protection:  Qualified earplugs or earmuffs must be worn in areas where noise levels exceed the standard (usually >85 decibels).
    • Respiratory protection:  When performing operations that generate a large amount of dust (such as cleaning paper powder), you must wear a dust mask (N95 level or higher).
  2. Work environment inspection:
    • Cleanliness and Tidiness:  Ensure the floor around the machine is dry, clean, and free of oil, debris, and debris (such as waste paper rolls, tools, and packaging materials). Ensure that passages are clear and unobstructed. Promptly remove paper scraps and dust from the floor and equipment to prevent potential hazards such as slips and dust accumulation.
    • Adequate lighting:  The work area, machine control panels, and key operating points must have adequate, glare-free lighting.
    • Emergency Exits:  Clearly mark and keep all emergency exits and evacuation routes clear.
  3. Machine status check:
    • Safety device verification:
      • Emergency Stop Button (E-Stop):  Check that all emergency stop buttons are clearly located, clearly labeled, and function effectively (the machine should come to an immediate and complete stop when pressed). This is the most important safety barrier!
      • Guards/Safety Doors:  Verify that guards and interlocking devices on all moving parts (gears, chains, belts, rollers, and cutter areas) are complete, secure, and effective. The interlocking devices must ensure that the machine cannot start if the guard is not fully closed; if the guard is opened while the machine is running, the machine should stop immediately or be unable to start.
      • Photoelectric protective device/safety light curtain:  If equipped, check that its transmitter and receiver are aligned, unobstructed, and that the function test is normal (the machine should stop or be unable to start when the light beam is blocked).
      • Two-hand operation button:  In dangerous workstations that require two-hand operation at the same time (such as die-cutting and stamping areas), confirm that the two-hand button is functioning properly and must be pressed by both hands at the same time to start.
    • Equipment integrity:  Visually inspect the machine to ensure there is no obvious damage or deformation, and that all components (such as cutters, clamps, and conveyor belts) are securely installed.
    • Lubrication points:  Confirm that the oil level at each lubrication point is normal and that the points that require lubrication have been lubricated (according to the equipment maintenance plan).
    • Energy isolation:  If internal maintenance, repairs, or clearing of serious paper jams is required, the "Lockout and Tagout (LOTO)" procedure must be followed to completely isolate the energy (main power, gas source) and hang up a personal safety lock and warning tag.

2. Standardization in operation: Concentration and vigilance are the safety shield

  1. Standard start and stop:
    • Before starting, you must give a loud warning (such as shouting "Start the machine!") and look around to confirm that there is no one in the danger zone of the machine, no tools left behind, and all protective covers are closed and in place.
    • Start the machine strictly according to the instructions in the equipment manual or control panel. After starting, run the machine at a low speed and observe for any abnormal sounds, vibrations, or odors. Once the machine is running smoothly and normally, gradually increase the speed to the operating speed.
    • When shutting down, follow the normal procedures. It is strictly forbidden to press the emergency stop button as a routine shutdown method in non-emergency situations to avoid impact on the equipment.
  2. Operation monitoring and operation:
    • Stay focused:  The operator must concentrate on the operation status of the machine throughout the operation. It is strictly prohibited to use mobile phones, chat with others or engage in things unrelated to the operation during operation.
    • No physical contact:  Never put your hands, head, or any part of your body into the operating machine (e.g., die-cutting, folding, gluing, transmission areas). Even if paper jams or minor malfunctions occur, the machine must be stopped and the LOTO procedure followed before any action can be taken.
    • Tool Use:  When adjustments or handling are required, use specialized tools (such as hooks, brushes, or long-handled tweezers) and keep your hands away from the danger zone. Do not push or pull paper or components with your hands or body.
    • Material adding:  When adding roll paper or handling the unwinding rack, ensure that the machine is in low speed or stopped state , and pay attention to standing position to avoid being hit or entangled by the roll paper.
    • Abnormal handling:  If you find abnormal noise, vibration, overheating, odor, smoke, control system failure, serious product failure, or safety device failure, immediately press the nearest emergency stop button to stop the machine and report it to the team leader or maintenance personnel. Never operate the machine with abnormalities!
  3. Fire and explosion protection:
    • Smoking and all open flames are prohibited in the paper bag machine area (especially near the heat sealing and glazing units).
    • Clean up paper scraps and dust around the equipment in a timely manner (use a vacuum cleaner, and do not use compressed air to blow to avoid dust explosion), and keep the work area clean.
    • Ensure that firefighting equipment (fire extinguishers) are clearly located, in good condition, and easily accessible. Operators should be familiar with their location and how to use them.

3. Maintenance, care and cleaning: safety is the premise of maintenance

  1. Lockout of Energy (LOTO): Before  any work requiring entry into the machine, access to moving parts, repair and maintenance, replacement of parts (such as blades or dies), thorough cleaning, or addressing severe paper jams, strict "lockout and tagout" procedures must be followed . Authorized personnel must personally disconnect and lock out energy sources (power switches and air valves), attach a personal safety lock and a "Do Not Operate" sign, and test to confirm that the machine has come to a complete stop and no residual energy is released. This is an ironclad rule to prevent accidental startup and protect the lives of maintenance personnel !
  2. Tools and programs:
    • Use the correct tools for maintenance.
    • Perform maintenance (such as lubrication, adjustment, and parts replacement) strictly in accordance with the procedures, cycles, and requirements specified in the equipment maintenance manual.
    • After the maintenance work is completed, count the tools to ensure that no tools are left in the machine. After all protective covers and safety devices are reset and confirmed to be effective, LOTO can be lifted according to the procedure and relevant personnel can be notified.
  3. Cleaning operations:
    • Daily cleaning should be carried out when the machine is stopped, avoiding dangerous areas.
    • When deep cleaning involves hazardous areas, LOTO procedures must be followed.
    • Use a vacuum cleaner or special cleaning tools to clean paper scraps, dust, glue stains, and oil stains. Do not clean while the machine is running or use compressed air.

IV. Emergency Response: Respond Calmly and Avert Danger

  1. Emergency stop:  In the event of any emergency that may endanger personal or equipment safety (such as personnel involvement, serious equipment failure, fire), immediately click the nearest emergency stop button (E-Stop) !
  2. Personal Injury:
    • Stop the machine immediately (press emergency stop).
    • Carefully rescue the injured person while ensuring your own safety. If the injured person is trapped in the machine, do not pull them out forcefully . Instead, try to safely move the machine parts in the opposite direction (if possible and safe) or wait for professional rescue while maintaining the injured person's condition.
    • Immediately report to the team leader and safety officer, activate the company's emergency plan, and call the emergency number.
    • Secure the accident scene pending investigation (unless moving is necessary to save lives).
  3. Equipment failure/accident:  Report after shutdown and have professional maintenance personnel handle it. Record the failure phenomenon.
  4. Fire:  Immediately shut down the machine and use the nearest fire extinguisher to extinguish any small fire (if within your capabilities and safe). If the fire cannot be controlled, immediately sound the fire alarm, evacuate along the evacuation route, and call the police.

V. Personnel Qualification and Training

  1. Certification required:  Personnel operating paper bag machines must undergo professional and systematic training organized by the manufacturer or company (including theory, practical operation, safety regulations, and emergency drills), and can only operate independently after passing the assessment .
  2. Continuous Training:  Regular refresher training covers new procedures, emerging risks, accident case analysis, and emergency response skills development. New employees must undergo internship training under a designated mentor and pass the assessment before they can operate independently.
  3. Clear responsibilities:  Operators are responsible for their own safety and the safety of the equipment they operate. They have the right to refuse illegal commands and are responsible for reporting safety hazards and abnormal situations.

The safe operating procedures for paper bag machines are by no means empty words, but rather life-saving rules written with lessons learned from accidents. From the standardized wearing of each piece of protective equipment to the confirmation of the emergency stop button before each operation; from the strict implementation of the iron rule of LOTO during maintenance to the calm handling of emergencies - the rigorous implementation of each link is a defense of the dignity of life and a guarantee of production continuity . The development of safety awareness requires the unremitting investment and supervision of management, and it requires every operator to internalize the procedures into muscle memory. Only when all employees are always on the alert for safety and integrate "safety first" into every operation and every decision, can we truly achieve the goal of zero injuries to personnel, zero accidents to equipment, and efficient production. Every employee should remember: Your safety is the greatest benefit of the company and the foundation of family happiness. Make safe operation an instinct and make safe production the norm!