Flexographic Printing SWMS

Flexographic printing operations expose press crews to a converging set of high-risk hazards: rotating anilox and impression rollers operating at web speeds exceeding 400 metres per minute, sharp doctor blades under spring tension, Class 3 flammable solvent inks (ethyl acetate, ethanol, n-propyl acetate), and dryer tunnels operating between 60°C and 90°C with forced-air recirculation. Under the Model WHS Regulations 2025 Chapter 4 Part 4.5 (Plant) and Part 7.1 (Hazardous Chemicals), any PCBU operating a flexographic press must document the specific controls applied to plant guarding, chemical exposure, and ignition-source management before work commences. A Safe Work Method Statement is mandatory because flexo work routinely triggers section 291 high-risk construction-adjacent work involving powered mobile plant and hazardous chemicals stored above manifest quantities. This SWMS captures the engineering interlocks, solvent-handling sequences, and emergency web-break response procedures required to discharge the primary duty of care under section 19 of the WHS Act.

Hazards identified

7 hazards covered, sorted by priority.

Control measures

Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.

1. 1Elimination — Remove the need for in-running reach by specifying presses with automatic web-threading and inline splice tables; eliminate manual blade contact via cassette-style doctor-blade systems.
2. 2Elimination — Procure pre-mixed solvent inks delivered in closed-loop IBCs to remove decanting and reduce open-vessel vapour generation at the press deck entirely.
3. 3Substitution — Substitute high-VOC ethyl acetate inks with water-based or low-migration UV-flexo inks where substrate and end-use permit, reducing Class 3.1 inventory below manifest threshold.
4. 4Substitution — Replace solvent wash-up with enclosed automatic anilox cleaning systems using bicarbonate blasting or ultrasonic baths to eliminate manual rag-and-solvent exposure.
5. 5Engineering — Maintain Category 3 interlocked guards on all nip points per AS 4024.1501 with dual-channel monitoring; verify stop time under 0.5 seconds at quarterly intervals.
6. 6Engineering — Install LEV hoods at ink trays and dryer extraction ducted to atmosphere via solvent-rated fans, maintaining face velocity 0.5 m/s and intrinsically safe Zone 1 rating within 1 m of ink stations.
7. 7Engineering — Provide overhead jib crane or roller-handling trolley rated to 150 kg for anilox changeover with tapered cradles preventing roll-off during transfer.
8. 8Administrative — Implement lockout-tagout per AS 4024.1603 before any blade change, sleeve mount, or in-press intervention; permits signed by press operator and shift supervisor with isolation verified.
9. 9Administrative — Conduct documented pre-start SWMS sign-on each shift covering web-break response sequence, solvent spill kit location, and dryer-tunnel hot-work exclusion zone of 3 metres.
10. 10PPE — Issue Type A chemical-splash goggles, nitrile gauntlets (0.38 mm minimum) tested to EN 374 for ethyl acetate, Class 5 hearing protection, and antistatic safety footwear per AS/NZS 2210.3.

Applicable Codes of Practice

Worked example

At a flexible-packaging converter running an eight-colour central-impression flexo press on a metallised film job, the shift supervisor convenes the 6:00 am pre-start brief at the press deck. The SWMS is opened on the line-side tablet and projected onto the supervisor's screen. The crew reviews the seven listed hazards, with particular attention paid to the web-break recovery procedure because the previous shift logged two breaks on the same substrate. The lead operator confirms the lockout-tagout permit book is on the deck and that the chambered doctor-blade cassette tool has been inspected. During the brief, an apprentice raises that the ethyl acetate IBC is reading low — the supervisor pauses the sign-on, references the SWMS control requiring IBC changeover under LEV with the press in safe state, and schedules the swap for the upcoming colour change rather than mid-run. Each crew member signs the SWMS register electronically with their HRWL number. Two hours into the run, a web break occurs in the dryer tunnel. The operator follows the documented sequence: e-stop, isolate, dump dryer heat, wait for tunnel temperature below 40°C confirmed on the HMI, then enter with a second person observing. The SWMS is re-opened, the deviation noted in the field-amendment log, and the recovery completed without incident. The document functioned as both training reference and live decision tool.

Related legislation

• WHS Act 2011 (model)
• WHS Regulation 2025
• AS 2550 — Cranes, hoists and winches; AS 1418 series

Frequently asked questions