Printing Solvent Handling & Storage SWMS

Printing operations across offset, flexographic, screen and digital sectors rely on a broad range of flammable and toxic solvents — including isopropanol, ethyl acetate, methyl ethyl ketone (MEK), glycol ethers and proprietary press washes — for plate cleaning, blanket washing, ink reduction and equipment maintenance. The receipt, decanting, dispensing, storage and disposal of these Class 3 dangerous goods generates simultaneous fire, explosion, inhalation and dermal exposure risks that escalate sharply in poorly ventilated press halls. Under WHS Regulation 2025 Part 7.1 (Hazardous Chemicals) and the Dangerous Goods (Storage and Handling) framework adopted in each jurisdiction, the PCBU must implement a documented Safe Work Method Statement before any worker handles solvents in bulk, decants from intermediate bulk containers (IBCs), or services flammable storage cabinets. This SWMS satisfies the consultation, control selection and record-keeping duties required for high-risk solvent work in print environments.

Hazards identified

7 hazards covered, sorted by priority.

Control measures

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

1. 1Elimination — Substitute solvent-based press washes with UV-cured or water-based ink and wash systems wherever press technology and substrate compatibility allow, eliminating Class 3 storage entirely.
2. 2Elimination — Order pre-mixed fountain solution and ready-to-use blanket wash in sealed cartridge systems to remove on-site decanting from bulk drums.
3. 3Substitution — Replace high-volatility toluene and xylene-based washes with low-VOC vegetable-ester or high-flash-point (>60°C) alternatives meeting AS 1940 Combustible Liquid classification.
4. 4Substitution — Use low-aromatic isoparaffinic solvents in place of MEK for routine cleaning to reduce workplace exposure standard pressure.
5. 5Engineering — Install AS 1940-compliant flammable liquids cabinet (≤250L capacity) with self-closing doors, integral bunding, flame arrestors and earthed dispensing taps within 10m of point of use.
6. 6Engineering — Provide local exhaust ventilation (LEV) at decanting station achieving ≥0.5 m/s capture velocity, ducted to atmosphere via spark-resistant fan per AS 1668.2.
7. 7Administrative — Implement bonded and earthed decanting procedure with documented verification of continuity (<10 ohms) before each transfer, recorded on the daily pre-start checklist.
8. 8Administrative — Restrict solvent handling to workers who have completed dangerous goods awareness training, verified SDS comprehension, and signed onto this SWMS at the pre-start briefing.
9. 9PPE — Issue Viton or laminated-film chemical gloves (AS/NZS 2161.10), splash goggles (AS/NZS 1337.1) and antistatic conductive footwear (AS/NZS 2210.5) for all decanting tasks.
10. 10PPE — Supply organic vapour respirator with A2 cartridges (AS/NZS 1716) and fit-test records for spill response and any task where LEV is unavailable or exposure exceeds 50% of WES.

Applicable Codes of Practice

Worked example

At a regional carton-printing facility, the morning shift supervisor opens the pre-start briefing in the press hall before the day's run of solvent-based flexo ink on corrugated stock. Three press assistants are rostered to decant 60 litres of ethyl acetate blanket wash from a 200L drum into 5L safety cans for the day's cleaning rounds. The supervisor opens this SWMS on the shared tablet and walks the crew through the hazard register, pausing on the static-discharge and vapour-cloud entries. The assistants confirm the bonding cable between drum and receiving can shows continuity below 10 ohms on the test meter, the AS 1940 cabinet LEV is running, and the spark-resistant pump is fitted. One assistant notes the cabinet's bunding contains residue from yesterday's minor drip; the supervisor pauses the task, has it absorbed with vermiculite and disposed of in the dangerous goods waste drum before decanting commences. All three workers sign onto the SWMS electronically, confirming they hold current dangerous goods awareness training and have donned Viton gloves, splash goggles and antistatic boots. Mid-shift, ambient temperature in the press hall rises above 30°C; the supervisor re-consults the SWMS escalation matrix, increases LEV to high setting and rotates decanting duties to limit individual exposure. The SWMS, sign-on sheet and bonding-test log are retained on the project file for two years.

Related legislation

• WHS Act 2011 (model)
• WHS Regulation 2025
• Managing Risks of Hazardous Chemicals CoP; AS/NZS 4024

Frequently asked questions