Press Operation SWMS

Hydraulic presses, mechanical presses, and punch presses are among the most dangerous machines in manufacturing. The closing point between the upper and lower die creates a severe crush and amputation hazard with forces sufficient to cause fatal injuries. Press-related amputations and fatalities continue to occur in Australian manufacturing, primarily when guards are removed, interlocks bypassed, or workers reach into the die area during operation. The WHS Regulation 2025 requires comprehensive machine guarding, two-hand control systems, and lockout tagout procedures for all press operations. This template maps controls to the binding Managing Risks of Plant Code of Practice effective 1 July 2026.

Legal Requirements

regulation

WHS Regulation 2025 Part 4.7 — Plant

hrcw category

Plant with entrapment and crush risk

code of practice

Managing Risks of Plant in the Workplace (binding 1 July 2026 under Section 26A)

section 26a binding

Yes — effective 1 July 2026. Non-compliance is admissible as evidence of breach.

Hazards

Hazard	Consequence	Likelihood
Crush and amputation at the point of operation between dies	Hand amputation, crush fatality	Possible
Unexpected ram descent during die change or maintenance	Crush injuries, amputation, death	Possible
Projectile ejection of work piece or scrap material	Eye injuries, facial lacerations	Possible
Noise from press operation exceeding 100 dB(A)	Permanent noise-induced hearing loss	Almost Certain
Manual handling of heavy dies during changeover	Back injuries, crush injuries to feet	Likely
Repetitive strain from sustained hand-feeding operations	Carpal tunnel syndrome, upper limb disorders	Likely

Controls (Hierarchy of Controls)

Install and maintain light curtains, interlocked guards, or fixed barrier guards on all presses

Implement two-hand control systems requiring simultaneous activation with anti-tie-down circuits

Use die safety blocks during die changes to prevent unexpected ram descent

Lockout and tagout presses during die changes, maintenance, and jam clearing

Use automatic or robotic feed systems to eliminate hand-feeding where production volume justifies

Provide Class 5 hearing protection for all press operators and workers in the press area

Use mechanical die handling equipment to minimise manual handling during changeover

Conduct annual press safety inspection including brake monitoring and overload protection testing

Recent Prosecutions

SafeWork SA prosecution$840,000

Apprentice killed during manufacturing equipment operation with inadequate guarding and supervision.

2024 — SafeWork SA Manufacturing Prosecution [2024]

Orica Australia Pty Ltd$1,200,000

Multiple plant safety failures in industrial operations resulting in occupational disease.

2024 — SafeWork NSW v Orica Australia Pty Ltd [2024]

What Your SWMS Must Include

✓Machine guarding specifications for each press including guard type and interlock configuration

✓Die safety block procedure for all die changes

✓Lockout tagout procedure specific to each press

✓Noise exposure assessment and hearing protection selection

✓Annual press safety inspection schedule and brake test requirements

Need a compliant Press Operation SWMS?

Our WHS consultants build press-specific SWMS that address guarding, LOTO, and die safety procedures for your press operations.