Die Cutting SWMS

Die cutting operations in printing and packaging facilities present severe mechanical hazards including amputation, crush injuries, and entanglement that can result in permanent disability or death. Flatbed die cutters operate with forces exceeding 200 tonnes and rotary die cutters run at speeds that can sever a limb before an operator can withdraw. Die changes require workers to handle sharp tooling while working within the machine envelope, creating a critical high-risk window during setup. The WHS Regulation 2025 strengthens requirements for plant guarding, interlock systems, and lockout-tagout procedures that directly apply to die cutting equipment. This SWMS template covers die cutter operation, die changes, waste stripping, and maintenance with controls mapped to the Managing Risks of Plant in the Workplace Code of Practice.

Legal Requirements

regulation

WHS Regulation 2025 Part 5.2 — Plant; Part 5.3 — High Risk Plant

hrcw category

Work near powered mobile plant (severe crushing and amputation risk)

code of practice

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

section 26a binding

Yes — Plant code binding July 2026. Non-compliance is admissible as evidence of breach.

Hazards

Hazard	Consequence	Likelihood
Amputation from contact with die cutting blades during operation or setup	Finger, hand, or arm amputation	Possible
Crush injury from platens closing during die change or clearing a jam	Fatal crush injuries, multiple fractures	Unlikely
Entanglement in feed rollers and delivery mechanisms	Degloving injuries, limb entrapment	Possible
Lacerations from handling sharp die tooling during changes	Deep lacerations, tendon damage	Likely
Noise exposure from die cutting impact and stripping operations	Noise-induced hearing loss	Likely

Controls (Hierarchy of Controls)

Maintain all perimeter guards and interlocked access doors — zero tolerance for operation with guards defeated

Implement lockout-tagout before any die change, jam clearing, or maintenance within the machine envelope

Provide cut-resistant gloves (AS/NZS 2161.3 Level 5) for all die handling and change operations

Restrict die cutter operation to trained operators with documented verification of competency

Install and maintain light curtains on feed and delivery zones as secondary protection

Conduct quarterly interlock testing and document results in the plant safety register

Provide hearing protection for all personnel in the die cutting area during operation

Recent Prosecutions

Die cutter amputation — South Australia$310,000

A worker suffered partial hand amputation when the safety interlock on a flatbed die cutter was found to have been bypassed with a cable tie. The employer had no documented interlock testing schedule and the bypass had been in place for several months.

2024 — SafeWork SA Prosecution Database

What Your SWMS Must Include

✓Guard and interlock register for each die cutter listing all safety devices and test schedule

✓LOTO procedure specific to each die cutter type — flatbed, rotary, platen

✓Die change procedure with step-by-step safety controls for each phase

✓Jam clearing procedure requiring LOTO before any reach into the machine envelope

✓Operator competency requirements and verification of competency records

Need a compliant Die Cutting SWMS?

Our WHS consultants develop die cutting SWMS with guarding requirements, LOTO procedures, and interlock testing schedules that satisfy regulator expectations.