Press Operation SWMS

Printing press operation exposes workers to nip point entanglement risks that can cause amputation and fatal crush injuries, sustained noise levels exceeding 85 dB(A), and chemical vapour exposure from inks, dampening solutions, and coatings applied during production runs. Multi-unit offset, flexographic, and web presses present multiple entanglement points across roller trains, impression cylinders, and delivery systems that operate at speeds capable of drawing a limb into the machine before an operator can react. This SWMS template covers press start-up, operation, changeover, and shutdown with controls mapped to the Managing Risks of Plant in the Workplace Code of Practice binding from July 2026.

Legal Requirements

regulation

WHS Regulation 2025 Part 5.2 — Plant; Part 7.1 — Hazardous Chemicals; Part 4.7 — Noise

hrcw category

Work near powered mobile plant, hazardous chemical exposure

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
Nip point entanglement at impression, blanket, and anilox roller interfaces	Amputation, fatal crush injuries, degloving injuries	Possible
Noise exposure exceeding 85 dB(A) during press operation	Permanent noise-induced hearing loss	Likely
Chemical vapour inhalation from inks, dampening solution, and coatings	Respiratory irritation, CNS depression, chronic lung disease	Likely
Electrical hazards during press electrical maintenance and fault finding	Electrocution, arc flash burns	Unlikely
Manual handling during plate changes, blanket replacement, and substrate loading	Musculoskeletal injuries, back strain	Likely

Controls (Hierarchy of Controls)

Maintain all press guards and nip point covers in position during operation — zero tolerance for guard removal

Implement lockout-tagout procedures for all press maintenance, adjustment, and cleaning tasks

Provide audiometric testing annually for all press operators and enforce hearing protection in press rooms

Ensure press room ventilation maintains chemical vapour concentrations below workplace exposure limits

Conduct pre-start press inspections checking guard interlocks, emergency stops, and safety curtains

Restrict press operation to trained and competent operators with documented verification of competency

Use inching mode only for authorised setup procedures with all personnel clear of running nip points

Recent Prosecutions

Printing press entanglement — NSW$280,000

A press operator suffered crush injuries when a guard interlock on a multi-unit offset press was found to have been defeated to allow operation with the guard open during a changeover. The employer had no documented procedure for press changeover safety.

2023 — SafeWork NSW Prosecution Database

What Your SWMS Must Include

✓Guard and interlock register for every press listing all safety devices and their test schedule

✓Lockout-tagout procedure specific to each press type — offset, flexographic, digital, web

✓Noise assessment results and hearing protection zone map for press room

✓Chemical vapour monitoring schedule covering IPA, solvents, and UV curing by-products

✓Operator competency requirements and verification of competency records

Need a compliant Press Operation SWMS?

Our WHS consultants develop press operation SWMS with guarding requirements, LOTO procedures, and noise controls that satisfy regulator expectations.