Web Threading & Splicing SWMS

Web threading and splicing on web-fed printing presses is one of the most hazardous routine tasks in a print facility because it requires workers to guide substrate through multiple nip points, roller trains, and drying systems while the press operates at inching speed. Even at reduced speed, the forces generated by tensioned web and rotating cylinders are sufficient to cause entanglement injuries, severe lacerations, and fatal crush events. Flying splice systems that execute reel changes at full production speed add further risk from high-speed web movement and adhesive tape dispensing mechanisms. This SWMS template covers manual web threading, flying splice operations, and tension adjustment with controls mapped to the Managing Risks of Plant code.

Legal Requirements

regulation

WHS Regulation 2025 Part 5.2 — Plant

hrcw category

Work near powered mobile plant (entanglement and laceration 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
Entanglement in roller nip points during web threading at inching speed	Fatal crush injuries, amputation, degloving	Possible
Lacerations from tensioned web edge during threading and tension adjustment	Deep lacerations to hands and arms	Likely
Entrapment in flying splice mechanisms during reel change preparation	Crush injuries, amputation	Unlikely
Struck by reel during loading and positioning on unwind stand	Crush injuries, fractures, fatality	Unlikely
Manual handling injuries from reel loading and web tension adjustment	Musculoskeletal injuries, back strain	Likely

Controls (Hierarchy of Controls)

Use dedicated web threading devices and ropes to avoid manual contact with nip points during threading

Ensure all personnel are clear of nip points before commencing inching mode operation

Maintain nip guards on all roller pairs and verify guard position before threading

Implement two-person procedures for web threading on multi-unit presses

Use mechanical reel handling equipment for all reel loading and positioning

Restrict flying splice speed adjustments to authorised personnel with documented competency

Install emergency stop pull cords along the full length of the web path

Recent Prosecutions

Web press entanglement — NSW$450,000

A press assistant suffered a fatal crush injury when entangled in the roller train of a web offset press during a manual threading operation. The nip guards had been removed to facilitate threading and the press was operated in inching mode without a spotter.

2022 — SafeWork NSW Prosecution Database

What Your SWMS Must Include

✓Web threading procedure specifying the use of threading devices to avoid manual nip point contact

✓Nip guard register and pre-threading guard position verification checklist

✓Two-person procedure for web threading on multi-unit presses with defined roles

✓Flying splice procedure including speed limits, exclusion zones, and operator competency

✓Emergency stop location map for the full web path with monthly testing schedule

Need a compliant Web Threading SWMS?

Our WHS consultants develop web threading SWMS with nip point controls, threading device specifications, and flying splice procedures that satisfy regulator expectations.