TIP 0301-01

ISSUED – 1994
WITHDRAWN AS TIP 0304-55 – 2001
REVISED AND RENUMBERED – 2002
REVISED – 2008
©2008 TAPPI

The information and data contained in this document were

prepared by a technical committee of the Association. The
committee and the Association assume no liability or responsibility
in connection with the use of such information or data, including
but not limited to any liability under patent, copyright, or trade
secret laws. The user is responsible for determining that this
document is the most recent edition published.

Corrugated boxplant − list of potential hazards

Scope

The information contained in this list of potential hazards is intended to encourage thought and action toward
the safe operation and maintenance of boxplant equipment. It is the responsibility of each equipment designer,
operator, maintenance technician, supervisor, and manager to design and enforce policies to assure the safe
operation of equipment. This list is intended to be helpful but should not be viewed as covering all possible
hazards−many of which can be unique to each plant.
Federal, state, and local regulations deal extensively with safety; be knowledgeable concerning requirements
and enforce them actively.
Equipment manufacturers provide specific documentation concerning the safe operation and maintenance of
their equipment. Request additional information and updates from the manufacturer if your file is incomplete.
Be fully aware of your company's policy concerning safety and enforce its requirements.

General list of hazards and safety precautions

Subject Action

General Guideline • No customer order, no schedule, no piece of scrap, no amount of product, no time
saving, etc., is worth the risk of injury−take proper time to work safely.

Daily Inspection (each shift) • Include personnel, plant, and equipment

• All phases of operation and maintenance

Lockout/Tagout (Ref: OSHA -
29CFR Part 1910.147)
• Lockout/Tagout properly before jam clearing, cleaning, troubleshooting and
maintenance.
• Lockout/Tagout procedures must eliminate all sources of potential energy
including electrical, mechanical, pneumatic, hydraulic and stored energy.
• Instructions of Lockout/Tagout must identify all the key lockout points at the
machine center.
• Follow specific procedures to restart.

Training • Operating and maintenance personnel must be continuously trained

concerning safety. Regular refresher training is essential (document for each
individual).
• Machine Knowledge - Never operate a machine unless fully trained and
certified by a qualified trainer in all aspects of the machine’s
operation/function.

TIP Category Automatically Periodically Reviewed (Ten-year review)

TAPPI
TIP 0301-01
Climbing on Equipment
Non-operating Personnel
Roll Nip Points
Rotating Shafts, Chains, and
Moving Belts
Loose Parts/Projectiles
Knives and Slitter Blades
Threading and Startup
Equipment Lubrication
Corrugated boxplant – list of potential hazards / 2
• Never climb on or above operating equipment.
• Never walk on moving belts and conveyors.
• Non-operating personnel are not permitted in the area of operating
equipment.
• Visitors should be thoroughly briefed on plant safety operations and must be
escorted.
• Roll nips are extremely hazardous.
• Guard specifically refers to OSHA nip guard guide.
• Never clean scrap from rolls that are in motion.
• Never wipe or clean rolls while the machine is running; gloves, rags, hands,
feet, etc., are instantly pulled into roll nips.
• In-running nips grasp objects instantly, exit nips present an entanglement
hazard.
• Loose clothing, long hair, gloves, jewelry, rags, etc., quickly become
entangled.
• Never clean or service shafts, chains, belts, etc., while the machine is
running. Use Lockout/Tagout.
• Guards must be securely installed with no exceptions.
• Never operate a machine with loose parts.
• Inspect continuously.
• Follow manufacturer's specifications for fasteners, torque, guards, etc.
• Foreign objects (tools) in contact with or falling into operating equipment can
become projectiles.
• Lockout/Tagout before scrap clearing, cleaning, and servicing.
• Use cut proof gloves for handling knives and blades.
• Keep personnel clear during restart; blade chipping can result from improper
adjustment.
• Use only manufacturer's specified fasteners with proper torque.
• Store properly.
• Use a box cutter knife with an automatic retractable blade.
• Cut away from your body when cutting samples.
• Define and enforce procedures which assure safe threading and startup.
• Assign responsibility: only one member per crew should be authorized to
initiate startup.
• Never permit personnel to lubricate moving parts during while equipment is
running.
• Assign responsibility for lubrication, service, and inspection and enforce safe
procedures.
3 / Corrugated boxplant – list of potential hazards TIP 0301-01

Stored Energy • Be aware of all forms of stored energy (potential for energy release):
hydraulic, steam, pneumatic, gravitational, mechanical (springs, torque,
tension, compression), electrical (capacitors), magnetic, etc.
• Define procedures to de-energize all systems before jam clearing, cleaning,
and servicing.

Pinch Points • Pinch points develop during the operation of many equipment components
such as doors, tables, lift trucks, shuttles, elevators, shafts, rolls, hinges, and
fingers.
• Securely install guards and interlocks.
• Access to equipment areas with pinch point hazard must be prohibited during
operation (automatic setup).
• Mark pinch point hazard areas clearly: signs, paint, warning devices, etc.
• Gloves do not prevent pinch point injury.

Jog Operation • Equipment jog at slow speed can cause injury; co-workers must be visible
and clear of all equipment before beginning jog operation.
Electrocution • Lockout/Tagout before beginning any service procedure; define and enforce
restart procedures.
• Complete routine checks of electrical equipment using heat sensing
equipment.
• Develop procedures and practices that allow technicians to troubleshoot
electrical problems while power is on but do repairs in Lockout Tagout mode.
• Maintain equipment per manufacturer's specifications with proper grounding,
insulation, controls, guards, circuit protection, etc.
• Never operate equipment with defective controls or wiring.
• Service with trained and authorized personnel only.
• Keep electrical drives, motors, and controls clean and dust free.
• Immediately stop operation and report unusual electrical conditions: heating,
sparking, erratic operation, etc. Do not restart until corrected.
• Be knowledgeable concerning stored energy devices.
• Water increases electrocution hazard. Do not approach electrical equipment
when water is present. Repair leaks, clear standing water, and never wash or
spray electrical equipment.
• Control cabinets, wireways, and junction boxes contain high voltage.
• Regularly inspect grounding, fusing, circuit breakers, and other protective
devices.

Strain Injury • Learn proper techniques for lifting and material handling. Do not attempt
loads beyond your capability.
• Keep work areas clean. Maintain proper footing and body position during lifting.
• Overcentered loads increase with rotation. ??????
• Use protective clothing, supports, braces, etc., to prevent injury.

Conveyors • Use walkways; never walk on belts and rollers.

• Inactive conveyors may restart at anytime.
• Stay clear of conveyors and associated devices to prevent crush from moving
conveyor components and loads
• Shuttle cars can move unattended; maintain clear areas at all times in shuutle
car aisles.
TIP 0301-01 Corrugated boxplant – list of potential hazards / 4

Safety Circuits and Interlocks • Maintain safety equipment in proper operating status with no compromise.
• Bypassing safety circuits and interlocks will cause injury; know the purpose
and function of all safety circuits and interlocks.

Vacuum Systems and Trim • High forces can result from vacuum systems; maintain clearance.
Chutes • Dampers and positioners operate periodically; keep personnel clear from
operating areas.
• Projectiles can result from high velocity air flow; guard properly.

Falls, Trips, Bumps
• Keep work areas clean, dry, and well lighted.
• Portions of equipment can move to new positions; clearly mark areas of
operation.
• Clear debris and spills immediately.
• Work areas should be free of overhanging objects, loose wires, etc.

Lift Trucks
Personnel Protection of Eyes,
Ears, Hands, Feet, Head,
Lungs, etc.
• Define lift truck routes and warn personnel on foot to keep clear of these
areas.
• Fuel and batteries present the potential for chemical injury, explosion, fire,
electrocution, etc. Service by trained and authorized personnel only.
• Define and enforce safe roll stacking and lift truck operating procedures.
Trained and authorized operators only should move roll stock.
• Maintain equipment in proper operating condition at all times: lights, mirrors,
horns, brakes, etc.
• Use proper personal protective equipment (PPE) for each situation; the cost
of protective equipment is low in comparison to injury cost. Permit no
compromise on the use of personal protective equipment as defined by safe
operating procedures.
• Ear damage is cumulative; wear protection every day. Sources of noise
include machinery, hydraulics, pneumatics, blowers, vacuum systems, etc.

Loose Clothing, Long Hair, • Enforce safety procedures to prevent entanglement with operating equipment.
Jewelry

Hose and Cable • Hoses (pneumatic, hydraulic, and steam), cables, and chains can cause whip
injury if broken. This equipment must be properly secured and guarded to
prevent whip injury.

Cleanup • Never attempt to clean any part of a machine that is in motion; hands, gloves,
rags, clothing, etc., can become entangled instantly.
• Spraying water, compressed air, steam, etc., will cause dust and projectile
hazard to operators and co-workers. Specify safety equipment and procedures.

Steam • Extreme hazard due to high pressure, temperature, and velocity. Enforce
strict policy−authorized personnel only, insulation, guarding, warning signs,
blow down procedures, etc.
• Promptly repair leaks and replace damaged components.

High Temperature • Burn injury can result from contact with high temperature surfaces-steam
equipment, preheaters, brakes, preconditioners, high friction areas, welders,
heaters, motors, etc. Guard, insulate, use warning signs, and mark clearly.
5 / Corrugated boxplant – list of potential hazards TIP 0301-01

Emergency Stop • Do not restart until cause for emergency stop is known.
• Define specific restart procedure.

Chemical Hazard • Unless clearly known, treat all liquids and powders as hazardous chemicals.
• Label all containers.
• Handle by authorized personnel only.
• Procedures must be clearly defined and enforced.
• Protective clothing is mandatory.
• Store properly in secure location and limit access.
• File of material safety data sheets must be updated and available to all employees.

Fire • All personnel must know action to be taken upon alarm of fire.
• Drills should be held on a regular basis
• Paper dust, trim scrap, oil, etc., are extremely combustible. Clean all areas
• Enforce strict policy on smoking, welding, cleaning, material storage, etc.
• Doorways−open, accessible, and clearly marked.

Tools and Equipment • Replace tools that are worn or defective. Use the proper tool for each task.
• Ladders, overhead platforms, and catwalks present special situations.
• Specify procedures
• Make first-aid equipment accessible and keep inventory up-to-date.

Closed Space • Toxic vapors remain in closed spaces for long periods.
• Clearly mark closed spaces and prevent access.
• Set team work policy with outside team member maintaining communication.

Housekeeping • Housekeeping must be part of daily routine.

• Someone must be accountable for every area of the plant.

Keywords

Converting plants, Boxes, Hazards, Safety

Additional information

Effective date of issue: March 4, 2008.

This TIP was originally issued as TIP 0304-55. The number was changed upon revision to TIP 0301-01 to
place it in the proper Subject Category (Safety – Corrugated).
Working Group:
Elaine Deak, Chairman, Smurfit-Stone Container Corp.
David Vollick, Smurfit-Stone Container Corp.
Richard Croker, Georgia Pacific Corp LLC
Ron Rhoades, Temple Inland Corp.