The injured person was working alone and there were no direct witnesses to the accident.
However it is believed that he may have been trying to remove a hickie from the rotating plate,
using a stiff piece of card, while the machine was at operating speed.
It is believed that the guarding of the machine was inadequate, and that at each print unit the
extension guard which normally sits below the "guard in front of the inking unit at the feeder side"
was missing.
According to Heidelberg the following guarding arrangement should be in place on this type of
machine:
Guard between dampening and inking rollers
Subsequent to lifting this guard it has to be hooked onto the closed guard. Thus both hands are
free to insert/remove rollers. When opened the press can neither be inched nor run. This guard is
designed in such a way that hickies can be removed from the plate while the press is in operation
using a specially designed tool.
It appears that this machine was in operation with a guard missing at feed side of each print unit.
The machine had probably been in this condition since it was installed second-hand in about 2003.
Further investigations by local and specialist HSE Inspectors are taking place. Normal operation of
the machine will not be permitted until it is fully guarded and safe to operate.
The BPIF and Unite strongly recommend that all employers or those who are responsible for the
safe operating of offset litho presses ensure the following points have been followed, or form part
of their internal Risk Reduction Programmes (RRP).
1. Ensure there is an up-to-date activity based risk assessment for any physical intervention in
setting, operating, cleaning and maintenance of offset litho presses relating to the feeder
running nip area.
2. Ensure that there are specific documented Safe Systems of Work (SSW) for access to
cylinders and inking rollers during cleaning, make ready and maintenance tasks.
3. Review your current guarding standards on all feeder and extension guards and consult
with your safety representations (if applicable) and/or machine operatives.
4. Ensure you have stringent standards for the monitoring and auditing of all press guards, to
ensure that all guards are working effectively and in sound condition to meet their
requirements.
5. Carry out a review of your training arrangements to ensure that all operatives are fully
trained and aware of the purpose of press guards, the SSW that should be adopted when
running or inching the press units.
6. Carry out a review of your current supervision arrangements that supports your risk
reduction programme. 3 of 3
Supporting legislation and guidance
Provision and Use of Work Equipment Regulations (PUWER) 1998
‘Printers Guide to Health and Safety’ (second edition) ISBN 0-7176-2267-3
Or contact your local BPIF/Unite Health and Safety Adviser or Press Manufacturer for further
advice.
Please Note: None of the aforementioned points neither implies nor confirms that these
were contributing factors in the above incident, they are merely standard controls that
companies should be following.
‘Chapel Action’
Chapels should ensure that:
• the attached alert (or the above information) is brought to the attention or relevant employers,
and that the advice given is implemented in full
• all print machines are properly guarded, in line with manufacturers' instructions
• particular attention is paid to machines that have been supplied second-hand
• Check that you are compliant with points 1-6 of this alert