Direct answer
Prevent access to dangerous parts during normal operation and foreseeable intervention. Fixed guards suit areas needing infrequent access; interlocked guards may be needed where regular access is required. Isolation, stored energy, restart prevention and safe systems must cover cleaning, jams, changeover and maintenance.
Why this matters
Many packaging injuries occur during non-production tasks when guarding is removed or a jam is cleared. The assessment must study real interventions, not only automatic running.
Decision table
| Task | Hazard question | Control evidence |
|---|---|---|
| Operation | Can anyone reach moving parts? | Guarding and safe distance |
| Jam clearing | Can stored or unexpected movement occur? | Isolation or engineered safe access |
| Cleaning | Are nip points exposed during routine cleaning? | Safe system and guard design |
| Changeover | Which guards and parts are removed? | Controlled sequence |
| Maintenance | Are pneumatic, hydraulic, electrical or gravity energies controlled? | Isolation procedure |
Information to collect
- List every mode and intervention.
- Observe operators, cleaners and maintenance staff.
- Identify mechanical and stored-energy hazards.
- Check guard openings, reach and bypass potential.
- Confirm emergency stops are not used as isolation.
- Record residual risks, information and training.
Practical method
- 1
Eliminate or reduce hazards by design first.
- 2
Use fixed or interlocked guards appropriate to access frequency.
- 3
Provide secure isolation and energy dissipation.
- 4
Validate safety functions after change.
- 5
Review after incidents, modifications or new products.
Common mistakes to avoid
- Assessing automatic mode only.
- Relying on emergency stops for maintenance isolation.
- Leaving cleaning access unguarded.
- Allowing defeated interlocks to become normal.
- Adding guards that make safe cleaning impractical.
Questions people also ask
When is an interlocked guard needed?
Where routine access is required and fixed guarding would be impractical, an interlock may be appropriate as part of the risk-reduction design.
Is an emergency stop an isolation device?
No. Isolation and stored-energy control require a separate defined method.
Who should complete the risk assessment?
A competent team with knowledge of the machinery, tasks, hazards and applicable requirements.
When should guarding be reviewed?
After modification, relocation, new products, incidents, repeated bypass or changes to cleaning and maintenance tasks.
Official and primary sources
These references support the regulated, standards-led or security points in this guide. Check the current source before making a project decision.
Continue from the requirement to the equipment
Use the specialist route that matches the product, pack and process. Final suitability requires representative samples, output targets and site information.