Product Overview

This Safe Work Method Statement (SWMS) provides a structured, step-by-step approach to managing risks when working with packaging, bottling and assembly line machinery, helping you maintain strong WHS compliance on site. It is a comprehensive document that covers multiple aspects of packaging, bottling and assembly line machinery operations, from manual tasks through to automated and robotic systems.

Activities & Specific Tasks Covered

This document includes specific risk controls for:

• Safe operation of bottle capping machines, including guarding, interlocks and jam-clearing procedures
• Use of can closing machines with controls for crush, entanglement and noise-related risks
• Set-up, adjustment and operation of carton folding and gluing machines to minimise contact with moving parts
• Manual and semi-automatic component assembly tasks, including ergonomic controls and repetitive strain risk reduction
• Finishing and assembly tasks such as labelling, inspection and quality checks along the production line
• Safe use and maintenance of glue rollers, including burn prevention, fume exposure control and spill management
• In-feed and out-feed tasks, including loading, unloading and clearing blockages on conveyors and transfer points
• Operating packing machinery with appropriate lock-out/tag-out procedures and emergency stop controls
• Operation of automatic machinery, including start-up, shutdown and isolation procedures for cleaning and maintenance
• Packaging of finished products, including manual handling controls, palletising and wrapping activities
• Packaging of finished trailers and large items, including securing loads and working around mobile plant
• General packaging operations involving repetitive tasks, sharp edges, tape dispensers and strapping tools
• Safe set-up and operation of pre-gluer equipment, including glue application, curing and ventilation controls
• Use of robot sprayers, including exclusion zones, guarding and controls for overspray and airborne contaminants
• Tasks involving robotic machinery, including programming, fault-finding and safe access within robot cells
• Housekeeping, waste handling and offcut removal around packaging and assembly line machinery

Who is this for?

This SWMS is designed for packaging and bottling plants, food and beverage manufacturers, assembly line operations, printing and carton facilities, and site supervisors overseeing automated and robotic packaging machinery.

Specific Job Steps & Hazards Covered

Legislation & References

This document was researched and developed to align with:

• Model Code of Practice – Managing Risks of Plant in the Workplace: Guidance on identifying hazards and implementing controls for machinery and equipment
• Model Code of Practice – Hazardous Manual Tasks: Risk management for lifting, carrying and repetitive packaging and assembly work
• Model Code of Practice – Managing the Work Environment and Facilities: Requirements for safe work areas around production and assembly lines
• Model Code of Practice – How to Manage Work Health and Safety Risks: Framework for hazard identification, risk assessment and control implementation
• AS 4024 Safety of Machinery (series): Principles for machinery guarding, interlocks and emergency stops on packaging and assembly line equipment
• AS/NZS 3000 Electrical Installations (Wiring Rules): Electrical safety requirements for powered packaging and bottling machinery
• AS/NZS ISO 12100 Safety of Machinery – General Principles for Design: Risk assessment and risk reduction for machinery used in packaging and assembly operations
• Work Health and Safety Act 2011
• Work Health and Safety Regulations 2017