Product Overview

Summary: This UV Coating and Lamination Safe Operating Procedure sets out clear, practical steps for running coating and laminating equipment safely while maintaining consistent, high-quality finishes. It is tailored for Australian print and packaging environments, helping you control chemical, UV light and machinery hazards while meeting WHS obligations and customer quality expectations.

UV coating and lamination are high-value finishing processes that can significantly enhance the durability and appearance of printed materials, but they also introduce a range of WHS and quality risks if not controlled. Operators work with fast‑moving rollers, heated elements, high‑intensity UV lamps and chemical products that can cause burns, respiratory irritation, eye damage and serious entanglement injuries. This SOP provides a structured, step‑by‑step method for planning, setting up, operating and shutting down UV coating and lamination equipment in a way that prioritises worker safety and product consistency.

Developed for Australian print, sign and packaging businesses, the procedure aligns with WHS legislative duties and recognised industry good practice. It covers everything from pre‑start inspections, guarding and lock‑out/tag‑out requirements to safe handling of UV curable coatings, adhesives and cleaning solvents, including ventilation and spill response. By implementing this SOP, businesses can demonstrate due diligence, reduce downtime due to preventable incidents, and provide a clear training and competency framework for new and existing operators. The result is safer work, fewer rejects and re‑runs, and a more reliable, compliant finishing process your clients can trust.

Key Benefits

• Ensure safe setup, operation and shutdown of UV coating and lamination equipment in line with Australian WHS requirements.
• Reduce the risk of chemical exposure, UV light injury and entanglement incidents through clearly defined control measures.
• Improve product quality and consistency by standardising machine settings, substrate checks and inspection points.
• Streamline onboarding and refresher training for operators with a clear, step‑by‑step procedure and role-specific responsibilities.
• Demonstrate due diligence to regulators, clients and auditors with documented, repeatable processes and risk controls.

Who is this for?

• Print Production Managers
• Wide Format Print Operators
• Packaging Machine Operators
• Bindery and Finishing Supervisors
• WHS Managers and Safety Advisors
• Maintenance Technicians
• Small Print Shop Owners
• Quality Assurance Coordinators

Hazards Addressed

• Exposure to ultraviolet (UV) radiation from curing lamps leading to eye and skin damage
• Contact with UV curable coatings, adhesives and cleaning solvents causing skin irritation or dermatitis
• Inhalation of vapours from coatings, adhesives and solvents in poorly ventilated areas
• Entanglement, crushing or amputation hazards from in‑running nips and rollers
• Burns from heated rollers, lamps or curing units
• Fire and explosion risks from flammable solvents and vapours
• Manual handling injuries from lifting and loading rolls, sheets and laminate reels
• Electrical hazards associated with UV curing systems and high‑voltage components
• Slip hazards from spills of coatings, adhesives or cleaning agents

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Definitions and Abbreviations
• 3.0 Roles and Responsibilities (PCBU, Supervisors, Operators, Maintenance)
• 4.0 Equipment Description and Safety Features
• 5.0 Hazard Identification and Risk Controls for UV Coating and Lamination
• 6.0 Required PPE and Safety Equipment
• 7.0 Pre‑Start Checks and Area Preparation
• 8.0 Chemical Handling, Storage and Labelling Requirements
• 9.0 Step‑by‑Step Operating Procedure – UV Coating
• 10.0 Step‑by‑Step Operating Procedure – Lamination
• 11.0 Quality Control Checks and Product Inspection Criteria
• 12.0 Cleaning, Maintenance, Lock‑Out/Tag‑Out and UV Lamp Handling
• 13.0 Spill Management, Waste Disposal and Environmental Considerations
• 14.0 Emergency Procedures (Fire, Exposure, Equipment Failure)
• 15.0 Training, Competency and Authorisation Requirements
• 16.0 Recordkeeping, Review and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and equivalent state and territory WHS Regulations
• Safe Work Australia – Managing Risks of Hazardous Chemicals in the Workplace: Code of Practice
• Safe Work Australia – Managing the Work Environment and Facilities: Code of Practice
• Safe Work Australia – How to Manage Work Health and Safety Risks: Code of Practice
• AS 4024.1 Safety of machinery (series)
• AS/NZS 1337.1: Personal eye protection
• AS/NZS 2161: Occupational protective gloves
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1680: Interior and workplace lighting (for UV and general lighting considerations)