Analysis of Hidden Dangers in Carton Packaging Industry and Countermeasures

Among the various types of packaging industry, the paper packaging industry has the largest contribution to the total output value of packaging. With the rapid development of the industry, the issue of safety in production has attracted the attention of people in the industry. First, the raw materials used in the carton industry are base papers. The base paper is flammable. Therefore, fire safety is very important. Second, in the carton production process, manual operations are compared. In many cases, mechanical injury accidents are very likely to occur. Third, electrical safety risks are high. There are slight carelessnesses. Line short-circuits are likely to occur, resulting in equipment failure. Fourth, pressure vessels such as boilers and preheating cylinders are used. Explosion-proof and anti-hot work is very difficult. Therefore, the operation and maintenance of equipment and the skill level of employees are required to be high. This article starts with analysis of the main safety hazards and weak links in the field management for the safe production of the carton industry, and puts forward several improvement countermeasures and measures:

I. Analysis of security risks

Involved in injury

At present, domestic corrugated board production lines are either single-sided corrugated board production lines or multi-layer corrugated board production lines, which are mainly composed of a base paper holder, a preheating cylinder, a single-faced corrugating machine, a double-sided machine, a dryer, a slitting and creasing machine Cutting machine, stacker and conveyor bridge and other components. Most of the connections between the units are mechanically linked, and the entire product is produced through various drive shafts and conveyor belts. Taking into account the cooling of the equipment, easy maintenance and operation, most of the equipment did not add protective devices, a considerable part of the rotating device exposed, if the operation is in violation, it can easily cause injury. This type of safety hazard includes: pulley or drive chain involved in injury; mixer motor pulley involved in injury; single-sided pedal without guardrail involved in injury; drying road entrance conveyor belt involved in injury; stacker export conveyor belt involved in injury; In case of damage to the groove device and the paper, the slotting knife has no cover collision or entrapped damage.

The author has carried out statistics on the accidents of minor injuries that occurred in a company in recent years. The results show that 90% of the incidents involved in the accident account for 50% of the accidents are caused by illegal operations. Most of these types of injuries are caused by the fact that no paper lifting is required to lift the paper directly. Since the speed is too fast, the position of the paper is not properly selected, and the arm is moved between the belt and the hot plate by the inertia of the fast moving paperboard. When the cardboard is cut, the attention is not concentrated, and the force is not grasped properly, causing the hand to bring the bearing of the splitter into the machine momentarily, causing injury; the other is that the machine is not turned on after the machine is shut down, causing damage. In addition, some employees are drawing paper and feeding paper conveniently, and the paper guide rollers and protective bars installed in front of the equipment are arbitrarily removed, thereby increasing the risk of accidents.

2. Blade cuts

Carton production equipment is mostly equipped with sharp cutting knives, corrugated board production line is equipped with a group of extremely sharp slitting knives; production equipment for rear lanes, sub-line production, sub-line production, slotting, and horns production processes are equipped with sharp Knife and blade. Therefore, when the carton equipment is in production or maintenance, if it violates the operating procedures, it is extremely easy to cause injury accidents.

This type of illegal operation is mainly reflected in the change of the production line during the production of the five-layer line. Sometimes, the flash is caught by a thin knife. The operator does not use tools to remove it. Instead, it is handled by hand. The result is not careful during handling. It hits a thin blade of a slitter that rotates at a high speed, causing an accident. According to the requirements of the operating procedures, when the equipment is abnormal, the power supply should be shut down and then processed. These are obviously safe accidents that can be avoided. It is just that the employees are troublesome in the production process and they neglect the basic safety knowledge.

3. Electrical short circuit

Short circuit in the electrical circuit is more common in the carton production process. First, because the buried wire is exposed or worn out, the wire connector looses and falls off; second, the wire cover is not covered properly, or the cover design is unreasonable, and the friction is moved for a long time, resulting in damage to the power cord and causing a short circuit; Due to the poor work environment on the site, dust and paper scraps generated during the production process adhere to the electrical appliances, causing short circuit in the control cabinet.

The consequences of accidents caused by electrical lines are often severe. Light-weight electrical and electronic components are burned and the production line is discontinued. Fire and personnel injuries are caused. If an enterprise occurs together, the cover of the power cord is not properly covered, and friction often occurs during cleaning, which results in damage to the power cord. Short circuit results in the result that some components and encoders of the main motor of the five-layer cross cutting machine and the upper blade servo system are damaged. Burned out, direct loss of nearly 10,000 yuan.

4. High temperature burns

In the production process of cardboard, the steam generated in the boiler needs to be sent to the preheating cylinder in the production line through the steam pipeline. The surface paper, liner paper, etc. are pre-baked through a preheating cylinder to evaporate the water, thereby adjusting the temperature of the paper web. The water content of the paper web is reduced and tends to be uniform, and the tension of the paper web during operation is adjusted so that it is well bonded with the corrugated medium paper, and thus plays a decisive role in the quality of the paperboard. The temperature of the preheating cylinder is very high, up to 200°C or more, and accidents caused by careless operation can cause burn injuries. If the steam insulation of the wrapped pipe is damaged, it can easily cause people to burn. Especially during summer and equipment maintenance, such events occur more often.

5. Fire and explosion

The cartons industry has large stocks of raw paper, and the average number of companies is in the hundreds of tons to thousands of tons. Occupying a large area of ​​the storage area, together with cardboard, cardboard boxes, semi-finished products, finished products and other full-stacked workshops, encountered peak seasons, such as poor logistics delivery, or equipment downtime maintenance, products, semi-finished products rose to the library, causing the passage of plugging. Therefore, fire safety is particularly important, as long as an unburned cigarette butt or short circuit may lead to a major fire accident. In addition, printing inks, gasoline for cleaning, diesel oil for power, and engine oil for lubrication are all flammable materials. For carton manufacturers, these items should be properly stored to prevent accidents.

A burning boiler may explode when a part is overloaded. Even in the case of normal pressure, the pressure element itself may be defective, or it may be damaged due to improper use. It may also burst; the equipment will suddenly experience cold when it is hot, such as when there is a serious lack of water to supply cold water, causing the shell, Furnace burst.

In a five-layer corrugated cardboard production line, a steel thin-wall cylinder preheating cylinder will significantly reduce the mechanical properties of the material under high temperature conditions, and the elongation, elastic modulus, linear expansion coefficient and corrosion resistance will also change significantly, resulting in poor management. , Operational errors or manufacturing defects can cause it to rupture or even explode.

Second, countermeasures and measures

1. Strengthen safety management, eliminate insecurity, and control unsafe behavior

In the composition of various safety accidents in the carton industry, human unsafe behavior and unsafe factors are the direct cause of the accident. For example, there is no protective device on the transmission part, the plastic shell of the electrical plug is damaged, there is a bare connector when the power cord is aged, and the paper is not manually operated by using a lifting stick. In order to prevent accidents from happening, the fundamental measure must be to eliminate potential risk factors (insecure state of things) and to make people not make wrong judgments or misoperations (human unsafe behaviors).

Before the accident, there must be dangerous behaviors and risk factors. In principle, as long as each employee recognizes and suppresses the occurrence of dangerous behavior or controls the transformation of risk factors into accidents, accidents can be avoided completely. Therefore, it is very important to strengthen safety management. Good safety management will reduce insecurity and unsafe behavior. On the contrary, it will increase unsafe behavior and unsafe behavior and increase the probability of accidents.

In recent years, in order to prevent the occurrence of various safety accidents, cartons manufacturing enterprises have introduced various advanced management models, such as the Occupational Health and Safety Management System (OHSAS18001), TPM, and 6S, and have formulated various safety operation regulations for safety education. The basic purpose of carrying out safety inspections, compiling safety measures, and managing programs is to correct people’s unsafe behavior and eliminate insecurity. In most cases, the “bridge” that constitutes an accident is caused by human insecurity and mismanagement. The four factors of people, things, environment, and management are related, like the four sides of a square, with one side. Change, the other three sides also follow changes. The factors that determine the other three sides are people! Therefore, it is of great significance to strengthen the safety management of employees and to prevent the occurrence of safety accidents in the carton industry and ensure safe production.

2. Strictly control the selection and configuration of personnel, improve the safety of employees, and regulate the safety behavior of employees.

Compared with the electronics industry, the carton manufacturing industry does not mean that the requirements for the quality of employees can be reduced, although the threshold for entry is relatively low, especially in recent years, microelectronics technology, automatic control technology, sensing technology, computer technology in the carton production equipment The wide application of the device, the higher and higher degree of automation of the equipment, which requires employees not only to master the operating technology of the equipment, but also to become familiar with various safety operations essentials. This brings new requirements to the employment principle of our industry: strict control over personnel selection and configuration. This mainly includes two aspects: First, the newly elected personnel should ensure compliance with the requirements of safety, especially for the high value of risk positions (cross cutting machine, slitting machine, slotting host, cutting host Hand, etc.) must select the appropriate staff in strict accordance with the relevant safety regulations; second, the dynamic assessment of on-the-job staff should be adjusted and reconfigured in a timely manner for those employees who are not qualified for the operation of the post at physiological or psychological changes.

Improving the safety of employees is the fundamental to preventing accidents at work. The staff's safety qualities are very rich in their connotations. They mainly include: safety awareness, concept of legal system, knowledge of safety skills, structure of cultural knowledge, ability of mental adaptability, ability of adapting to psychological endurance, and ability to restrain behaviors. At present, most of the carton enterprises have training and education in this area that are still in place. In the establishment and management of personnel safety information systems, such as the employee's psychological safety features, physiological conditions, physical examination records, job types, violation records, and safety Information such as assessments need to be improved and strengthened.
Regulating the safety behavior of employees is the difficulty in the safety management of the entire carton industry. Research by the UK Health and Safety Department (HSE) showed that although corrugated cardboard boxes already had relevant safety procedures and work instructions, Yamauchi failed to comply with and adopt them in cattle production. In reality, 80% of them could have been avoided. The security incident still happened. The proportion of domestic carton industry is even higher. At present, the main countermeasures taken are: psychological adjustment, incentive measures, disciplinary measures, organizational management measures, and corporate safety culture construction.

3. Develop practical and feasible on-site safety precautions for the characteristics of the carton industry

——For carton production equipment, the following precautions must be taken:

(1) Each time you turn on the phone, you must press the bell first, and then the other operating staff of the machine can respond to the boot. If you do not drive after pressing the bell, press the bell again after a period of time to drive again, and confirm the safety before proceeding.

(2) The safety device on the equipment must be sensitive and reliable at all times, and it must not be dismantled or artificially adjusted, so that the safety device will be ineffective, and any damage should be promptly repaired;

(3) Electrical control cabinets, electrical installations and electrical components should be kept clean, regularly check components for looseness and aging, and eliminate hidden dangers in a timely manner; power must be cut off during commissioning and inspection;

(4) The protection of equipment should be "six" and "six", that is, there must be a wheel cover, a shaft must have cover, a table must have a column, a hole must have a cover, there must be a rolling point Baffle and special danger must be interlocked;

(5) Remove the sticky paper on the pressure roller or wipe the machine.

(6) When changing the ink or washing the ink, be sure not to touch the rotating part of the machine, and do not use a rag to wipe off the stain on the ink roller;

(7) When adjusting the knife or dividing the line, the starting power should be turned off and the surrounding personnel should be reminded to boot;

(8) The operator who feeds the paper at the entrance of the dryer shall not contact the belt to prevent crushing.

- For pressure vessels such as boilers and preheated cylinders, it is necessary to strengthen regular inspections and inspections. It should:

(1) Keep the safety valve clean, prevent the valve body spring from being covered or rusted by dirt, prevent the safety valve exhaust pipe from being blocked by foreign matter, and periodically perform a manual discharge test on the safety valve and submit it periodically;

(2) Check whether the rotation and fluctuation of the pressure gauge pointer are normal; check whether the connecting pipe of the pressure gauge leaks or leaks steam. Pressure gauges should be submitted for inspection on a regular basis;

(3) Keep the water level table clean and bright constantly, so that the operator can clearly observe the water level displayed by the operator; the steam, water cocks and water discharge cocks of the water level meter should be kept tight;

(4) In accordance with the regulations and standards, the state's statutory monitoring department conducts necessary inspections and tests on the safety conditions of the boilers in use, including external inspections, internal inspections, and hydraulic pressure tests, so as to detect and eliminate hidden defects in equipment in a timely manner. Avoid accidents in the operation of the boiler;

(5) Preheating cylinders shall be regularly monitored by the national statutory monitoring department, including structural, geometrical dimensions and welds, such as the maximum diagonal misalignment of vertical/circumferential welds and the maximum angularity of vertical/circumferential welds. In the aspect of appearance inspection, attention should be paid to whether the body and the weld are cracked, overheated, deformed, or leaked, or whether the inside and outside surfaces are corroded or mechanically damaged.

- For the carton production environment, the following safety regulations must be met:

(1) The layout of the production site should be closely integrated with the production process to meet the requirements of sanitation, fire prevention, explosion protection and anti-leakage. The stacking height of cardboard and carton shall not exceed 2 meters; the people and vehicles shall be diverted and the roads shall be open; in places prone to failure and in places with high risk, striking safety colors and safety marks shall be configured; the fire extinguisher placement position and escape route shall be clear;

(2) The warehouse must have strict management systems and safety measures such as fire protection and explosion protection. Raw paper, ink and fuel oil should be protected by walls or firewalls. The general transportation passage is 2m-3m wide, which is convenient for the forklift to transport the base paper; the width of the manual work track is 1m-1.5m; the width of the inspection passage is not less than 0.5m, and the distance between the base paper and the wall is not less than 0.5m;

(3) Create a good light environment. Due to the characteristics of the carton industry, the general production site has a large site. The stacked cardboard and carton boxes are large in size and high in height, which affects the lighting and lighting of the workshop to some extent. The poor light environment causes people to identify objects for longer periods of time, lowering their efficiency and affecting employees' emotions. As a result, they are prone to safety accidents. In general, the operating illuminance of the carton industry should not be less than 150lx. Use natural light as much as possible, such as using additional sunroofs or making roofs with different heights and other measures to improve lighting.