Direct answer
A packaging machine risk assessment should examine each task and lifecycle stage, identify who may be harmed and how, evaluate existing controls and apply further risk reduction using inherently safe design, engineering safeguards, information and safe systems. The assessment must reflect the actual installed machine and work.
Key takeaways
- Define machine boundaries, people and tasks.
- Observe work and challenge safeguards.
- Record controls, actions and verification.
- Review after changes, incidents and adverse trends.
Establish the legal and technical scope
Include infeed, outfeed, conveyors, utilities, stored energy, adjacent equipment and interfaces. Assess operators, cleaners, engineers, contractors and others during production and non-production work.
- Map normal, setup and fault tasks
- Include access above, below and inside guards
- Identify product, chemical and environmental hazards
- Consider reasonably foreseeable misuse
Assess the actual machine, task and site
Review trapping, crushing, cutting, drawing-in, ejection, hot surfaces, pressure, electrical energy, slips, lifting and ergonomic hazards. Check whether controls create new risk or can be defeated easily.
- Verify guard distances and openings
- Test stopping and restart behaviour
- Review isolation and stored energy
- Observe jam clearing and cleaning
Create and retain suitable evidence
Use clear hazard descriptions, risk evaluation, action owners and due dates. Verify completed actions and update instructions, maintenance and training where needed.
- Controlled risk assessment revision
- Safeguard and safety-function test results
- Action closure evidence
- Training and safe-work instructions
Keep the control current
New packs, speeds, tooling, software, guards or maintenance methods can alter exposure. Near misses, recurring jams and bypasses are important triggers for review.
- Use modification and software change control
- Investigate near misses and repeated interventions
- Reassess relocated or integrated equipment
- Schedule periodic review based on risk
Comparison table
| Control area | Key question | Typical evidence |
|---|---|---|
| Scope | Define machine boundaries, people and tasks. | Applicable legislation, standards and responsibility |
| Assessment | Observe work and challenge safeguards. | Risk assessment and verified safeguards |
| Records | Record controls, actions and verification. | Drawings, declarations, tests and training records |
| Review | Review after changes, incidents and adverse trends. | Change control, inspection and periodic review |
Free working templates
Download these files and adapt them to the actual machine, product, site and acceptance plan.
Official guidance and further reading
These sources provide the current regulatory or standards context. Always check the latest version before making a compliance decision.
Related buyer guides and tools
Relevant machinery and support routes
Use the guide to define the requirement, then compare the specialist routes below against representative product, packaging and output evidence.