FTA (изд-во). Flexography: Principles And Practices. Vol.1-6

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CHAPTER 2

Pressroom Practices

OFF

DO NOT

OPERATE

166 FLEXOGRAPHY: PRINCIPLES & PRACTICES

ACKNOWLEDGEMENTS

Author/Editor: Jim Reinke, Fox Valley Technical College

Contributors: Steve Utschig, Fox Valley Technical College

Mark Keller, Fox Valley Technical College

A special thanks to all individuals involved in the writing and editing of the

FFTA FlexSys Training Manuals, which were used as a resource for this volume.

PRESSROOM PRACTICES 167

n any flexographic printing plant, big or

small, whether it is corrugated, tag and

label, or wide-web packaging, the print-

ing press is the key element in the graph-

ic reproduction process. The pressroom

is where all the planning and elements

of the flexographic process come together to

ensure that the customer’s requirements are

met, and success is achieved for the customer

as well as the printer.

Success in the pressroom can only be

achieved when pressroom personnel under-

stand basic flexographic principles and

practices and apply them to every customer

request.

Because of the scope of the flexographic

printing industry, it is not practical to explain

all the procedures used in every printing and

converting plant in the industry. This volume

will discuss generic procedures for press-

room personnel involved in narrow-web,

wide-web and corrugated flexographic print-

ing, as well as common principles that can be

used in every segment of the flexo process.

Introduction

ersonal and pressroom safety

issues are critical concerns for

every flexographic printing com-

pany and for each individual.

Printing presses have numerous

pinch points that will cause seri-

ous injury. Every person involved in a printing

department must be concerned with personal

safety and the well-being of the environment.

As is true with any discussion of safety, the

intent is not to interfere with the work envi-

ronment or the company procedures that

have been tailored to meet specific work

requirements. The guidelines that have been

set up by the management and supervisory

personnel to maintain a safe workplace must

be followed to prevent injury to individuals.

PROPER DRESS

Proper dress is vitally important at the

work site. Personal safety begins with the

following basic rules:

• Clothing must be relatively tight-fitting.

Short sleeves and regular work pants

are appropriate. Loose clothing could

catch on moving parts.

• Steel-toed shoes help prevent foot

injury. For extra safety protection,

clamp-on steel boots can be worn. Steel

clamps afford better protection than

steel-toed shoes alone.

• Jewelry such as rings, watches, chains

or long earrings should never be worn

around machinery since they can easily

get caught in moving parts.

• Long hair must be tied back or con-

tained in a hair net so it doesn’t become

entangled in moving parts.

• Eye protection must be worn during

cleanup to prevent ink or wash-up sol-

vent from being splashed into the eyes.

Personal eye glasses must meet the

standards for safety glasses. Many reg-

ular glasses do not.

• Ear plugs or protectors should be worn

to minimize noise exposure.

• Tight-fitting protective gloves should be

worn during ink wash-ups to prevent

skin contact.

COMMON SENSE

Common sense is an important part of

overall safety. This concept is difficult to

explain or teach, yet comes very much into

play when working around the press. Some

examples of common sense include:

• Keeping hands away from moving parts.

• Familiarization of all pinch points bet-

ween various rolls. A pinch point is re-

ferred to as a nip and is created by the

direction that each roll turns. Use extra

caution when working near these areas

since rags, clothing and fingers can eas-

ily be drawn between these rolls and

into the nips;

• Using proper lifting techniques (back

straight and knees bent) as shown in

Figure .

• Folding rags neatly during wash-ups to

prevent corners from getting caught in

PRESSROOM PRACTICES 169

Personal and

Pressroom Safety

170 FLEXOGRAPHY: PRINCIPLES & PRACTICES

machinery parts (Figure ).

• Noting an excessive solvent smell,

which may indicate faulty or insufficient

ventilation.

• Asking questions about equipment or

procedures when points are not clearly

understood. It is easier to answer a

question than it is to fix a mistake.

• Not smoking on the job. Smoking is an

extreme fire hazard and will not be tol-

erated on the work floor and, in many

cases, on company premises.

• Insuring flammable materials are not

close by when operating an electrical

hand tool. Flammable gases or liquids

are easily ignitable.

• Insuring careful handling of metal-to-

metal tasks. A small spark may start a

fire or cause an explosion.

• Grounding all presses properly.

When using solvents around the press, UL-

approved containers should be used and

grounded to the press. Alligator-type clips

should be clamped to the container and to

an unpainted metal part of the press.

SAFETY SIGNAGE

A press can be very dangerous if handled

improperly. Operators and service personnel

must obey all caution signs and safety

instructions. If not, severe injuries and pos-

sibly death, could result.

There are rules to be followed and signs to

be aware of on the shop floor. The most

important rule on the floor is: Do not run any

of the press sections with their safety guards

removed.

There are many signs used in the industry

that represent different dangers. The Occu-

pational Safety and Health Administration

(OSHA) regulates signs that are applied to

equipment to warn of any physical dangers.

Signs and colors are used on machines to

point out possible dangers. These labels are

used to give personnel a continual mental

reminder that a danger is present. Although

these labels differ from industry to industry,

they all have four general headings:

Caution signs. Yellow, black and white signs

indicate a possible danger area or condition

that could cause personal injury (Figure ).

Danger signs. Red, black and white signs

indicate a possible “condition” that could

cause personal injury or damage to the

equipment (Figure ).

Warning signs. Orange, black and white signs

indicate a possible danger area or condition

that could cause personal injury, such as a

nip area (Figure ).

Note signs. Green and white signs indicate

parts or situations needing special attention

and/or an explanation (Figure ).

Proper lifting technique

allows the weight to be

absorbed by the legs –

not the back and knees.

Rag corners should

be tucked in to prevent

them from becoming

caught in the

machinery.

EMERGENCY EQUIPMENT

Personal safety goes hand in hand with a

good knowledge of the printing press and

department. A safety-first approach to the

press and surrounding area is essential at

all times.

Personnel working in the pressroom must

know the location of safety and emergency

equipment in the pressroom such as emer-

gency stops, lockout switches, personal

emergency equipment and fire extinguishers.

Emergency Stops. Emergency stop buttons

will bring the press to a quick, though not an

immediate stop (Figure ). Emergency life

lines are cords that can be pulled to bring the

press to a quick stop.

These safety features are located in vari-

ous convenient places on the press to be eas-

ily reached by operators. Emergency stops

should only be used in emergency situations

when the press must be stopped quickly.

Lockout Switch. A lockout switch prevents the

machine from being turned on (Figure ).

It cuts the power to all of the switches on the

press, thus eliminating an unwanted starting

of the machine. A lockout switch is used

when the press is being cleaned or is down

for simple maintenance. Examples of simple

maintenance include such things as making

simple adjustments or fixing paper jams. The

device shown in Figure locks the power

off when the button is pushed in. It remains

off until the operator resets the switch by

pulling it back out.

OSHA requires that equipment be locked-

out during repair or service and under cer-

PRESSROOM PRACTICES 171

Caution signs, yellow,

black and white in

color, indicate a

possible danger area

or condition that could

cause personal injury.

A red, black and

white sign indicates a

possible dangerous

condition that could

cause personal injury

or damage to the

equipment.

An orange, black and

white warning sign

indicates a possible

danger area, such as a

nip area, or condition

that could cause

personal injury.

A typcial notice sign,

green and white in

color, indicates parts or

situations needing

special attention and/or

an explanation.

Hazardous voltage!

Will shock, burn, or cause

death.

DO NOT work in this

enclosure unless familiar

with these electrical

circuits and safe servicing

procedures.

DANGER

To prevent serious injuries:

• DO NOT put hands

near rotating rolls.

• Only operate machine

with guard in place

over hold down roll.

WARNING

OPERATING SAFETY INSTRUCTIONS

REQUIREMENTS FOR RE-CERTIFYING

AS AN EXPLOSION PROOF PRESS

1. Reconnect power wire W213 to the control instruments cabinet

and re-calibrate the LFL monitor in accordance with

manufacturer’s instructions.

2. Remove blue jumper wire on the purge pressure switch terminal

block, terminals 212 to 351.

3. Remove the two AFIs from the main Allen Bradley PLC5

program in rungs 36:71 to 36:73. These rungs are for the alarm

message.

4. Remove blue jumper wire on lower console front from terminal

213 to terminal 969. Re-install W969 into the 969 terminal.

5. Verify that all intrinsic barriers are connected and that no jumper

wires exist.

SAFETY GLASSES

MUST BE WORN

AT ALL TIMES

CAUTION

172 FLEXOGRAPHY: PRINCIPLES & PRACTICES

The emergency

stop button brings

machinery to a quick

but not immediate stop

during emergency

situations.

Lockout switches

prevent machinery from

being turned on, espe-

cially during cleanup or

maintenance.

The machine is under

“tag-out,” which means

it is down for repair or

service and should not

be turned on.

A typical tag that could

be attached to a lock-

out device, identifies

the lockout status of

the equipment.

Eye-wash stations

should be easily

accessible in the

press area during

emergencies.

Fire extinguisher

classifications

indicate the type of

fire extinguisher

needed to put out a

fire.

OFF

This lock/tag may

only be removed by:

Lock-Out

Switch

DO NOT

OPERATE

Name

Dept.

Expected Completion

This lock/tag may

only be removed by:

Letter

Symbol Types of Fires

Picture

Symbol

For wood, paper,

cloth, trash, and other

ordinary materials.

For gasoline, grease,

oil, paint, and other

flammable liquids.

For live electrical

equipment.

tain other conditions. Generally in these

cases a padlock or other locking device is

utilized over the main power switch or plug.

Tag-out. Tag-out is a safety procedure, used in

conjunction with the lockout device, to alert

everyone that the tagged machine is down for

repair or service; and that under no circum-

stance should the power be turned back on

(Figure ). A lock/tag is attached to the lock-

out device (Figure ).

This tagging procedure brings attention to

the reason that the machine or tool has been

locked-out. If a lock/tag is hanging on a

machine, instructions must be carefully fol-

lowed. Figure illustrates one of the many

phrases used on lock/tags to identify the

lockout status of the equipment. Other phras-

ing examples of lock/tags are:

• Do Not Start.

• Do Not Close.

• Do Not Open.

Personal Emergency Equipment. In every press

area, there should be one or more eye-wash

stations (Figure ). Personnel must know

their locations and how to use them in an

emergency.

There should also be one or more first aid

kits within a plant. Kit location and injury

treatment policies must be known by all

employees, as well as the locations of any

other safety items, such as emergency show-

ers, spill containment kits and fire blankets.

At least one individual on every shift

should have emergency medical training and

be designated to handle emergency situa-

tions. Some companies employ full-time

nurses. Press operators should identify

these people to insure clear responses dur-

ing emergency situations.

Fire Extinguishers. Fire extinguishers are

vital safety equipment in any printing plant.

As with any emergency equipment, all peo-

ple in the pressroom should know extin-

guisher location and use.

Fire extinguishers vary and may be effec-

tive on some types of fires but not others.

Extinguishers are labeled to indicate the

type of fire they will be effective to control

(Figure ).

Many printing plants have installed carbon

dioxide (CO

) fire systems onto each press.

Entire pressrooms can be protected with a

Halon gas fire safety system, which can put out

a fire in two to four seconds by depleting the

room of oxygen. This system requires that all

doors and windows be closed to contain the

gas. To further aid containment, all outgoing

exhausts are stopped on the press when the

system goes off. Halon leaves no residue to

contaminate ink or damage press equipment.

FLAMMABLE MATERIALS

Many inks and solvents are flammable

materials and must be handled with care to

avoid ignition and fire. There are three pos-

sible causes for pressroom fires: heat from

friction, static electricity and sparks.

Heat from Friction. Rubbing parts can start a

fire if the temperature of the ink is raised to

its flash point. The flash point of a material is

the lowest temperature at which the sub-

stance can be ignited under standard test con-

ditions. Friction can occur in an ink station

while the press is running. Extinguish this

type of fire with the press running slowly to

keep heat from building up and overheating

the next higher print station.

Static Electricity. Sparks from static electricity

can create a fire. Static is especially notice-

able during the winter months when the

humidity indoors is low. All flammable sol-

vent containers must be grounded when fill-

ing or dispensing to protect against static

sparks. (Figure ).

Also, it is important for the press to be

grounded to eliminate a buildup of static elec-

tricity between the web and the press rollers.

Spark or Flame. Solvent liquid and vapor can

be ignited by spark or flame. Hand tools

should be properly grounded and operated

in an area where there are no signs of flam-

PRESSROOM PRACTICES 173

174 FLEXOGRAPHY: PRINCIPLES & PRACTICES

mable or gaseous materials. Metal striking

metal can also be a source of sparking.

Individuals must use extreme caution when

working with a spark or flame potential on

the pressroom floor.

HAZARDOUS MATERIALS

OSHA regulations require that hazardous

materials such as solvents, inks and cleanup

solutions be marked with a Hazardous Ma-

terials Identification System label.

The hazardous material label is a diamond-

shaped label that is divided into four color-

coded categories (Figure ). The categor-

ies are rated by number from zero to four,

indicating the degree of hazard. These

degrees are:

Health Hazard (blue). Indicates the health haz-

ard of using a material on a scale of zero to

four, four being fatal.

Flammability (red). Indicates the material’s

flash point on a scale of zero to four, four

being below 73° F.

Reactivity (yellow). Indicates detonation sen-

All flammable solvent

containers must be

grounded when filling

or dispensing to pro-

tect against static

sparks.

The hazardous material

label is a diamond-

shaped label that is

divided into four color-

coded categories. The

categories are rated by

number from zero to

four, indicating the

degree of hazard.

Fire

Health

Special

Reactivity

Health Hazard

4 - Deadly

3 - Extreme Danger

2 - Dangerous

1 - Slight Hazard

0 - No Hazard

EMPLOYEE HAZARD COMMUNICATION REFERENCE

Reactivity

4 - May Detonate

3 - Explosive

2 - Unstable

1 - Normally Stable

0 - Stable

Fire Hazard (Flash Points)

4 - Below 73°F

3 - Below 100°F

2 - Below 200°F

1 - Above 200°F

0 - Will Not Burn

Special Hazard

- Water Reactive

OX - Oxidizer

- Radioactive

—

sitivity of a material on a scale of zero to

four, four being extreme.

Special (white). Indicates whether the materi-

al is a chemical base that might react violent-

ly with air and water. It also includes recom-

mended personal protection equipment.

Disposal of Hazardous Materials

Flexographic printers, like those in other

industries, are facing stricter regulations con-

cerning personal safety and the environment.

While this subject is covered in another vol-

ume, the intent here is to point out some

basic regulatory concerns in the pressroom.

Hazardous substances and materials

include:

• ink;

• solvent;

• wash-up solutions; and

• solvent-laden disposable rags.

Several basic rules concerning the disposal

of hazardous substances and materials are:

• No liquid waste, ink or solvent may be

poured into sinks, toilets or drains.

• No liquid waste, ink or solvent may be

disposed of in a regular garbage can or

on the ground outside the plant.

• Solvent-laden disposable rags must be

placed in special containers and sent

out for burning by an approved waste

incinerator.

• Solvent-laden shop rags should be placed

in designated containers to be washed by

an industrial cleaning company.

Right-to-Know Law

Companies that use hazardous materials

in the workplace must comply with the

Emergency Planning and Community Right

to Know Act. This federal law requires that

every company have a written program that

lists all the hazardous materials used; and

that forms called Material Safety Data

Sheets (MSDS) are on-hand and available for

employee inspection.

MSDS forms are detailed information

sheets provided by the product’s vendor.

They describe the hazards of the material.

MSDS forms also provide treatment instruc-

tions in case of exposure or ingestion. (See

Volume 3, Chapter 1, for further details and

examples of MSDS sheets.)

TOOL SAFETY

Many tasks in the press area involve the

use of hand tools or power tools. The follow-

ing guidelines are intended to prevent injury

or damage to the equipment when such tools

are being used:

• Use the proper tool for the job.

• Put away tools immediately after they

are used;

• Use explosion-proof tools in ink rooms

or press areas when flammable liquids

are being used or stored;

• Never use electric extension cords in

explosion proof areas where solvent or

solvent based ink is stored.

• Never use bare razor blades. Razor

blades should always be used in blade

holders. Old blades should be placed in

a waste container designated for razor

blades only.

PRESSROOM PRACTICES 175

Soiled rags should

only be placed in

designated containers

with tight closing lids.