Overview: Enhancing Operator Safety in Film Packaging
In the high-speed world of film and label packaging, safety is often at odds with productivity. Leading manufacturers like Avery Dennison and Sonoco operate complex machinery that runs 24/7 to meet global demand. Yet many of these machines, especially legacy equipment, lack modern guarding or access controls to protect operators from the very real dangers of nip points, rotary knives, and hazardous motion.
This case study explores how PowerSafe Automation partnered with both manufacturers to engineer and install tailored custom machine guarding that did not just meet OSHA and ANSI standards, it improved uptime, simplified maintenance, and created a safer culture across multiple facilities.
Client Profile: Global Leaders in Film & Label Packaging
Avery Dennison
A Fortune 500 company known for adhesive technologies, labeling, and high-speed converting equipment. Operations include slitting, laminating, and web handling at industrial scale.
Sonoco
A global packaging solutions provider offering film packaging, thermoforming, and flexible container production. Their production lines rely on a mix of legacy machinery and modern automation.
Shared Challenge: Balancing operator access and production throughput with updated machine safety requirements across diverse equipment platforms.
The Problem: Safety Hazards Hidden in Plain Sight
Film packaging and converting lines often expose operators to multiple hazards:
- Rotating drums and rollers with fast-moving pinch points
- Open cutting assemblies and pneumatic shears
- Manual threading tasks requiring close access to moving parts.
- Legacy machines with little or no OEM guarding or safety interlocks.
Operators performing web threading or cleaning often bypass guarding or disable emergency circuits just to perform routine tasks. This risk not only puts employees in danger, but it also creates serious liability under OSHA 1910 Subpart O and ANSI B11 standards for industrial equipment.
“You cannot improve safety by just slapping on a cage. That is why tailored guarding is critical for film packaging environments,” — Applications Engineer, PowerSafe Automation
Goals of the Project
- Achieve Risk Reduction using OSHA 1910.212 and ANSI B11.19 guarding standards.
- Preserve full access for threading, cleaning, and maintenance.
- Standardize guarding across multiple OEM platforms and plant locations.
- Integrate safety controls into existing PLC logic or stand-alone relays.
- Minimize downtime during installation and ongoing operations.
The Solution: Tailored Custom Machine Guarding by PowerSafe Automation
Rather than relying on “one-size-fits-all” kits, PowerSafe Automation delivered a turnkey custom solution, beginning with a detailed risk assessment and operator workflow audit.
Key Features of the Installed Guarding Systems:
| Feature | Benefit |
| Modular Polycarbonate & Aluminum Extrusion Guards | High visibility, rigid structure, customizable fit |
| Tool-less Hinged Panels | Quick access for cleaning and threading without removing panels |
| Zone-Specific Interlocked Doors | Enforced safe access with machine-stopping capability |
| Integrated Safety Devices | Including Allen-Bradley safety relays, light curtains, and RFID switches |
| Color-Coded Guarding Sections | Improved operator orientation and maintenance training |
| Built-In Threading Slots | Maintains productivity without compromising guarding integrity |
Visual Design Considerations
All guarding systems were engineered using PowerSafe’s in-house CAD and SolidWorks library, ensuring precision fitment around motors, rollers, and feed systems. Tailoring each design to match the operator’s workflow was a priority—this meant designing around threading paths, vision sensors, and tool-clearance zones.
Electrical Safety Integration
Film packaging machines require precise coordination between safety hardware and machine control logic. PowerSafe integrated new guarding with:
- Stand-alone safety relays for simpler legacy machines
- Safety PLCs and zone control logic on complex lines
- E-stop redundancy testing and zone-isolated lockout features.
In many cases, previously bypassed or “dummy-wired” devices were removed and replaced with TÜV-certified fail-safe components, bringing these machines up to ISO 13849-1 Performance Level d or better.
Install Strategy: Minimal Downtime, Maximum Coordination
PowerSafe coordinated install windows during pre-scheduled shutdowns or off-shift hours. Teams arrived with:
- Pre-cut and labeled guarding assemblies.
- Electrical panels and cable trays pre-wired
- Mobile toolkits and lifts for safe field assembly
- Final inspection and operator training documentation
Across Avery Dennison and Sonoco, install timelines averaged 2–3 days per machine, with zero unplanned downtime and successful post-install signoffs from both internal EHS and third-party compliance auditors.
Results: Safety + Productivity Improvements Delivered
| Metric | Pre-Guarding | Post-Guarding | Result |
| OSHA/ANSI Compliance | Non-conforming | 100% compliant | Regulatory success |
| Safety Incidents | 4+ per year avg | <1 per year | 75% reduction |
| Downtime for Access Tasks | 30–45 mins | <15 mins | 60% improvement |
| Near-Miss Reports | Frequent threading/cutting | Nearly eliminated | Improved morale |
| Operator Satisfaction | Moderate | High | Safer, clearer work zones |
“Now we do not have to choose between safety and uptime. The guards open quickly, lock automatically, and give us a clear view of the machine. That is a win.” — Operator Feedback, Sonoco
Scalability: One Guarding Strategy, Multiple Plants
Because both clients operate across multiple U.S. sites with different OEM machines, standardizing safety was a challenge. PowerSafe solved this by:
- Creating a custom guarding package library by machine type and size
- Providing reusable engineering documentation and install guides.
- Training EHS staff and maintenance teams for repeatable in-house application
- Supporting remote locations with virtual install support and pre-assembled kits
This scalable approach helps plants save time and cost when rolling out upgrades across multiple lines or facilities.
Why PowerSafe Was the Right Partner
| Reason | Description |
| Expertise in Film Packaging Hazards | From winding stations to slitters and web paths |
| Custom Engineering, Not Commodity Guards | Designed to your equipment, not just for it |
| Safety + Operator Workflow | Threading, maintenance, and cleaning all factored in |
| Fast Turnaround | Engineering, fabrication, and install handled in-house |
| Safety Verified Services™ | From risk assessment to compliance sign-off |
Client Testimonials
"Our EHS team was struggling to standardize machine guarding across old lines. PowerSafe did not just solve the problem—they made it easy to replicate and scale." — Corporate Safety Manager, Sonoco
"We were dealing with old OEMs, missing guards, and unclear regulations. PowerSafe’s team walked our plant, mapped out every hazard, and delivered systems that work for our operators—not against them." — Maintenance Supervisor, Avery Dennison
Takeaway for Industrial Facilities
If you are operating film packaging, slitting, laminating, or web converting equipment, your risk is higher than average. Machine guarding can no longer be an afterthought.
With PowerSafe Automation’s Tailored Custom Machine Guarding, manufacturers like Avery Dennison and Sonoco are proving that compliance and performance can go hand-in-hand—and that one retrofit can lead to scalable improvements across multiple sites.
