Introduction
In the fast-paced world of corrugated box manufacturing, safety and efficiency must go hand in hand. Leading manufacturers like WestRock and International Paper operate high-speed equipment that is essential for global packaging distribution—but also poses serious safety risks if not properly guarded.
This case study explores how PowerSafe Automation delivered tailored custom machine guarding solutions for both organizations, improving compliance, protecting personnel, and preserving production uptime.
Visit the full solution page: Tailored Custom Machine Guarding
Industry Background: Corrugated Packaging Safety Risks
Corrugated box production involves a complex series of high-speed processes including:
- Paper feeding
- Corrugating (using heated rollers)
- Gluing and drying
- Slitting, scoring, and die-cutting.
- Flexographic printing and stacking
Each step contains mechanical hazards like:
- In-running nip points
- Rotating shafts
- Hot surfaces
- Sharp blades
- Automated motion risks
Both WestRock and International Paper required a safety solution that would:
- Meet or exceed OSHA 1910.212 and ANSI B11 requirements.
- Prevent wrap points, entanglements, and crush injuries.
- Allow for non-disruptive maintenance and cleaning.
- Fit unique legacy equipment with non-standard dimensions
PowerSafe’s Approach: Engineered Machine Guarding Built to Fit and Function
Rather than offering generic guarding panels, PowerSafe Automation applies a turnkey engineering-led process:
- On-site Assessment
- Review of each machine’s operational hazards
- Documentation of guarding gaps and compliance risks
- Custom Design
- CAD modeling and fit-up of polycarbonate, steel, and mesh guarding
- Ergonomic access planning for operators and maintenance techs
- Controls Integration
- Incorporation of interlocks, enabling switches, pneumatic locking mechanisms, and laser area scanners
- Wiring to safety relays, PLd-rated controllers, and E-stop circuits
- Fabrication + Installation
- U.S.-based CNC, cutting, bending, and finishing.
- Field installation by trained technicians with minimal production interruption
WestRock Case Study: Guarding High-Speed Corrugators
Company Overview
WestRock is one of the largest corrugated packaging manufacturers in North America, with hundreds of plants producing shipping boxes, e-commerce mailers, and industrial cartons.
The Challenge
At a key WestRock facility, operators worked alongside:
- Corrugators with massive, heated rollers
- Slitters with rapid up/down actuation
- Dryer sections with limited egress
Operators had to manually monitor and intervene in several machine zones—especially during changeovers and jams—placing them in hazardous proximity to moving equipment.
Specific Risks Identified:
- Lack of fixed guards near roller feeds
- Exposed wrap points on glue units
- No interlocks on access doors
- No presence detection around maintenance areas
PowerSafe's Solution
PowerSafe designed and deployed:
- Custom polycarbonate barriers over corrugating units for visibility and protection
- Laser area scanners to provide zone muting and reentry detection.
- Pneumatic safety interlocks with mechanical fail-safes on all access doors
- Safety relays wired to existing control systems to enable safe stops.
Outcome
- OSHA-compliant guarding across multiple zones
- Zero production downtime during installation phases
- Improved operator morale and fewer near-miss incidents.
- Guards designed to withstand WestRock’s humid, high temperature environment.
Quote from Site Manager:
“PowerSafe’s team didn’t just sell guards—they engineered a safe, practical solution that worked with our machines, not against them.”
International Paper Case Study: Mill-Wide Guarding Across Flexor Lines
Company Overview
International Paper produces corrugated packaging for retail, industrial, and agricultural clients. Many of their plants run multiple flexor folder-gluer lines and die-cutting systems, with complex conveyor and stacking systems.
The Challenge
International Paper needed to address:
- Inconsistent legacy guarding between machine brands
- Exposure to nip points on wet-lap conveyors
- Lack of presence detection near auto-stackers
- Disabling of guards due to cumbersome access
They required a solution that could:
- Standardize safety across lines and locations.
- Integrate into a national safety improvement initiative.
- Be installed with minimal disruption to 24/7 operations.
PowerSafe’s Solution
PowerSafe developed:
- Modular T-slotted extrusion guard frames with fast-install brackets
- Sloped-top polycarbonate panels to prevent dust and promote visibility.
- Integrated Inxpect radar detection to supplement light curtains where line-of-sight was blocked.
- Hinged access points with monitored safety switches
Outcome
- Reduced bypassing of guards due to ergonomic design
- Real-time machine feedback with access requests logged.
- Measurable reduction in safety event reporting across multiple facilities
- Corporate Safety Director approved similar guarding for national rollout.
Quote from EHS Director:
“PowerSafe made our multi-plant guarding strategy scalable without making it feel like a cookie-cutter solution.”
Technical Highlights: What Made These Projects Stand Out
| Feature | WestRock | International Paper |
| Barrier Material | High-temp polycarbonate | Clear polycarbonate + aluminum |
| Safety Devices | Laser scanners, interlocks | Inxpect radar, light curtains |
| Guarding Zones | Corrugators, slitters, dryers | Folder-gluers, conveyors, stackers |
| Controls Integration | PLd-rated relay systems | Distributed I/O for access requests |
| Customization Level | 100% custom CAD per line | Modularized frames + shared components |
| Implementation Time | < 5 days per line | Rolling deployment during maintenance shifts |
Why PowerSafe Over Standard Vendors?
Many vendors offer prefabricated guarding kits. PowerSafe offers:
- Fit-for-purpose design engineered from real-world site conditions.
- Seamless safety device integration that does not conflict with existing PLCs.
- Fast deployment with full OSHA/ANSI compliance documentation
- Field installation teams that understand safety AND production
And most importantly:
A safety-engineering-first mindset, not just a guarding parts catalog.
Results That Scale Beyond a Single Facility
Both WestRock and International Paper have:
- Reengaged PowerSafe for repeat guarding scopes.
- Used these pilot projects as templates for corporate safety standards.
- Reported improvements in:
- OSHA audit readiness
- Employee perception of safety
- Uptime due to fewer LOTO disruptions
Closing Thoughts: Safety + Productivity = Competitive Advantage
PowerSafe Automation continues to prove that machine safety guarding does not have to come at the cost of productivity. For high-volume corrugated packaging facilities like WestRock and International Paper, the right safety partner can:
- Lower incident rates
- Reduce liability exposure.
- Increase compliance and morale.
- Support scalable safety improvement programs.
Explore PowerSafe's custom guarding options for corrugated, printing, converting, or packaging lines at:
https://powersafeautomation.com/tailored-custom-machine-guarding
