Introduction
In the fast-paced world of food and beverage packaging, machine safety is more than just a regulatory checkbox…it is a competitive necessity. For Amcor, a global leader in flexible packaging solutions, keeping production lines safe, efficient, and compliant is mission critical. Yet like many manufacturers, they faced increasing challenges with aging guarding systems, evolving OSHA and ANSI safety standards, and the need for rapid changeovers and sanitation protocols.
Enter PowerSafe Automation—a turnkey safety partner specializing in custom-engineered machine guarding. Through a collaborative engineering-led process, PowerSafe delivered a fully tailored guarding solution that not only brought Amcor’s equipment into compliance but enhanced daily operations and reduced downtime. This case study details the full transformation and showcases how tailored custom machine guarding can elevate performance and safety in food and beverage manufacturing environments.
The Client: Amcor’s Commitment to Safety and Sustainability
Amcor is a Fortune 500 company and one of the world’s largest producers of sustainable packaging solutions, serving major brands in the food, beverage, healthcare, and personal care markets. With more than 220 sites worldwide, Amcor’s North American facilities focus heavily on producing high-volume film packaging and rigid containers for food-grade applications.
Their packaging lines must maintain:
- High-speed throughput
- Stringent hygiene standards (washdown compliance)
- Zero-downtime preventive maintenance routines
- Worker safety in high-risk environments (cutting, sealing, forming machines)
Amcor's safety philosophy aligns closely with continuous improvement and proactive risk reduction—yet their legacy guarding systems no longer supported the agility and compliance needed in today’s regulatory environment.
The Challenge: Aging Guarding Systems and Compliance Risk
Before partnering with PowerSafe Automation, Amcor’s packaging lines were equipped with guarding that:
- Obstructed visibility into machine operations
- Required tools to remove panels (slowing sanitation)
- Offered minimal modularity for isolated maintenance zones.
- Failed to integrate with modern safety interlocks and circuits.
- Created bottlenecks during scheduled clean-in-place (CIP) procedures.
Common issues observed during risk assessment:
- Exposed pinch points at the film-feed and roller zones.
- Sharp-edge tooling without physical or electronic guarding
- Unsafe manual access procedures during film threading
- Non-compliant safety distances on light curtains and switches
- Guarding materials that corroded over time with aggressive cleaners
These risks not only jeopardized operator safety, but also left Amcor vulnerable to unannounced OSHA audits and potential citations under OSHA 1910.212 and ANSI B11 standards. The opportunity was clear: upgrade the guarding to meet modern safety, hygiene, and operational needs—without interrupting production.
The Solution: Tailored Custom Machine Guarding by PowerSafe Automation
PowerSafe Automation’s approach began with a detailed machine safeguarding risk assessment, conducted alongside Amcor’s safety and maintenance teams. Each machine zone was evaluated using a performance-based methodology aligned with:
- OSHA 1910.212 general guarding requirements
- ANSI B11.19 and B11.22 standards for functional safety
- ISO 13849-1 safety circuit design principles
- NSF and food-grade material compatibility for hygienic areas
Tailored Guarding System Features Delivered:
| Feature | Benefit |
| Stainless steel framing and hardware | Corrosion-resistant and hygienic |
| Polycarbonate and stainless mesh panels | Visibility + safety + durability |
| Tool-less removable panels | Fast access for cleaning and maintenance |
| Color-coded modular zones | Visual workflow segmentation |
| Integrated Keyence safety interlocks | Machine control feedback and lockout |
| Smart light curtains and presence-sensing devices | Enhanced operator safety with auto-stop |
| Custom mounting for OEM machines | Seamless fit for legacy and modern equipment |
Each guarding element was designed-to-fit using digital scans and 3D CAD models of Amcor’s packaging lines—eliminating guesswork, reducing install time, and ensuring a clean, functional look across the production floor.
Installation Process: Zero Downtime, Full Turnkey Delivery
PowerSafe executed the guarding upgrade in three phases:
- Pre-Installation Engineering:
- On-site laser scans
- Full 3D modeling of equipment layouts
- Mock-ups shared with Amcor’s safety team for feedback.
- Safety circuit diagrams with E-stop and interlock logic reviewed.
- Fabrication & Pre-Assembly:
- Guarding units manufactured at PowerSafe’s facility.
- Assembled and staged for rapid install.
- Finalized with stainless fasteners, food-safe labeling, and clean welds.
- Field Installation:
- Coordinated around Amcor’s weekend production schedule.
- Performed by PowerSafe’s trained field crew.
- Safety circuits tested, validated, and documented.
- Final walk-through with Amcor’s EHS and maintenance leads
Notable outcome: PowerSafe completed full installation with zero impact to production uptime, while simultaneously delivering full documentation packages (maintenance instructions, safety circuit schematics, panel maps, and risk assessment reports).
The Results: Measurable Safety and Productivity Gains
After the guarding upgrade, Amcor reported:
Improved Safety Compliance
- All machine zones now compliant with OSHA 1910.212 and ANSI B11.19
- Guarding meets PLd and SIL2 functional safety levels
- Pass-through guarding integrated with light curtains and interlocks.
Reduced Downtime
- Maintenance teams cut changeover and cleaning times by over 20%.
- Tool-less access panels eliminated wrench-and-bolt frustration.
- Modular guarding zones allowed partial-line access without full shutdown.
Enhanced Operator Visibility and Confidence
- Polycarbonate windows restored line-of-sight to key motion zones.
- Operators felt more confident entering protected zones.
- No reported safety near-misses in first 90 days post-install
Audit-Ready Documentation
- Safety circuit diagrams, interlock validation reports, and risk assessments stored digitally.
- Used to pass third-party audits and internal EHS inspections with no findings.
Brand-Level Rollout Potential
- Following initial success, Amcor greenlit assessments for similar upgrades at other North American plants—creating a scalable safety standard for all locations
Client Feedback
“PowerSafe Automation gave us more than a guarding upgrade—they gave us a fully engineered safety solution. Their team understood our production needs and worked around them. This is the kind of partnership we want for every facility.” — EHS Manager, Amcor Packaging North America
“We used to struggle with cleaning and visibility. Now, with the tool-free panels and windowed doors, we do not waste time or risk safety. This is how guarding should be done.” — Maintenance Technician, Amcor Operations Team
Why Tailored Custom Guarding Matters in Food & Beverage Manufacturing
Food and beverage facilities present unique guarding challenges due to:
- Frequent washdowns requiring corrosion-resistant materials.
- High-speed lines with fast-moving conveyors, rollers, and cutting stations.
- Strict hygiene regulations that limit the use of certain materials and adhesives
- Operator-access areas for threading, loading, or cleaning
Off-the-shelf guarding systems often fall short in these environments. PowerSafe’s tailored approach ensures every design decision accounts for:
- Line-of-sight needs.
- Material compatibility (e.g., stainless steel, UHMW, polycarbonate)
- Operator workflow and changeover access
- Functional safety integration with controls and safety PLCs
The result? A guarding solution that is not just safe, but smarter, faster, and easier to maintain.
Key Takeaways for Safety Managers and Plant Engineers
If you are managing a food and beverage packaging facility and dealing with:
- Outdated or non-compliant guarding
- Frustrated maintenance teams
- Long changeover cycles
- OSHA or ANSI audit concerns
- New equipment installs or retrofits.
Then tailored custom machine guarding is not a luxury, it is a competitive advantage.
PowerSafe Automation offers:
- Engineering-led risk assessments
- Custom CAD-modeled guarding systems
- Integrated safety circuits and controls
- Field-proven install crews across the U.S.
- Documentation to help you pass audits.
Ready to Upgrade Your Machine Safety?
PowerSafe Automation designs and delivers turnkey machine guarding solutions for the food and beverage industry that do not just meet code, but improve your entire operation.
Learn how our tailored custom guarding solutions can help your facility by visiting:
Tailored Custom Machine Guarding – PowerSafe Automation Or contact us directly at sales@powersafeautomation.com to schedule a guarding assessment.
