Chapter 2 - Goodheart

This sample chapter is for review purposes only. Copyright © The Goodheart-Willcox Co., Inc. All rights reserved.
Safety Benefits Everyone
American business and industry once contained
hazards that no longer even exist. Advances in technology and the 1971 establishment of the Occupational
Safety and Health Administration (OSHA) eliminated these hazards. During the last 30 years,
workplace-related injuries and illnesses have been
reduced by 40%. For example, the clear guard shown
in this photograph of a booklet stitcher helps to
prevent operator injury. The guard is in place while
the machine is running, and lifting the guard stops
the machine.
Chapter 2
Preventing workplace injuries benefits everyone.
Employeesenjoyasafeworkingenvironment.Management
enjoys several advantages—increased production that is
not interrupted by injury, reduced insurance costs, and the
many benefits of having happy employees.
Just as everyone benefits from workplace safety,
everyone must contribute to the effort. Management
and employees must be aware of their roles in
promoting safety. This chapter acquaints the student
with many issues and practices involved in advancing
safety and health in the workplace.
Safety and Health
(Heidelberg, Inc.)
Learning Objectives
Key Terms
barrier guard
decibel (dBA)
dust collector
ergonomics
flash point
infrared (IR) light
ink mist
laser beam
lockout device
main disconnect (master)
switch
material safety data sheet
(MSDS)
mercury vapor lamp
nip point
Occupational Safety and
Health Administration
(OSHA)
personal protective
equipment
pulsed xenon lamp
(PXA)
respiratory protection
device
safety color code
skin protection device
static eliminator
tagout device
ultraviolet (UV)
radiation
volatile organic
compound (VOC)
When you have completed the reading and
assigned activities related to this chapter, you will
be able to do the following:
List and explain factors that make a safety and
health program successful.
Demonstrate safe work habits that help prevent
on-the-job physical injuries.
Identify and explain the application of lockout
and tagout devices.
Select the proper personal protection devices
for specific situations.
Practice proper material and tool handling, as
well as proper techniques for lifting.
State the recommended procedures for storing
and using toxic and flammable liquids.
Describe proper noise control and means of
preventing ear damage.
Give examples of means for fire prevention
and control.
Discuss safe practices to be used when
operating computer equipment.
Explain ways in which printing facilities can
minimize damage to the environment.
35
36
Section I Introduction to Offset Lithographic Technology
Safety and health are important considerations in
the printing industry. This fact holds true for school
graphic arts programs, training laboratories, small
printing operations, and large printing firms. Many
accidents are caused by carelessness and ignorance and
can be prevented if all employees are well informed in
preventive and predictive safety measures.
The wide variety of processes performed in a
printing facility creates great potential for injury,
illness, or death. It is vital for workers to know basic
safety procedures. Most printing operations provide
safety and health programs based on the five safety
hazard areas specified by the Occupational Safety
and Health Administration (OSHA). The five
OSHA-specified hazard areas are mechanical, chemical, noise, fire, and light. Each area is not exclusive,
and there is often a great deal of overlap.
Planning a Safe Working
Environment
Planning for safety starts with an organized
safety and health program dedicated to accident
prevention. This type of program can be used to
recognize, evaluate, and control potential hazards in
the workplace. An effective safety program begins
with informed students and employees. Safety and
health programs are often tailored to suit individual
operations. The most effective programs include
all five OSHA-specified areas and topics such as
personal protection and first aid.
To ensure the success of the safety and health
program, management leadership is essential. The person
assigned responsibility for the safety and health of the
facility must have the authority to enforce the program,
and everyone in the establishment must be aware of the
plan. A safe operation depends on all personnel being
properly informed of potential hazards, accident prevention measures, and the proper first aid response.
Safety Tours
Students entering a graphic arts program and
employees new to a printing facility should be given
the opportunity to review all relevant safety documents and be given a safety tour of the facilities in
which they are working. See Figure 2-1. The safety
tour should include information indicating inherent
dangers, such as presses, paper cutters, folders,
stitchers, and chemical hazards. The locations and
use of master switches, emergency stop buttons, fire
extinguishers, fire alarms, and first aid kits should be
stressed. In addition, items such as safety color codes
should be emphasized and explained in detail.
Chapter 2 Safety and Health
Safety Color Codes
37
Web press
rear reel
stand guard
In an effort to make educational, training, and
working facilities safer, safety color codes have been
developed. See Figure 2-2. Safety color codes have
been established to alert and inform students and
workers to take precautionary action around potential hazards. With proper implementation, color
codes help improve personal safety and minimize
the possibility of injury during the operation and use
of tools, equipment, and machinery.
Varying standards designate the safety colors
and how they should be used for specific purposes.
See Figure 2-3. There are many potential safety
hazards in a printing facility or graphic arts lab. If
you have any questions regarding the safety colors
used in your facility, you should discuss their application with your supervisor or instructor.
Web press
side reel
stand guard
Personal Conduct
Safety is the responsibility of every person.
Students and employees should be properly trained
in all safety procedures and regulations before beginning work. It is not uncommon for instructors or
supervisors to administer written safety tests before
allowing students or employees to begin working.
Unsafe conduct and work habits by workers or
students should be reported and corrected immediately. The offender should be informed that this type
of behavior could result in removal from the lab or
dismissal from the job. Horseplay of any kind should
never be allowed.
Safety Regulations
OSHA governs the safety and health of workers in
the United States. Besides developing and enforcing
job safety and health regulations, the agency also
works to educate employers and employees. All
types of businesses and industrial firms are required
to comply with OSHA regulations or face severe
penalties.
Although OSHA regulations apply to all types of
businesses, many industry-specific regulations have
been developed. The following guidelines apply
to offset lithography operations, but they are just a
brief summary of safety precautions that should be
followed. These regulations, in their entirety, can
be found at any OSHA office. Careful adherence to
regulations, good housekeeping, and a healthy attitude toward safety can make the facility a safe and
pleasant place to work.
Web press
side reel
stand guard
Floor safety
lines and guards
Figure 2-1. Most safety guards and danger zones in the pressroom are painted with safety colors. These colors serve
to warn workers of potential hazards.
Mechanical Hazards
Oftentimes, on–the–job physical injuries are the
result of mechanical hazards. These hazards can
be controlled. The following regulations should be
followed:
• Machines must be properly guarded.
• Lockout and tagout devices must be used during
maintenance.
• Workers must use personal protective equipment.
• Materials, tools, and equipment must be handled
safely.
Machine guards
Safety in a printing facility requires awareness
of the many types of potential hazards. The reciprocating, rotating, shearing, and pinch–pointing
actions of the types of machinery used in the
printing industry present many mechanical
hazards. See Figure 2-4. Consequently, proper
placement of machine guards is important for the
operator’s protection.
Occupational Safety and Health Administration (OSHA): the
agency of the U.S. Department of Labor that promotes and enforces
safe and healthful working conditions. This administration also
educates employers and employees about industrial hazards.
safety color code: a color code established to alert and inform
students and workers to take precautionary action around potential
hazards.
personal protective equipment: various types of eye, ear,
respiratory, and skin protection devices used to prevent physical
injury.
38
Section I Introduction to Offset Lithographic Technology
Color
Indication
Applications
Safety Red
Danger or
Stop
Identify hazards that can cause death or serious injury.
Identify safety cans or containers of combustible or flammable materials (the name of contents
should also be on the can or container).
Mark stop buttons, stop bars, or electrical switches for the emergency stopping of machinery.
Identify fire equipment or the area where fire equipment is located.
Safety
Orange
Warning
Identify hazardous parts of machines/equipment.
Mark hazardous machine parts that may cut, crush, or electrically shock and may cause
serious injury or even death.
Emphasize hazards such as open or removed guards and shields, exposed gears or belts, or
any other unguarded moving parts.
Identify exposed parts of pulleys, gear rollers, cutting devices, etc.
Identify levers of machine tools which must not be moved while the machine is operating.
Safety
Yellow
Warning
Mark physical hazards that can cause a person to stumble, trip, fall, or become caught in or
under, or strike-against.
Identify storage cabinets for flammable materials (cabinets should be clearly labeled
“Flammable, Keep fire away”).
Identify containers for explosives, corrosives, or unstable materials by painting them yellow or
have a yellow band at least one-quarter the height of the container around the middle
(contents should be painted on the container).
Identify adjustable levers, knobs, or control wheels which may be adjusted while the machine
is operating.
Yellow lines should be painted on the floor to designate Equipment Operator Zones for
operators of fixed-power equipment and Keep Clear Zones in front of fire and first-aid
equipment and electrical panels, etc.
Safety Green
Safety
Show the location of first-aid kits and equipment, safety showers, and emergency exits.
Safety
Blue
Safety
information
Warn people not to start, use, or move equipment that is being serviced.
Provide mandatory information for the wearing of protective clothing and/or equipment such as
hard hats, goggles, gloves, etc.
Safety
Purple
Radiation
hazards
Used in areas where radioactive materials are stored, handled, or where an area has been
contaminated with radioactive material.
Safety Gray
Work areas
May be used on floors or work areas around machines and for metal bench tops.
Safety Black or
Safety White
Chapter 2 Safety and Health
Safety Black or Safety White or combination of the two indicates traffic and housekeeping areas.
Safety White lines on the floor indicate aisles and stairways.
Fluorescent
Colors and
Other
Reflective
Materials
Danger spots
in dark areas
Used for stripes on stair railings and risers to make them visible in the dark.
Arrows that indicate the direction of exits and fire escapes.
Marking electrical switch plates so they may be seen in the dark.
Piping
Systems
Marked at
point of use to
indicate the
materials
carried by the
pipe.*
Safety Red w/Safety White lettering on fire extinguisher materials.
Safety Yellow w/Safety White lettering for flammables, explosives, chemically active substances,
extreme temperatures, and pressure fluids (steam and hot water).
Safety Green w/Safety White lettering on cold water pipes.
Safety Blue w/Safety White lettering for compressed air or other inert gases at low pressure.
Figure 2-3. Fluorescent paint can be used to help workers
identify exits during power outages. (IDESCO Corp.)
Caution
Never use any piece of equipment unless you have
demonstrated your ability to operate the machine
safely to the instructor’s or supervisor’s satisfaction.
Machine guards protect the operator, as well as
other workers in the facility. The guards serve to
prevent flying fragments from cutting, smashing, or
hitting parts of the human body. Guards also protect
equipment from damage from foreign objects.
Machine guarding is necessary wherever hazardous
machine parts are within reach of the operator. Guards
should be in place over all points of operation. These
points of operation include cylinders, shears, rollers,
gears, clamps, drills, punches, fasteners, shafting,
pulleys, cutters, flywheels, chains, and belts.
Most machines used in the printing industry
are equipped with some type of guarding. See
Figure 2-5. Equipment should not be used if guards
are missing, broken, or out of adjustment. Likewise,
guards should not be removed to perform an operation or running adjustments.
Reciprocating and rotating motions create
hazards at the point of operation and the points
where power or motion is being transmitted from one
part to another. Bodily contact with any rotating part
is dangerous and can lead to serious injury or even
death. Loose clothing or hair can be drawn into the
equipment and cause severe injury. Therefore, long
hair should be tied back or worn under a cap, and no
jewelry should be worn when operating equipment.
Specialized types of guarding are used on some
machines. For instance, a common control device
used on paper cutters requires both hands of
the operator to be on the operating controls. See
Figure 2-6. A paper cutter blade is very sharp, and
all precautions should be taken to avoid injury
when cutting stock or changing the blade. Movable
or hinged barrier guards are often used to keep a
person out of the operating area. If the guard is not in
its proper position, power is cut off to the machine.
*All pipes should be identified by the appropriate colors. Rubber and flexible synthetic hoses and pipes should not be painted.
Figure 2-2. Many manufacturers and users of equipment follow the same color-coding standards. Many color-coding
recommendations have also been incorporated into the OSHA standards.
Spinning
Rollers
Rotating Chains
and Sprockets
39
Turning Gears
Figure 2-4. Mechanisms found in a printing facility can cause serious physical injury.
barrier guard: a plastic or metal safety barrier covering a point of operation on machinery.
Rotating Belts
40
Section I Introduction to Offset Lithographic Technology
Chapter 2 Safety and Health
Emergency
stop button
Register
board guard
Feeder
guards
Cylinder
guards
Delivery
guards
Emergency
stop button
agency should periodically inspect all cords, plugs,
and switches. All electrical components must comply
with existing electrical codes. Grounded (three–
prong) plugs and outlets should be used throughout
the facility.
Avoid locating electrical equipment near sinks
or water pipes. Even a minor mishap in such an
area could cause a severe shock or electrocution.
Additional safety measures, such as the installation
of ground-fault circuit interrupter (GFCI) outlets,
should be taken.
Lockout and tagout devices should be used
whenever a piece of equipment is being serviced.
Lockout devices use a key or combination lock to
hold an energy–isolating device (such as a manually
operated circuit breaker) in the off position to prevent
the machine from energizing. A tagout device is a
prominent warning attached to an energy-isolating
41
device. No attempt to restore power at a tagged power
box should be made until repairs are completed and
the person who placed the tag has removed it. See
Figure 2-7.
Personal protective equipment
The use of personal protective equipment should
not be taken lightly. Personal comfort or vanity
should not take precedence over safety concerns.
Operators should never wear watches, rings, ties,
medallions, bracelets, scarves, or loose clothing while
working with machinery. Long hair should be tied
up, and cleaning cloths should not be left dangling
out of your pocket. Personal protective equipment
includes various types of eye, ear, respiratory, and
skin protection devices. Certain operations, such as
press, bindery, and storage, typically require foot
protection.
Figure 2-5. Safety guards should always be kept in place while the machine is operating.
Caution
When operating a power paper cutter, never
bypass the safety device requiring both hands to
be used to operate the blade. Turn the machine
off. Use the proper safety procedures to correct
any problems or malfunctions.
Control
buttons
Figure 2-6. Both control buttons on this cutter must be
pressed at the same time to operate the blade. This type
of dual mechanism ensures that the operator’s hands
cannot be near the blade when cutting. (Heidelberg, Inc.)
Electrical considerations
The school graphic arts lab or commercial
printing facility should have an accessible main
disconnect (master) switch that allows all power
to machinery and small appliances to be turned
off when the lab or facility is not in use. Emergency
disconnect buttons or switches should be installed at
every machine location. These allow anyone to turn
off the power in case of emergency or malfunction.
In the industry, these buttons are sometimes referred
to as panic buttons.
Frayed and damaged electrical cords, plugs,
and switches should be replaced. A local inspection
Figure 2-7. Lockout devices and tags are used to prevent the operation of machinery that is damaged or being serviced.
The tags often provide a space for the authorized person’s name and sometimes a photograph. (IDESCO Corp.)
main disconnect (master) switch: a switch that allows all power to machinery and small appliances to be turned off when a facility is not in use.
lockout device: a key or combination-type lock to hold an energy-isolating device in the off position to prevent the machine from energizing.
tagout device: a prominent warning attached to an energy-isolating device to prevent power from being restored to a particular circuit.
42
•
•
•
•
Section I Introduction to Offset Lithographic Technology
Eye protection devices. Includes safety goggles,
glasses, and face shields. Eye protection should be
worn when operating any type of machine that
can cause material to fly and strike workers. This
protection should also be worn when preparing
or working with any type of chemicals.
Ear protection devices. Includes earplugs, earmuffs, moldable inserts, and noise-reducing
headsets. Ear protection should be worn when
sound levels exceed permissible levels.
Respiratory protection devices. Includes respirators and dust masks. Respiratory protection
devices should be worn when airborne particles
create respiratory hazards, such as ink mists and
chemical vapors.
Skin protection devices. Includes rubber, leather,
or plastic gloves, aprons, and boots and full
safety suits. Skin protection devices should be
worn when working with or cleaning up chemicals and solvents that can cause minor irritation
or severe bodily damage. See Figure 2-8. At the
very least, aprons and gloves should be worn to
keep your hands and clothes clean.
First aid kits and equipment
Even if the proper personal protective devices
are worn, accidents do happen. It is important that
everyone working in a printing facility be trained
in basic first aid. First aid kits should be visible and
Figure 2-8. The proper type of personal protection
equipment provides the worker with effective resistance
to chemicals. (Kimberly-Clark Corp.)
easily accessible, and they should be checked and
stocked on a regular basis.
In addition to first aid kits, equipment such as eye
and face wash units should be installed in work areas
where hazardous chemicals are used. See Figure 2-9.
Emergency telephone numbers should be posted in a
prominent location near the lab or office telephone.
Chapter 2 Safety and Health
Tips for Safe Lifting
Clear a pathway Before you move things from one place to
another, be sure you have a clear pathway.
Check weight
Check the object’s weight to see if you will
need help lifting it.
Request help
Ask for help from another person if you
need it, or use mechanical lifting equipment.
Proper material and tool handling
You can avoid physical injury by correctly
handling materials and tools, practicing good housekeeping, and following basic safety rules. When
lifting materials, you should keep your knees bent
and your back straight. Leaning over while lifting is
poor practice and causes you to use your back rather
than your legs to lift. Follow the tips for safe lifting in
Figure 2-10. If materials are too heavy or bulky to lift,
use a dolly or request assistance. See Figure 2-11.
Whether you are using hand tools or power
equipment, you should use the tool only for the job
it was intended to do. Tools should be kept clean
and in good working condition and stored in the
appropriate storage cabinet. Following these simple
rules helps prevent physical injury and damage to
equipment.
Good housekeeping habits also help maintain
a safe working environment. Floors should be kept
clean, dry, and clear of obstacles. Spills should be
cleaned up immediately, and cleaning materials
Figure 2-9. The eye and face water wash unit is
designed to furnish first aid to chemical splash victims.
(Lab Safety Supply)
43
Keep your back Your back should be straight and vertical
straight
to the ground.
Lift with your
knees
If you can, bend your knees when lifting;
don’t stoop over the object.
Keep objects
close to your
body
Always bring the object as close to your
body as possible.
Tighten your
stomach
Tighten your stomach muscles. This helps
your back stay in balance.
Deliver carefully Use care when you put the object down.
Follow the same guidelines as you would
for lifting.
Figure 2-10. Prevent painful back injuries by following
these tips for safe lifting.
should be disposed of properly. Nonskid mats, adhesive strips, or coating materials can be applied to the
floor around work areas. See Figure 2-12.
Safety rules have been designed to protect
personnel and prevent damage to equipment. You
should never use or adjust any equipment unless
you have been properly trained to do so. If you are
unsure of the proper use of any piece of equipment,
do not be afraid to ask your instructor or supervisor
for instruction.
Equipment such as forklifts and air compressors
can cause serious harm if not handled properly. Only
certified drivers should operate forklifts, and riders
should never be permitted. Many forklifts use an
audible backup warning signal to alert other workers
of their presence.
Compressed air should never be used to clean off
clothes or do general cleanup work. An air nozzle can
force air through the skin and into the bloodstream,
creating a condition that can cause death. The careless release of compressed air can also stir up paper
dust, making breathing difficult and causing eye
irritation.
Figure 2-11. Using the proper equipment to lift and
move materials prevents physical injury and spills. The
skid turner illustrated on the bottom is used to lift and
turn over a pallet of paper. (Kimberly-Clark Corp.; Vijuk
Equipment, Inc.)
respiratory protection device: a mask that prevents harmful matter
from entering the respiratory system.
ink mist: tiny droplets making up a spray, fog, or mist of ink, created
as rotating press rollers throw tiny droplets of ink into the air.
skin protection device: gloves or other clothing that protects the
skin from contact with harmful materials.
44
Section I Introduction to Offset Lithographic Technology
Chapter 2 Safety and Health
Pressuresensitive
guard
Nip point
sheets must be complete. The label on the product
itself should indicate the potential hazards (such as
flammability, medical, health, and exposure limits)
and give detailed handling instructions. Product
labels also include information that might be useful
to firefighters.
Note
Rollers
Figure 2-12. Nonskid mats, adhesive strips, or coating
materials are used to prevent workers from slipping or
falling. (Rust-Oleum Corporation)
Figure 2-13. Nip points occur where two rollers come
together. The rollers illustrated use a pressure-sensitive
guard that shuts off the press if anything is pulled into
the nip point.
Caution
When operating a compressed air nozzle, do
not exceed 30 psi (200 kPa). Also, always wear
eye protection. Insertion of an air nozzle into
body cavities with subsequent activation of air
pressure can cause serious injury or even death.
Printing facilities require workers to follow basic
safety rules. These facilities also require workers to
take added safety precautions. When operating a
printing press or bindery or finishing equipment,
people should keep the following factors in mind:
• Check to make sure all guards are in place.
• Never turn on a machine unless all tools have
been removed from it and all mechanisms have
been set correctly.
• Make sure no one is near the machine before
starting it.
• Hands should be kept clear of any point of operation while the machine is running.
• Do not try to grab paper, perform adjustments,
lubricate parts, or do anything that places your
hands near rollers, nip points, drills, punches, or
cutting blades while the machine is running. See
Figure 2-13.
• Always work with an assistant when cleaning or
operating machinery.
• While working around operating machinery,
people should not wear long sleeves (except if
•
•
•
they are snug fitting), bulky sweaters, pants with
cuffs, jewelry, medallions, necklaces, ties, watches,
rings, bracelets, scarves, or other loose items.
Keep long hair tied back or tucked under a hair
net to prevent it from being caught in machinery.
The floor of the facility should always be kept
clean of liquids and debris.
Hands should be washed before eating or drinking to remove any toxic products.
Chemical Hazards
As production processes in the printing industry
have progressed from manual to electronic methods,
chemical use has been greatly reduced. Toxic materials are, however, still being used and produced as
by-products. The first defense against toxic materials
is to know the types of chemicals being used and
the hazards involved. Certain substances are more
harmful than others. The amount of exposure to a
toxic substance and the duration of exposure affect
the degree of harm the substance can cause.
Hazard communication programs
OSHA requires employers to keep a list of all
hazardous chemicals used on their premises, maintain files of material safety data sheets (MSDSs) on
the chemicals, and train their employees to use the
chemicals and respond properly should an accident
occur. Printers must also have a thorough labeling
program so chemicals can be readily identified. An
MSDS gives the chemical name; common name;
hazardous components; and name, address, and telephone number of the manufacturer. See Figure 2-14.
Employees must have access to MSDS files, and the
MSDSs must be readily available. An MSDS
includes very specific information. This sheet is
extremely useful if a medical emergency occurs.
MSDSs are part of OSHA’s Hazard Communication program (HCP), which in turn, is part of
the Hazard Communication Standard (HCS). The
program is directed at the “right to know” of all
employees. The responsibility of both the HCP and
the HCS is to inform employees as to the various
chemicals in the plant, the dangers inherent in using
MATERIAL SAFETY DATA SHEET
HI-TEMP PRODUCTS CO.
14936 GROVER ST.
OMAHA, NEBRASKA 68144
TELEPHONE NUMBER FOR
INFORMATION
1-402-330-3344
1 PRODUCT NAME:
HT 0801 AKRYA Cut
2 PRECAUTIONARY STATEMENT FROM PRODUCT LABEL
WARNING
WEAR SAFETY GLASSES. MAY CAUSE EYE IRRITATION. IF EYE IRRITATION
OCCURS, FLUSH EYES FOR 15 MINUTES WITH WATER. IF SWALLOWED, DO
NOT INDUCE VOMITING. DRINK WATER OR MILK. IN EITHER CASE, CALL A
PHYSICIAN IMMEDIATELY. REFER TO MSDS FOR CHEMICAL HAZARDOUS
INFORMATION.
INGREDIENTS
ISOPROPYL ALCOHOL
%
<3
CAS NO.
67-63-0
PEL/TLV
a
3
ppm mg/m
SKIN: MAY IRRITATE SKIN, CAUSE LIGHT REDDENING IN PATIENTS WITH PREEXISTING SKIN
DISORDERS.
EYES: MAY CAUSE EYE IRRITATION, BURNING, AND REDNESS.
SWALLOWING: MAY CAUSE MOUTH AND THROAT IRRITATION, BURNING, AND POSSIBLE ABDOMINAL
DISCOMFORT OR NAUSEA.
BREATHING: PROLONGED BREATHING OF MIST MAY IRRITATE NASAL PASSAGES.
+ HEALTH
1
^ FIRE
0
7 EMERGENCY AND FIRST AID PROCEDURES
* REACTIVE
0
ON SKIN: WASH WITH SOAP AND WATER. IF IRRITATION PERSISTS, SEEK MEDICAL ATTENTION.
HAZARD RATING
0 – LEAST
1 – SLIGHT
2 – MODERATE
3 – SERIOUS
4 – SEVERE
IN EYES: FLUSH EYES WITH PLENTY OF RUNNING WATER FOR 15 MINUTES, LIFTING EYELIDS
OCCASIONALLY. GET IMMEDIATE MEDICAL ATTENTION.
SWALLOWED: CALL A PHYSICIAN IMMEDIATELY. DO NOT INDUCE VOMITING. IF CONSCIOUS, DRINK
PLENTY OF WATER OR MILK.
BREATHED:
KEEP OUT OF THE REACH OF CHILDREN.
3 HAZARDOUS COMPONENTS OSHA – >
each of them, and the proper response if there is an
accident. The idea behind the right-to-know regulation is to develop a universal warning system.
The MSDSs are of no value unless they get into
the hands of the right people. It is a supplier’s responsibility to provide data sheets to product dealers,
who in turn, make sure the printers receive copies.
Printers should, therefore, be aware that complete
data sheets must be provided with chemicals and
kept on file in the printing facility.
OSHA requires employers who use chemicals in their facilities to educate their employees.
Employers must have a written educational program,
and training must be done at regular intervals.
Educational programs must include information
on the potential hazards of the chemicals, how to
use the chemicals, how to dispose of the chemicals,
what personal protective equipment should be worn
when handling the chemicals, and how to administer proper first aid in case of spills. See Figure 2-15.
Employers must clearly label any hazardous material
6 HEALTH HAZARD INFORMATION – SIGNS AND SYMPTOMS OF EXPOSURE
DATE PREPARED 3/07
EMERGENCY PHONE NUMBER
1-402-333-8323
1-402-359-5796
TWA
a
3
ppm mg/m
400
983
45
c
STEL
a
3
ppm mg/m
500
1230
CEILING
a
3
ppm mg/m
REMOVE TO FRESH AIR. GIVE ARTIFICIAL RESPIRATION IF NOT BREATHING. SEEK
IMMEDIATE MEDICAL ATTENTION.
8 TOXICITY DATA
ORAL: N/A
DERMAL: N/A
INHALATION: N/A
CARCINOGENICITY: NOT CONSIDERED TO BE A CARCINOGEN BY IARC.
NTP? N/A
IARC MONOGRAPHS? N/A
OSHA REGULATED? N/A
9 PERSONAL PROTECTION
4 PHYSICAL/CHEMICAL CHARACTERISTICS
Specific Gravity (H20=1)
212° F
Boiling Point
Melting Point
Vapor Pressure (mm Hg.)
N/A
Vapor Density (Air = 1)
Evaporation Rate
N/A
(Butyl Acetate = 1)
Solubility in water
MISCIBLE
Appearance and Odor
PURPLE THICK EMULSION, BANANA ODOR
5 Fire and Explosion Hazard Data
Flash Point
N/A
Flammable Limits
N/A
LEL
N/A
Extinguishing Media
WATER TO COOL DOWN CONTAINERS
Special Fire Fighting Procedures
N/A
DIRECT FLAME FROM BUTANE TORCH
WILL NOT IGNITE MATERIAL.
Unusual Fire and Explosion Hazards
N/A
N/A
N/A
N/A
VENTILATION: LOCAL OR MECHANICAL EXHAUST.
RESPIRATORY PROTECTION: IF NECESSARY, WEAR A PARTICLE MASK OR AN OSHA APPROVED MASK
FOR MIST CONCENTRATIONS.
EYE PROTECTION: WEAR GOGGLES OR SAFETY GLASSES.
SKIN AND PROTECTIVE CLOTHING: WEAR RUBBER GLOVES.
10 HAZARDOUS REACTIVITY
STABILITY:
UNSTABLE?
STABLE?
UEL
N/A
CONDITIONS TO AVOID: N/A
X
INCOMPATIBILITY: N/A
HAZARDOUS BYPRODUCTS: N/A
HAZARDOUS
POLYMERIZATION:
MAY OCCUR
CONDITIONS TO AVOID: N/A
WILL NOT OCCUR
X
Figure 2-14. MSDSs vary in design but usually include the same types of information. (Hi-Temp Products Co.)
nip point: the point where two rollers come together.
material safety data sheet (MSDS): a sheet that gives the chemical name and the name, address, and telephone number of the
manufacturer.
46
Section I Introduction to Offset Lithographic Technology
used in the printing facility. The labels must include
the following:
• The name of the chemical.
• The word caution, warning, or danger.
•
•
•
•
•
•
Chapter 2 Safety and Health
A brief description of the major hazards, such as
“extremely flammable.”
Measures for avoiding possible hazards, such as
“wash hands thoroughly after handling.”
First aid instruction, in the event of exposure to
the chemical.
How to extinguish a fire caused by the chemical.
Information for treatment by medical personnel.
Directions for handling and storage.
Offset lithographic chemicals and agents
The types of chemicals and chemical agents
posing hazards to workers in the printing industry
are commonly classified as solvents, platemaking
chemicals, ink mists, gases, fumes, and dust.
Although this list might sound intimidating, some
of these hazards do not exist in most printing plants.
None are a threat if they are handled properly.
Safety Can
Waste Container
Figure 2-15. Safety cans with flame arrestors should be
used when transferring flammable liquids. Flammable
debris should be placed in approved waste containers.
Oily or ink-soaked rags should never be stored in a
container that does not meet fire safety requirements.
(Justrite Manufacturing Co.)
Chemical handling and disposal
Historically, the printing industry has had to
dispose of waste chemicals that were used to develop
plates, clean ink from the press during washup, and
clean machine parts. In addition, used dampening
solution and waste ink needed to be disposed of
properly. In the last 10 years, however, there has been
a great reduction in the volume of waste chemistry.
Several years ago, dampening solutions commonly
contained isopropyl alcohol (IPA), some of which evaporated and contaminated the air in the pressroom.
Today, propylene glycol and other alcohol substitutes
are more environmentally friendly than IPA, but they
still contain chemicals that must be disposed of at
some point. In addition, dampening solutions become
contaminated with ink residue, paper particles, and
other impurities. One method of reducing the volume
of waste dampening solution is to filter out these
impurities, instead of replacing the solution.
The platemaking process is a potential source
of hazardous waste. Although some systems use no
harmful chemistry, some direct imaging processes
place silver or a strong alkaline exceeding the limits
of the local sewer system into the wastewater. In this
situation, the chemistry must be collected and stored
as a hazardous material.
The most common source of hazardous waste in
a lithographic printing facility is the solvent used to
wash ink from the press. These solvents are usually
used with rags to clean the press, and the contaminated rags must then be stored as hazardous material.
The rags need to be placed into covered containers so
fumes from the solvent do not escape.
After most of the solvent has been removed, the
rags are stored in Department of Transportation
(DOT)–approved drums and eventually removed
from the printing facility by an industrial laundry
service. Recovered solvent can then be distilled to
produce clean solvent that can be reused. Solvent
recycling can be performed within the printing
facility or off-site.
Although there are nontoxic cleaning solvents
available, many blanket and roller washes contain
volatile organic compounds (VOCs). VOCs are
compounds emitted from organic chemicals contained in certain liquids or solids. The term volatile
refers to the ease of evaporation. Examples of materials
that emit VOCs are paints, cleaning supplies, permanent markers, adhesives, correction fluids, carbonless
paper, and alcohol. Workers can protect themselves
when cleaning a press by wearing personal protective equipment and properly handling washes. As
the solvents evaporate, however, VOCs can pass into
the air, and breathing these solvent vapors can be
very harmful. Many vapors do not give off a strong
odor, and students and workers should not rely on
their sense of smell to warn them.
Some solvents are more harmful than others.
Solvents that should not be used include benzene,
carbon tetrachloride, gasoline, chloroform, and carbon
disulfide. When possible, solvents that are less irritating to the skin, are noninjurious to offset rollers
and blankets, are nonflammable, or have a high flash
point should be used.
A solvent’s flash point is the lowest temperature
at which the solvent emits vapors that will ignite
if exposed to an open flame or spark. For example,
kerosene is relatively safe, with a flash point as
low as 100°F (38°C), while gasoline has a low flash
point of only –40°F (–40°C). This means that gasoline ignites or supports combustion as low as –40°F
(–40°C). For this reason, gasoline should never
be used as a solvent for washing ink from a press.
Instead, a blanket wash with a flash point over 150°F
is the safer choice.
Harmful vapors are not limited to the use of
cleaning solvents. Some types of shrink-wrap film
used in the bindery can cause employees to suffer
from a condition known as meatpacker’s asthma. This
condition results from inhaling hydrogen chloride
gas emitted during the heat-shrinking process.
To diminish the possibility of inhaling harmful
vapors, working areas should be well ventilated,
and employees who work near concentrations of
hazardous fumes should wear approved respiratory
equipment. See Figure 2-16.
47
Figure 2-16. An expert must select the proper respirator
for each situation.
Caution
You should never attempt to identify a solvent
by sniffing it. Inhaling harmful vapors can
cause serious physical injury or even death.
Platemaking chemicals
Platemaking chemicals can irritate the skin
and cause burns. To prevent physical harm when
processing lithographic plates, a platemaker should
always wear the proper personal protective equipment and keep the following factors in mind when
working with potentially hazardous platemaking
chemicals:
volatile organic compound (VOC): an organic compound that
significantly participates in photochemical reactions and is released
as hazardous emissions. A VOC eventually vaporizes and reacts with
the atmosphere and sunlight to create smog and other pollutants.
flash point: the lowest temperature at which a solvent emits vapors
supporting combustion if exposed to an open flame.
48
•
•
•
•
•
•
•
•
•
•
Section I Introduction to Offset Lithographic Technology
Wearing an apron prevents chemicals from
staining clothing and seeping through to the skin.
Rubber or plastic gloves protect the hands from
chemical burns. Gloves should be inspected for
tears and holes before beginning work.
Face shields and splash goggles are the best form
of eye and face protection.
Never wear contact lenses when working with
chemicals. If splashed in the eyes, chemicals can
seep under the lenses and cause severe burning.
Do not store food or beverages in the same area
as platemaking chemicals.
Properly labeled and stored platemaking chemicals pose less risk.
When processing offset plates by hand, follow
the manufacturer’s recommended procedure.
Be sure bottle caps are tight before shaking
containers.
Clean up spilled chemicals or oil immediately.
Using an oil-absorbent cleanup product keeps
the work area dry and slip free without press
contamination. See Figure 2-17.
Make sure there are adequate mechanical
exhaust ventilation and a supply of clean air
available where chemicals are used or stored.
Caution
Figure 2-17. Chemical-sorbent materials often come
in portable dispensers. Most sorbent materials are
designed to fit under equipment, around corners, and
into tight areas. These materials are also designed not
to leave granules or dust residue, reducing cleanup time
and preventing contamination. (3M Company)
and the vast amount of paper used for printing can
create dust. When inhaled, microscopic dust particles can lodge in the lung tissue, causing respiratory
disease and lung damage. Systems for controlling
dust, providing adequate ventilation, and scrubbing
the air should be installed in all printing facilities.
See Figure 2-18.
Chapter 2 Safety and Health
Noise Hazards
Fire Hazards
Printing, binding, and finishing equipment
creates loud noise. Excessive noise in a printing
facility can reduce the efficiency of the facility’s
workforce, interfere with clear communications, and
cause permanent hearing damage. The first step in
protecting students and employees from hearing loss
is to control the sound level of noise created in the
plant. This is often done by modifying machines and
installing sound barriers or sound-absorbing materials to the facility. When it is not possible to reduce
the noise to an acceptable level, all employees must
wear the proper ear protection. See Figure 2-19.
Sound levels are expressed in units called
decibels (dBA). OSHA has established permissible
noise levels and time periods industry personnel can be
exposed to the noise. The chart in Figure 2-20 compares
typical sound intensities to those found in a printing
facility, as well as the maximum exposure limits.
The maximum allowable exposure for an employee
is 90 dBA of continuous noise for eight hours. If noise
levels are higher than 90 dBA, employee exposure
must be shortened, per OSHA regulations.
Printing industry employees must be alert to
situations that can cause fire. Good housekeeping,
preventive measures, and education are the key
elements to a sound fire protection plan. The National
Fire Protection Association lists the following as
major problem areas in the printing industry:
• Flammable debris left on floors and around
equipment-operating areas—safety trash containers should be used for this purpose.
• Low flash point cleaning solvents for presses—
solvents with a flash point of over 100°F (38°C)
should be used.
• Static electricity accumulation on presses—static
eliminators should be installed on all presses.
• Oily cloths left outside cans with self-closing
lids–cans with self-closing lids should be used
for disposal of solvent-soaked and oily cloths.
• Flammable ink and solvent storage—ink and
solvent cans should be stored in a safety cabinet
when not in use.
• Greasy metal parts and tools should be cleaned
in a special parts– cleaner machine.
• Paper dust from bindery and press areas—dust
collectors should be installed in these areas.
• Scrap paper accumulation—all scrap paper
should be placed in bins.
• Setoff spray powder accumulation, with possibility of dust cloud formation and ignition—
avoid this condition.
When diluting platemaking chemicals, always
pour the acid into the water. Never add water
to a concentrated acid. Doing so can produce a
dangerous splattering of the acid.
Airborne hazards
Besides the solvent vapors roller and blanket
washes emit, pressroom personnel should be aware
of hazards from ink mists, gases, fumes, and dust.
Ink mists are created as rotating press rollers throw
tiny droplets of ink into the air. These droplets are
small enough for unprotected press operators to
inhale. Ink mists often contain harmful pigments,
polymers, plasticizers, resins, and solvents. On some
types of presses, face shields and respirators should
be worn for protection. Harmful gases such as ozone
(O3) are emitted from the breakdown of VOCs found
in solvents, carbon arcs, some antistatic devices, and
ultraviolet (UV) ink-curing units. Acids and molten
materials can emit harmful fumes.
A large amount of dust can accumulate in a
printing facility. Printing press antisetoff powders
49
Sprinkler systems and hoses
The invention and installation of sprinkler
systems have greatly reduced the chance of tragic
industrial fires. Sprinkler systems also reduce
the amount of potential water and fire damage by
isolating the fire to a specific area. If the sprinkler
system is not properly maintained, however, its
presence is of no use. Along with regular inspection by local fire departments, all sprinkler system
components should be regularly serviced by a
Figure 2-18. Filtration systems vary in size and design.
This mist collector can achieve filtration efficiencies
of up to 99%. The collector also features a pressuredifferential gauge that indicates when maintenance is
required. (Torit® Products)
Figure 2-19. Ear protection is often needed in the
pressroom and bindery area of an offset lithography
plant. Protective devices for ears include headsets,
earmuffs, moldable inserts, and earplugs.
decibel (dBA): a unit of measure for stating sound levels.
static eliminator: a press attachment used to reduce the amount
of static developing on a press because of low relative humidity and
the movement of paper over metal surfaces. This attachment is also
used to eliminate ink setoff or paper-feeding problems.
dust collector: a vacuum system that captures airborne dust and
removes it to a storage compartment.
50
Section I Introduction to Offset Lithographic Technology
Chapter 2 Safety and Health
Permissible Noise Exposure
Noise sources
Pneumatic chipper (at 5 ft.)
Rock-n-roll band
Punch press
pressroom
Sound
level
dBA
Maximum
exposure
per day
dBA
Indicators of level
(speaking effort required
between two persons
at various distances)
Nearly impossible to
communicate by voice
115
15 min.
110
30 min.
Very difficult to
communicate by voice
105
1 hour
1.5 hours
Shout with hands cupped
between mouth and other
person's ear
2 hours
Shout at 0.5 foot
Figure 2-21. Fire department connections should be
properly marked and easily accessible.
Shout at 1 foot
Caution
Newspaper printing press
Pneumatic air hoist, 4000 lb.
Newspaper folder
100
Rotogravure press
Web offset press
Eight color press
Dual folder
95
Web letter press
Color letter press
Rotary press
Flatbed press
90
Printer slotter
Composing room
Vaneaxial ventilating fan (1500 CFRM)
Paper machine, wet end
85
Saddle stitcher
Die cutter
3 hours
4 hours
6 hours
8 hours
Normal voice at 0.5 foot
Raised voice at 1 foot
Shout at 2 feet
Telephone use impossible
Normal voice at 1 foot
Raised voice at 2 feet
Shout at 4 feet
Garbage disposal (at 3 ft.)
80
Normal voice at 1.5 feet
Raised voice at 3 feet
Shout at 6 feet
Inside a car (50 mph)
75
Normal voice at 2 feet
Raised voice at 4 feet
Shout at 8 feet
Figure 2-20. OSHA determines permissible noise exposures. When employees are subjected to sound exceeding the
levels prescribed, employees must wear the proper ear protection.
facility’s maintenance department. Although sprinkler systems vary, most operate under the same principles and use the same basic components.
Exterior fire department connections and hose
systems should also be examined regularly. See
Figure 2-21. The connections should be properly
marked and easily accessible. Hose lines and valves
should never be obstructed or blocked. Hoses
should be checked regularly for rot, mildew, and
other damage. The hoses should never be used
for anything but periodic testing and fire fighting.
Hydrants should also be flushed and tested to make
sure they operate.
Fire extinguishers
All printing facilities use flammable and combustible materials. Therefore, fire prevention is a
crucial part of plant safety programs. Students and
employees should be aware of fire extinguisher locations, evacuation routes, and the proper response in
case of a fire.
The proper fire extinguishers should be located
near potential hazard areas. See Figure 2-22.
Extinguishers should be easily accessible and
properly charged.
Types of fires
As indicated in Figure 2-22, there are four general
types of fires—Class A, Class B, Class C, and Class D.
It is important to know the different classes of fires
because, depending on the material burning, different
means of controlling and extinguishing the fire must be
used. For example, water is ideal for putting out a paper
fire. When used on an electrical fire, however, water
can cause additional damage to electrical equipment or
electrocution because the water conducts electricity.
In order to extinguish an electrical fire, the
power source must be turned off!
Water cannot be used on flammable liquids, such
as gasoline, because it might disperse the liquid,
causing the fire to spread. Such liquids burn at the
surface, where the vapors are given off. Therefore,
smothering or blanketing the burning liquid is the
best technique for extinguishing the fire.
Light Hazards
Light hazards include light sources that can cause
damage to a person’s skin or eyes. These hazards
also include insufficiently lit work and storage
areas. Light sources commonly used in the printing
industry include UV radiation, infrared (IR) light,
laser beams, pulsed xenon lamps (PXAs), mercury
vapor lamps, and ozone lights.
Ultraviolet (UV) radiation is used for curing
ink and exposing plates. Although UV light rays are
not visible to the human eye, they can be harmful
to the eyes and skin. Damage from UV rays can be
prevented by wearing the proper eye protection and
clothing and avoiding exposure.
Caution
Most platemakers operate at extremely high
voltage. The platemaker should always be
unplugged when the bulbs or lamps are replaced
or repairs are made.
51
Infrared (IR) light is often used in ink-drying
and ink-curing devices. Similar to UV light, IR light
can cause eye and skin burns with extensive exposure. Laser beams are commonly used for plate
exposure and are potentially harmful. Although the
rays used in the printing industry might not be able
to cut through metal, they can cause a great deal of
damage to unprotected skin and eyes.
Potentially harmful sources of light also include
pulsed xenon lamps (PXAs) and mercury vapor
lamps used on antisetoff devices. The proper eye
protection devices must be worn. See Figure 2-23.
Exposure lamps used in cameras and platemakers
can reach extremely high temperatures. Care should
be taken when working around them or changing
the bulbs. The bulbs should be allowed to cool down
completely before being changed.
To avoid tripping or falling, lights should be
turned on when working with machines, at workstations, and when entering stockrooms. This, of course,
is not true when the process prohibits illumination,
such as in darkrooms. Insufficient lighting can also
cause undue strain on your eyes.
Ergonomic Hazards
The awareness of ergonomics has increased
greatly. Manufacturers, employers, and consumers
have dedicated a great deal of time and money to
the science of fitting the job to the worker. Although
OSHA does not yet regulate ergonomic issues, many
types of workstations have been redesigned to meet
the physical needs of the worker. See Figure 2-24.
Properly designed workstations help workers remain
healthy, increase productivity, and prevent accidents.
ultraviolet (UV) radiation: a range of electromagnetic radiation lying
outside the visible spectrum. In the printing industry, UV rays are
used for producing various types of proofs, curing ink, or exposing
plates.
infrared (IR) light: a range of the electromagnetic spectrum that
serves as a source of heat.
laser beam: a beam of nearly parallel and monochromatic light
moving in phase.
pulsed xenon lamp (PXA): a primary light source in graphic arts
photography. This source provides a constant output with a spectral
composition resembling sunlight.
mercury vapor lamp: an enclosed light source that produces
radiation by passing an electrical current through gaseous mercury.
ergonomics: the study of equipment design that improves
convenience, ease of use, and operator comfort.
52
Section I Introduction to Offset Lithographic Technology
Chapter 2 Safety and Health
these principles into daily business operations.
Called Responsible Care (RC), the initiative includes
the following codes of practice:
• Establish community awareness and emergency
response programs at every facility.
• Ensure that research and development operations
protect the environment at all stages of chemical
development and use.
• Protect workers and the environment during
manufacturing operations.
• Ensure the transport of chemical products in a
manner minimizing environmental risks.
• Track the distribution of chemical products.
• Address all options related to hazardous waste
management.
Fire Extinguishers and Fire Classifications
Fires
Type
Use
Class A Fires
Ordinary Combustibles
(Materials such as wood,
paper, textiles.)
Requires...
cooling-quenching
Soda-acid
Bicarbonate of
soda solution
and sulfuric
acid
Okay for use on
Operation
A
B
A
Class B Fires
Flammable Liquids
(Liquids such as grease,
gasoline, oils, and
paints.)
Requires...blanketing or
smothering
Pressurized Water
Water under
pressure
Okay for use on
A
Direct stream at base of
flame.
B
Carbon Dioxide (CO2)
Carbon dioxide
(CO2) gas
under pressure
C
B
Not for use on
Foam
Solution of
aluminum
sulfate and
bicarbonate
of soda
Dry
Chemical
Environmental Considerations
Direct stream into the
burning material or
liquid. Allow foam to
fall lightly on fire.
B
A
Not for use on
Ordinary BC
type
type
B
Okay for
B
C
Not okay for
C
Computer Sense
Direct stream at base of
flames. Use rapid leftto-right motion toward
flames.
D
A
D
Okay for use on
Smother flames by
scooping granular
material from bucket
onto burning metal.
Not for use on
A
B
• Use a chair with adjustable back support. Your feet
should touch the floor, and your thighs should be
parallel with the floor.
• Place light sources perpendicular to your computer, so
they will not shine in your eyes or reflect on the monitor.
If there is a glare problem, install a glare screen or
three-sided hood.
Not okay for
D
D
The Chemical Manufacturers Association (CMA)
established environmental protection principles.
Many printing industry vendors (companies that
sell supplies and equipment to printers) incorporate
Along with the safety and health guidelines
OSHA established, the federal government has
established many environmental protective regulations. The Environmental Protection Agency (EPA)
enforces most of these regulations. The Clean Air Act
Amendments (CAAA) and Clean Water Act (CWA)
significantly affect printing establishments.
The CAAA regulates toxic emissions and air
pollution controls. The CWA regulates the discharge
of pollutants into U.S. waters, regulates water pollution control, and enforces industrial laundry guidelines. See Figure 2-25. In addition, local communities
place restrictions on the volume of certain chemicals
D
Multi-purpose
A
Figure 2-23. Wearing the proper protection device
prevents damage to your eyes from chemical splashes,
airborne particulates, and potentially harmful light
sources.
D
Okay for use on
Okay for
Dry Chemical
Granular type material
Federal Regulations
Direct discharge as
close to fire as possible,
first at edge of flames
and gradually forward
and upward.
C
C
Class D Fires
Combustible Metals
(Flammable metals such
as magnesium and
lithium.)
Requires...blanketing or
smothering
D
Okay for use on
A
C
D
C
Not for use on
B
Class C Fires
Electrical Equipment
(Motors, switches, and so
forth.)
Requires...
a nonconducting agent
Direct stream at base of
flame.
Not for use on
53
• Use an antistatic cloth to keep dust and fingerprints off
the monitor’s glass.
• Inspect and clean the computer’s exhaust fan slot
periodically.
• Position the monitor 16″ to 30″ away from your eyes,
depending on what is comfortable. The angle between
your eyes and the monitor should be 0 to 45. It should
be 4″ to 8″ lower than eye level, so you are looking
slightly down toward it. It should be tilted slightly up as if
it were a book or magazine.
• When typing from copy, keep it as close to the monitor
as possible to prevent swiveling your gaze back and
forth.
• Take periodic breaks, at least 15 minutes every two
hours.
• Make an effort to blink frequently. If necessary, use
artificial tears to keep your eyes moist.
C
Figure 2-24. To promote safety and reduce health hazards relating to computer workstations, keep this information in mind.
Figure 2-22. The classification system for fire extinguishers uses letter, color, and shape designations to denote the
type of material on which the extinguisher can be used.
54
Section I Introduction to Offset Lithographic Technology
Shop Towels, Rags, and Gloves
Before the enactment and enforcement of federal
and state laws on clean air, clean water, and other
environmental factors, cloth shop towels, rags, and
gloves were placed in the trash and hauled away to
landfills. Now, that practice is against the law, and
offenders are subject to fines and criminal prosecution. As a result of the new environmental laws,
“industrial dry cleaning laundries” now clean and
recycle shop towels, rags, and gloves, using solvents
instead of water for cleaning. The laundries meet all
the requirements for environmental compliance.
Contaminated shop towels, rags, and gloves are
picked up from the printing facility in drums the
DOT has approved and are taken to the laundry.
After a thorough cleaning, the waste residue from
the laundry operation is removed by DOT-licensed
haulers and incinerated at facilities the EPA has
licensed. By using the cleaning services, printers
save from 30% to 50% of the money spent annually
for new towels, rags, and gloves. Industrial laundries
also dispose of worn-out towels, rags, and gloves.
Helping the Environment
Figure 2-25. A parts cleaner combines state-of-the-art
separation technology with improved solvents to help
minimize waste and reduce disposal costs. (Safety-Kleen)
that can enter their wastewater treatment facilities.
Printing companies must become acquainted with
these limits.
For detailed information on the CAAA and CWA,
as well as other environmental regulations, contact
your local, state, or federal EPA office. The phone
number and address of your local EPA office can
be found in the telephone directory. The Internet is
also a good source for reviewing the most current
regulations.
Manufacturers of printing supplies and equipment have taken the responsibility of developing
new environmentally friendly technologies and
materials. The printing industry is meeting these
challenges by taking action on the following issues:
• Negotiating long-term contracts for the purchase
of recycled paper, thereby allowing suppliers to
speed up research, development, and production
of recycled paper.
• Establishing cooperative research and development relationships with paper and ink suppliers
to ensure new and more environmentally friendly
products.
• Investing in air and water quality control equipment that meets and exceeds current and future
standards.
• Recycling preconsumer waste paper, inks,
solvents, and other materials and supporting
paper-recycling programs at the plant and
community level.
Chapter 2 Safety and Health
•
Training employees to consider the environmental implications of all manufacturing
processes and material purchases.
• Establishing sound environmental company
policies.
Everyone talks about being committed to preserving
our environment. In order for our good intentions
to have any effect, however, we must take action.
Here are some simple tips to reduce waste, increase
efficiency, and positively affect the environment:
• Use recycled paper. A lot has been done to
improve the quality of recycled papers. Today’s
recycled papers have stronger fiber characteristics and fewer problems on press than their
predecessors did. The costs have come down to
be competitive with nonrecycled papers.
• Know what is environmentally smart and what
is not. By establishing a close relationship with
your suppliers, you can keep abreast of the developments in environmentally friendly printing
materials. There is a variety of recycled papers,
vegetable-based inks, and water-based glues
already available, with new products coming on
the market all the time.
•
•
55
Recycle at school, work, and home. With so
many recyclable products, there is no reason not
to recycle. Set up a recycling center at the school
or office for paper, aluminum and other cans, and
corrugated boxes. Check with your local trash
collection company about picking up recyclable
materials.
Perform environmental audits. Regularly assessing a facility’s compliance with environmental
regulations helps keep the facility in compliance
and protect the environment.
Safety Is Your Responsibility
Unsafe machines, work areas, and procedures
are the cause of many accidents. Take time to inspect
all equipment and work areas. Never assume an area
is safe because there are no large machines or toxic
chemicals.
Periodic inspections are one of the most important aspects of a successful safety and health
program. When unsafe conditions exist, take immediate action to correct and eliminate them. A sample
safety inspection checklist is shown in Figure 2-26.
56
Section I Introduction to Offset Lithographic Technology
Chapter 2 Safety and Health
Guards—adequate
Attire—appropriate for job
Safety Inspection List
Sa
tis
Un fact
sa ory
ti
No sfa
t A cto
ry
Da ppl
ng ica
bl
er
ou e
s
Date: _______________________________________________Area: ________________________________________________
Inspectors: __________________________________________
_______________________________________________
Jewelry—appropriate for job
Computers/keyboards—properly placed
Work space—adequate
Storage
Ladders and stools—adequate
Heavy objects—near floor level
Remarks
Housekeeping
General impression
File cabinets—secured or weighted
—open drawers do not block
Aisles—not blocked or cluttered
Clean and orderly work areas
Waste containers—adequate/orderly
Desks and tables—orderly
Tripping and/or Slipping Hazards
Waste containers—adequate/orderly
Carpets and mats—in good condition
Floors—clean and in good condition
Proper materials available for
housekeeping
Fire Safety
Maintenance schedules used
Waste paper disposal
Properly marked aisles
Other trash disposal
Warnings and cautions posted
Flammable liquid storage
Containers labeled
Exits—not blocked, properly marked
Storage space—adequate/orderly
Fire extinguishers—inspection current
Chairs—in good condition
Other fire hazards (specify)
—properly used
Administration
Ladders—inspection current
Safety progr am
—in good condition
Education
Personal Protection Equipment
Incentives
Eye protection
Ear protection
Procedures
Record keeping
Foot protection
Accident and injury
Head protection
Emergency evacuation plan
Protective clothing
Job hazard analysis
Respiratory equipment
Other observations and explanantion of items needing attention
Security
Personal valuables—lockers provided
Locks—adequate
Electrical Equipment
Inspection current
Cords—in good condition
—away from aisles
Tampering—no evidence of
Panel boxes—properly enclosed/locked
Lighting—adequate
Lighting—emergency adequate
Machines and Equipment
Operators trained
Figure 2-26. A safety inspection checklist should be used when performing periodic inspections.
Figure 2-26. (Continued)
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58
Section I Introduction to Offset Lithographic Technology
Summary
Safety and health issues are the responsibility
of every student or employee working in a printing
facility. All printing firms must follow the safety
guidelines OSHA has established. Knowledge of
safety colors, machine lockout devices, and tagout
devices is essential to making your work area a safe
and enjoyable place to be. Following recommended
procedures for storing and using chemicals, solvents,
and flammable liquids helps prevent physical injury
and fire.
Noise abatement is a factor in all printing facilities.
All workers and students should wear the proper ear
protection to prevent hearing damage or loss. Good
housekeeping, preventive maintenance, and education are the key elements to a good fire protection
plan. This includes the proper disposal of hazardous
materials and the recycling of appropriate materials
whenever possible.
Review Questions
Please do not write in this book. Write your answers on a
separate sheet of paper.
1. What are the five OSHA–specified hazard
areas?
2. Of what use are safety color codes?
3. What purpose does OSHA serve?
4. How can on–the–job physical injuries resulting
from mechanical hazards be controlled?
5. What should an operator do before working on
any electrical equipment?
6. What is the purpose of a lockout device?
7. How are lockout and tagout devices applied?
8. Name the personal protection devices that
could be used in three different situations.
9. List five guidelines for handling tools and
materials properly.
10. What information can be found on an MSDS?
11. Define the term flash point.
12. What are the recommended procedures for
storing and using toxic and flammable liquids?
13. How can noise be properly controlled in a
printing facility?
14. What is the maximum allowable dBA exposure
limit for an eight–hour day?
15. List five ways fires can be prevented and
controlled in the printing industry.
Chapter 2 Safety and Health
16. List the four color, letter, and shape
designations used to identify the types of
material on which fire extinguishers can be
used.
17. Why is it dangerous to use water on an
electrical fire?
18. List three guidelines for safely operating
computer equipment.
19. What is meant by the statement “Safety is your
responsibility”?
Skill-Building Activities
1. Design a safety inspection form suitable for the
lab in which you are working. Conduct a safety
inspection using the form. Prepare a written or
oral report.
2. Invite a local fire department official to discuss
fire drill procedures and fire prevention. Ask
the official to demonstrate the proper use of
fire extinguishers in the graphic arts lab.
3. Invite the school nurse or another health
official to demonstrate first aid procedures
for each kind of accident that might occur
in a printing facility (electrical shock, cuts,
poisoning, burns, and chemical spills).
4. As a class activity, design a bulletin board
or other type of display with a “Safety in the
Printing Industry” theme. Sources for visual
aid materials include OSHA, the local labor
department, the school health office, and local
printing plant safety representatives.
5. Ask the school nurse or another health official
to assist the class in assembling a first aid
kit for the lab. Be sure all required items are
obtained and in good condition. Place the first
aid kit in a prominent location in the graphic
arts lab.
Press rooms are extremely noisy during a pressrun. It is
important to wear hearing protection whenever you are
in the press area. (3M Company)
59