Workplace injuries have long been a concern for both employees and employers. These incidents not only result in pain and suffering for workers but also lead to increased healthcare costs and lost productivity for businesses. In an era of technological advancement, automated strapping machines reduce workplace injuries and are emerging as a solution to enhance workplace safety.
Understanding Workplace Injuries
According to the U.S. Bureau of Labor Statistics, more than 1.2M work injuries related to transportation, material handling and production jobs were recorded in the United States from 2021 to 2022. More than 460,000 injuries are caused by overexertion ranging from sprains and strains. The factors contributing to these workplace injuries often include manual labour, repetitive tasks, and the use of traditional strapping methods.
The Role of Manual Strapping in Workplace Injuries
Traditional strapping methods involve manual labour and contact with heavy objects that pose significant risks. In 2020, there were 196,140 workplace injuries in the United States resulting from contact with objects and equipment. Employees frequently encounter hazards such as heavy lifting, awkward postures, and repetitive motions when using manual strapping tools. These conditions create a breeding ground for injuries ranging from back strains to musculoskeletal disorders.
To illustrate the real-life consequences, consider a scenario in a warehouse where workers manually strap packages. The repetitive bending, lifting, and pulling can lead to back injuries, sprains, and even slips and falls due to the presence of loose straps. These injuries not only cause pain but also result in increased absenteeism, workers' compensation claims, and higher insurance premiums for employers. Consequently, this is where automated strapping machines come into play. Automated strapping machines reduce workplace injuries by replacing manual strapping labour.
Manual Strapping Risks and Injuries in Various Industries
Except for common injuries caused by bad working posture, pinching fingers by miss tensioning, and slicing hands due to sharp steel straps, there are many other types of injuries related to specific industries.
Metal Fabrication Industry
- Cut and shire due to sharp edge
- Heat burns by hot product
- Severe injury caused by pup coil string back
- Overexposure to harmful fume
Lumber Product Manufacturing
- Pierced by splintering wood
- Crush injury due to falling lumber product
Beverage and CPG Production Line Manual Strapping Hazards
- Product pallet fails
- Struck by collapsing loads due to mishandling or damaged pallet
How Itipack’s Automated Strapping Machines Reduce Workplace Injuries
Itipack’s automated strapping machines are innovative solutions designed to address workplace safety concerns. These machines use technology to streamline the strapping process, minimizing the need for manual labour. They come equipped with various safety features and ensure consistent, secure strapping of packages. Here are some key advantages of how Industrial safety is enhanced through workplace automation with Itipack’s strapping machines:
1. Efficiency and speed:
Automated machines are significantly faster than manual strapping, improving productivity and reducing the time workers spend on repetitive tasks.
2. Consistency in strapping:
With proper maintenance, automated machines provide uniform tension and sealing, reducing the risk of injury caused by improperly strapped packages.
3. Safety features:
Itipack’s automated strapping machines include automated and manual safety features to protect workers from accidents.
4. Automated strapping machines reduce physical strain on workers:
Automation eliminates the need for heavy lifting and strenuous repetitive motions, reducing the risk of musculoskeletal injuries.
Maximize Safety with Proven and Secured Strap Seal
Itipack’s steel series strapping machines deliver a strong strap seal approved by the American Railways Association (AAR), ensuring maximum safety and reliability for your packaging needs.
Seal Efficiency and Consistency
Minimizes the risk of product damage and accidents due to failed strap seals, protecting both products and personnel. This efficiency ensures that each seal is applied with precision, maintaining consistency across all packaging.
Superior Durability
Seals maintain their integrity over long distances and through varied environmental conditions. This durability guarantees that your packages remain securely strapped from the point of origin to the final destination, regardless of the journey's challenges.
Transportation Safety
Supports safer handling and transportation of heavy or hazardous materials. By providing robust and reliable seals, our strapping solutions contribute to safer logistics operations, reducing the risk of accidents during transit.
Prevent Injuries with Automated Intervention Systems
Itipack’s strapping systems are equipped with various safety mechanisms and sensors to prevent emergencies. Here's how these features synchronize with the system and create a safer work environment through proactive hazard prevention.
Electrically Locked Safety Fence
Electrically locking fences provide a multi-layered approach to preventing injuries in your strapping systems. It stands out through these advantages:
Visual Deterrence
The presence of a physical barrier serves as a constant visual reminder of the hazardous zone. It helps to reinforce safe work practices and encourages operators to use proper procedures when interacting with the strapping system.
Increased Awareness
Knowing that all operators are required to unlock and open the fence to enter the hazardous zone increases their awareness of potential dangers within the strapping system. This extra vigilance helps them identify and avoid hazards proactively.
Machine Interlock
The fence door is programmed to interlock with the strapping machine control systems. It ensures the machine cannot operate when the fence door is open, preventing injuries during operation.
Multiple Emergency Buttons Stopping Danger
Automated strapping machines occupy a significant space. Itipack engineers design emergency buttons in multiple areas, such as on the strapping head control box, the accumulator control box, and the main control panel. This approach allows operators to stop the machine in the shortest time. Fending off the hazard from aggravating.
Motion Locking Safety Pin
A Motion Locking Safety Pin is incorporated into Itipack’s custom-engineered strapping system as an additional safety device, This simple yet effective mechanical safety features offer several key benefits:
Immobilizing Moving Parts
The safety pin is designed to be inserted into designated slots on the machine's platen or pivotal arm, to physically lock it from moving. This ensures that critical components remain stationary during maintenance, eliminating the risk of accidental injury from unexpected motion.
Sensor-Triggered Lockout
A proximity sensor faces the safety pin's holder to detect its presence. If the pin is pulled out from its holder while the machine is operating, then the sensor triggers an immediate system lockout. This redundant safety measure prevents the machine from operating until the pin is placed back in its holder and the operator commands to resume the operation.
Safety PLC (Programmable Logic Controller)
Unlike traditional PLC, Safety PLC is engineered with specific features that optimize safety without compromising operational efficiency. Here’s a detailed look at what sets Safety PLC apart, focusing on wirings, components, programming and engineering aspects.
Dedicated, Dual Channel Hardware with Fail-Safe Operations
Safety PLC is compliant with UL 508A, and it’s built with dual-channel wiring for redundancy, ensuring that if one channel fails, the system will operate through the secondary channel at the same time the programming logic triggers the strapping system to stop, preventing potential injuries.
Stricter Programming Standards
Safety PLC is required to meet stringent international safety standards. The programming and engineering aspects are rigorously tested and certified to ensure they provide the highest level of safety.
Forced Stoppage
Safety PLC has the authority to override standard PLC commands in critical situations. This ensures that safety functions always take precedence, preventing the machine from operating in unsafe conditions.
Safety-Rated Components
Safety PLC is designed to work with safety-rated components like proximity sensors, light curtains, and emergency stop buttons. These components communicate directly with the Safety PLC, ensuring a swift and reliable response to safety hazards.
Configurable Safety Levels
Safety PLC offers configurable safety levels based on the specific risk assessment of the application. This allows for a tailored approach to safety, balancing risk mitigation with operational needs.
Light Curtain
The safety light curtain consists of a series of infrared beams projected between two units—a transmitter and a receiver. These units are positioned on opposite sides of the strapping machine's hazardous area. It offers these benefits:
Automatic Shutdown
Upon detecting an interruption in the beams, the safety light curtain immediately sends a signal to the PLC. This signal triggers an automatic shutdown of the machine's operation, effectively stopping the movement of any parts that could cause injury.
Rapid Response
The reaction time of a safety light curtain is extremely fast, often within milliseconds, which is crucial for preventing accidents and minimizing potential injuries.
Invisible Safety Barrier
While the machine is operating, these infrared beams create an invisible safety barrier. If anything interrupts the beams—like a hand or any part of the body—the light curtain detects this intrusion and triggers the machine to shut down.
Flexibility in Placement
Safety light curtains can be positioned according to the specific safety requirements of the strapping machine, ensuring comprehensive coverage of all hazardous areas without hindering the machine's operation or accessibility for maintenance.
2D Safety Scanner
One of the most advanced safety features, a 2D scanner can be incorporated into an automated strapping system. The 2D scanner targets an object with a laser, measuring the time the reflected light returns to the receiver. This process allows the 2D scanner to generate a detailed 2D image with spatial and depth data, enabling the PLC to process the data and trigger different actions. Here are the benefits of this advanced unit:
Wide Area Coverage
The 2D scanner continuously scans more than 200° area around the device, its warning zone reaching over 30 meters in radius. Save costs for other sensors and wiring.
Multi-Layered Safety Zones with Custom-Defined Warning Triggers
The 2D scanner detects unauthorized access within a multi-layered, custom-defined warning zone. It triggers varying levels of warning and system responses based on the specific proximity the object enters.
Dynamic Protection with Custom Programmable Zones
Our 2D Safety Scanner solves the complex challenge of protecting personnel and equipment in dynamic, moving environments with changing safety parameters. With the capability to cover up to 70 dynamic safety zones and triggers, the system can adapt to a wide range of scenarios and applications.
Comprehensive Safety Warning Systems
Itipack’s automated strapping machines feature robust safety warning features to minimize workplace injuries. These features provide real-time alerts, intuitive diagnosis, and remote monitoring capabilities. These elements ensure operational safety while enhancing efficiency and productivity, creating a safer and more effective working environment.
Display Warning with the Flashing Stack Light Warning
The stack light, a simple yet effective safety feature atop the electrical control panel, comprises three colours—green, yellow, and red—spanning around 20 inches and emitting an obvious, bright light, easily discernible from a distance. Its colours convey easy-to-understand messages: flashing green signals the strapping head is at the home position, with the system idle and awaiting commands. Yellow indicates smooth operation and is free of major issues, while red warns of an error that needs attention.
Intuitive Warning System on Human Machine Interface (HMI)
The custom-designed application in Itipack’s HMI goes beyond basic control functions. It constantly monitors for anomalies and issues. It also displays clear, actionable warnings in case of potential hazards. The intricate HMI warning and troubleshooting system offers numerous benefits:
Reduced Error Risk
User-friendly controls and clear displays minimize operator mistakes, promoting safe and efficient operation.
Predictive Maintenance
Maintenance alerts and troubleshooting guidance ensure machines are optimally maintained, reducing the likelihood of failure-related accidents.
Data-Driven Safety
Logged data enables proactive safety measures like identifying recurring error patterns and implementing targeted safety protocols.
Improved Training
The HMI can serve as a valuable training tool, visually demonstrating proper operation and potential hazards.
Remote Monitoring and Warning System
The bidirectional wireless module Ewon allows connected devices, normally held by managers, to access and configure the strapping system from a distance. These connected devices not only display real-time data and warnings but can also send commands wirelessly through Ewon to the machine, facilitating comprehensive system control. The benefits of this remote function are substantial:
Enhanced Communication
Streamlines the flow of warnings from operators to managers, ensuring quick and informed decision-making.
Rapid Emergency Response
In emergencies, managers equipped with authorized computers can swiftly take action, potentially preventing workplace injuries.
Efficient System Recovery
Managers can remotely reactivate the strapping system after resolving errors, minimizing production downtime.
Itipack Systems Reduce Workplace Injuries with Diagnostics
Diagnostics on strapping machines play a pivotal role in reducing workplace injuries by proactively addressing potential issues. Itipack's strapping machines are equipped with advanced diagnostic systems featuring sensors and technology that continuously monitor the machine's performance. These are critical factors in ensuring that strapping machines reduce workplace injuries. By constantly evaluating the strapping process, they can detect irregularities or malfunctions, such as loose straps or equipment failures, before they escalate into safety hazards.
This early detection allows for timely maintenance and repairs, preventing unexpected machine breakdowns or incidents that could result in injuries. Additionally, diagnostic data can be analyzed to identify patterns or trends, enabling businesses to implement preventive measures and improve overall machine reliability. In this way, diagnostics not only enhance the longevity and efficiency of strapping machines but also contribute significantly to the safety of the workplace environment by reducing the risk of accidents and injuries.
Following Regulatory Compliance and Standards
Itipack specializes in crafting custom strapping machines tailored to specific industries, ensuring alignment with workplace safety regulations and standards. Compliance with these regulations not only safeguards workers but also shields businesses from potential legal implications and fines associated with workplace injuries. Employers should be aware of the relevant safety standards in their industry and ensure their automated strapping machines, known for their effectiveness in strapping systems to reduce workplace injuries, meet these requirements.
Thorough Employee Training and Education
Proper training and education are crucial elements of a successful transition, enabling strapping machines to effectively reduce workplace injuries. Itipack goes further by assisting businesses in developing comprehensive training programs that teach workers how to operate the machines safely, troubleshoot common issues, and perform routine maintenance. Engaging employees in the process helps build trust and buy-in for the new technology, ultimately enhancing workplace safety.
ROI of Itipack’s Strapping Machines in Reducing Workplace Injuries
Assessing the return on investment (ROI) for automated strapping machines requires a comprehensive evaluation of upfront expenses and long-term savings. Although the initial investment might appear substantial, the decrease in workplace injuries, fewer workers' compensation claims, and enhanced productivity typically outweigh these initial costs. It is crucial to delve deeper into the economic advantages beyond injury reduction, including boosted employee morale and increased customer satisfaction.
Future Trends in Industrial Safety through Workplace Automation
As technology continues to advance, automated strapping machines will evolve as well. Future trends will include even more sophisticated safety features, integration with other automated systems in warehouses and production lines, and the adoption of artificial intelligence to enhance strapping precision and efficiency. The role of automation in workplace safety is expanding, further reducing the risk of injuries.
Automated strapping machines have emerged as a powerful tool for enhancing industrial safety through workplace automation. By automating the strapping process, these machines alleviate the physical strain on workers, improve productivity, and enhance overall workplace safety. While there may be initial challenges, the long-term benefits, including cost savings and compliance with safety regulations, make automated strapping machines a wise investment for businesses. Embracing automation is not just about efficiency but also about prioritizing the well-being of employees and creating safer workplaces for all.
