AS 4024 Packaging Machine Safety Upgrades
AS 4024 Packaging Machine Safety Upgrades
AS 4024–compliant safety upgrades for packaging machines, including risk assessments, emergency stops, interlocks and safety PLC retrofits.
AS 4024 Compliant Packaging Machine Safety Upgrades
Most packaging machines are mechanically sound—but their safety systems no longer reflect how the machine is actually used.
In Australian facilities, these machines are required to comply with current AS 4024 machinery safety standards and obligations under the Work Health and Safety Act. Where existing equipment no longer meets these requirements, compliance is typically achieved through targeted retrofit upgrades rather than full replacement.
Safety upgrades are most often applied to machines such as bagmakers, weighers, robotic pick-and-place systems, and sealing equipment where the underlying mechanical design remains serviceable but safety-related control functions no longer align with current operating conditions.
Common Safety Risks In Packaging Machines
Packaging machinery presents a repeatable set of safety risks due to exposed motion, cyclic operation, and frequent operator and maintenance interaction. These risks are commonly identified during a machine risk assessment or guarding audit and include:
- In-running nip points at conveyors, sealing jaws, and rotary mechanisms
- Access to hazardous motion during clearing of product jams or film changeovers
- Unexpected restart following access or fault recovery
- Inadequate emergency stop coverage along extended machine layouts
- Maintenance activities requiring guard removal without defined safe states
Additional risks often arise from auxiliary systems such as compressed air, pneumatic actuators, and vacuum systems where stored energy is not adequately controlled during access.
Why Old Packaging Machines Often Fail AS 4024 Requirements
Older packaging machines frequently fail compliance due to changes in safety of machinery requirements rather than deterioration of the equipment itself. Many machines were designed under earlier editions of AS4024.1 or international standards that do not fully align with current Australian safety practices.
Typical non-compliances include:
- Emergency stop circuits implemented as standard control system functions
- Guarding systems without monitored interlocking or restart prevention
- Single-channel safety circuits lacking diagnostic coverage
- No defined separation between operator safety and maintenance safety conditions
- Absence of documented machine safety verification and validation
These gaps are often identified during compliance audits, incident investigations, or when reviewing obligations under applicable safety legislation.
Typical Safety Upgrades For Packaging Machines
Packaging machine safety upgrades are implemented as engineering controls integrated into existing machine design, electrical control systems, and automation architecture.
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Our Approach To Packaging Machine Safety Retrofits
Packaging machine safety upgrades are delivered as structured engineering projects rather than isolated component changes. A typical retrofit process includes:
- A formal machine safety risk assessment against AS 4024 and WHS obligations
- Identification of compliance gaps and required risk reduction measures
- Development of safety architectures and safeguarding specifications
- Implementation of control system and guarding modifications
- Factory acceptance testing and onsite verification
This approach ensures upgrades are technically sound, auditable, and defensible within Australian regulatory frameworks.
When To Upgrade Or Replace Packaging Machinery
The decision to upgrade or replace packaging equipment is driven by technical feasibility rather than age alone. Factors typically considered include:
- Mechanical condition and remaining service life
- Extent of guarding and structural modification required
- Availability of electrical and control documentation
- Impact on production performance and maintenance access
Where compliance can be achieved through control system upgrades and localised guarding modifications, retrofitting is generally preferred. Replacement is usually considered only where compliance would require fundamental machine redesign.
Related Safety Upgrade Solutions
Packaging machine safety upgrades are commonly delivered as part of broader compliance and maintenance programs, including:
- Machine safeguarding audits and safety inspections
- Emergency stop and interlock standardisation
- Safety PLC upgrades across production lines
- Hazardous area safety improvements
- Preventative maintenance and verification programs
These activities support ongoing compliance with Australian machinery safety standards while maintaining operational reliability.
Next Step
If you require assistance assessing packaging equipment against AS 4024 requirements or defining the scope of a safety upgrade, contact us to discuss risk assessment, retrofit options, and validation requirements.