Plastic Injection Moulding Machine SWMS

For plastics manufacturers, moulding shops and their setters, operators and supervisors. It follows the work from the pre-start check of guard gates and emergency stops through loading resin, changing the mould, purging, taking off parts and clearing a stuck part, to isolating the machine and releasing hydraulic stored energy for maintenance. Hydraulic repairs and the crane lift itself are covered by separate SWMS.

Operating a moulding machine in a factory is not high risk construction work by itself, so a SWMS is legally required only if the work is part of high risk construction work (WHS Regulation s 299). Otherwise this works as a written safe work procedure and task risk assessment, and no item is pre-ticked. If the work is construction work, for example installing or relocating a machine as part of building work, tick the items that apply.

New to SWMS? Read What Is A Safe Work Method Statement?

What Is Covered In Our Plastic Injection Moulding Machine SWMS?

After the standard pre-start checks, the job steps run from “Pre-start check of the machine, guards and emergency stops” to “Shut down and make the machine safe”. The hazards and controls include:

• Crushing in the mould area and between platens
• Bypassed guard gates and interlocks
• Machine starting during a mould change
• Stored hydraulic energy after the power is off
• High-pressure hydraulic fluid injection
• Burns from hot platens, barrels and nozzles
• Molten plastic splash when purging
• Heavy mould lifts and dropped loads
• Fumes and dust from heated polymer
• Hearing loss from machines and hydraulics
• Slips on pellets and spilt oil
• Cuts from flash and sprues

High Risk Construction Work

None of the high risk construction work items (WHS Regulation 2011 (Qld) s 291) are pre-ticked, because this job is not high risk construction work by itself. Tick any that apply on your site.

Licences, Training and Competency

• Operators trained and assessed as competent on the make and model of machine, its controls, guard gates, interlocks and emergency stops (no high risk work licence class in Schedule 3 applies to plastic injection moulding machines)
• Setters and mould changers trained in mould fitting, clamping, hydraulic and cooling connections, and the machine’s isolation and lock-out points
• Training in the site’s isolation and lock-out procedure for anyone who clears a stuck part, cleans or maintains the machine (WHS Regulation s 39; operator controls must be lockable in the off position, s 210)
• Competent person to maintain, inspect and test the machine, its guards, interlocks, emergency stops and hydraulic system (WHS Regulation s 213)
• Licensed electrical worker for work on heater bands, controls, wiring and switchboards (Electrical Safety Act 2002 s 55)
• Where an overhead crane is used for mould changes: bridge and gantry crane high risk work licence if the crane falls within Schedule 3 item 12 (that class includes the load estimation and slinging for moving a load with the crane), and dogging licence (item 4) for anyone else who slings the mould or directs the crane operator when the load is out of the operator’s view
• High risk work licence for the forklift truck class (Schedule 3 item 24) where a forklift moves moulds, resin or pallets
• First aiders briefed on burns, crush injuries and hydraulic fluid injection injuries (WHS Regulation s 42)

Legislation and Codes of Practice Referenced

• Work Health and Safety Act 2011 (Qld)
• Work Health and Safety Regulation 2011 (Qld)
• Work Health and Safety Regulation 2011 (Qld): ss 205 to 213 (plant: unauthorised alterations, proper use, plant not in use, guarding, operational controls, emergency stops and maintenance and inspection)
• Work Health and Safety Regulation 2011 (Qld): s 209 (guarding or insulating parts of plant associated with heat or cold), s 219 (plant that lifts or suspends loads) and s 226 (records for plant with a presence-sensing safeguarding system)
• Work Health and Safety Regulation 2011 (Qld): ss 56 to 58 (noise) and ss 49 and 50 (exposure standards and air monitoring)
• Work Health and Safety Regulation 2011 (Qld): s 60 (hazardous manual tasks), ss 78 and 79 (falls), s 40 (workplace facilities) and ss 344 and 346 (safety data sheets and the hazardous chemicals register)
• Work Health and Safety Regulation 2011 (Qld): Schedule 3 items 4, 12 and 24 (dogging, bridge and gantry crane and forklift truck licence classes)
• Work Health and Safety Act 2011 (Qld): ss 35 to 39 (notifiable incidents and preserving the site)
• Managing Risks of Plant in the Workplace Code of Practice 2021
• Hazardous Manual Tasks Code of Practice 2021
• Managing Noise and Preventing Hearing Loss at Work Code of Practice 2021
• Managing Risks of Hazardous Chemicals in the Workplace Code of Practice 2021
• Managing the Risk of Falls at Workplaces Code of Practice 2021
• Managing the Work Environment and Facilities Code of Practice 2021
• First Aid in the Workplace Code of Practice 2021
• How to Manage Work Health and Safety Risks Code of Practice 2021
• Electrical Safety Act 2002 (Qld): s 55 (only licensed electrical workers do electrical work)
• Electrical Safety Regulation 2026 (Qld): s 17 (unsafe electrical equipment is disconnected or isolated)
• AS 4024 (series) Safety of machinery (named only as the Managing Risks of Plant in the Workplace Code of Practice 2021 Appendix D lists it)

What You Get

• An editable Microsoft Word document (16 A4 landscape pages). Type your business, client and job details once and they fill in on every page, with a space for your logo
• 11 job steps for this work, each with its hazards, controls, initial and residual risk scores and the person responsible
• PPE listed for this job: safety boots with toe protection and non-slip soles; safety glasses with side shields in the mould area, and a face shield for purging and clearing the nozzle
• Emergency arrangements for: person trapped in the mould area, burn from molten plastic or a hot surface and hydraulic fluid injection or an oil fire
• Plus the parts every Work Safety QLD SWMS shares, from the s 291 checklist to the worker sign-on sheet (see the layout in our free SWMS template)

Adjust it for your site, plant and crew, and talk it through with your workers before work starts. Please make sure you read our Disclaimer before downloading this SWMS.

Checked against the Queensland laws and codes of practice listed above. Last reviewed November 2026.