Key points
- Only trained and authorised people should operate a baler
- Check guards, interlocks and emergency stops before every shift
- Never reach into the chamber or try to clear a jam while the machine is live
- Report defects straight away — and don't use a baler that isn't safe
Balers are powerful machines, and most serious incidents happen when someone reaches into a machine that hasn't been properly isolated or when safety devices have been bypassed. A short routine of checks, and a few firm rules, prevents most of them.
This guide is general advice. Every site should have its own risk assessment and safe system of work for its balers, and should follow the manufacturer's instructions.
Who can use the baler
Only people who have been trained on the specific machine, and authorised by the site, should operate it. Training should cover normal operation, the emergency stops, recognising faults, and how to isolate the machine. Keep a record of who is trained.
Before each shift
- Check that guards are in place and undamaged
- Test the emergency stop buttons
- Check that door and gate interlocks stop the machine when opened
- Look for hydraulic leaks, damaged hoses or loose parts
- Make sure warning signs and control labels are present and readable
- Check the area around the baler is clear and the floor isn't slippery
If anything fails, don't use the baler — report it and get it fixed.
During operation
- Never reach into the chamber or feed opening while the machine can operate
- Never climb on the machine or stand in the feed hopper
- Keep the loading area tidy and free of trip hazards
- Stay clear of the bale exit when bales are being ejected — finished bales are heavy and can move unexpectedly
- Use suitable handling equipment for moving bales, and make sure the operator is trained to use it
Clearing jams safely
Jams are where many incidents happen. To clear one safely:
- Stop the machine and isolate it at the main isolator
- Lock off the isolator with a personal lock so it can't be switched back on
- Make sure stored energy is released and moving parts can't drop
- Only then clear the jam, using tools rather than hands where possible
- Remove locks and restart only when everyone is clear
Never bypass safety devices
Interlocks and guards are often defeated "just to get the job done". It's one of the most dangerous things anyone can do with a baler. If a safety device is causing problems, it needs repairing — not bypassing.
The legal side
Under the Provision and Use of Work Equipment Regulations 1998 (PUWER), employers must make sure work equipment is suitable, maintained in a safe condition, inspected where needed, and only used by people who have been properly trained. Where a baler or compactor includes lifting equipment, such as a bin lift, the Lifting Operations and Lifting Equipment Regulations 1998 (LOLER) may also apply.
If you don't have a health and safety specialist on site, our NEBOSH-certified consultants can help with risk assessments and safe systems of work.
Frequently asked questions
What should a daily baler safety check include?
At minimum: guards in place, emergency stops tested, door interlocks working, no leaks or damage, signs readable and the surrounding area clear. Record the check, and don't use the machine if anything fails.
Does PUWER apply to balers?
Yes. Balers are work equipment, so PUWER requires them to be suitable, maintained in a safe condition, inspected where necessary and used only by trained people.
What's the safest way to clear a baler jam?
Stop the machine, isolate it, lock off the isolator with a personal lock, release any stored energy, then clear the jam using tools rather than hands where possible.
This guide is general information to help you understand your equipment. Always follow your machine manufacturer's instructions and your site's safe systems of work, and isolate machinery before any inspection or maintenance.