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Col-Tec Overseas
Horizontal collators automate print finishing with precision and speed. However, their moving parts and high-speed systems demand a strict safety-first approach. Each year in the UK, avoidable incidents caused by removed guards or missed checks disrupt production and put staff at risk. Sadly, in busy environments, safety can often become an afterthought, but the consequences can be severe.
At Col-Tec, we design and manufacture various types of collators with operator safety in mind. This includes features such as emergency stops, sturdy safety covers, and easy-to-service layouts. We also have six engineers set aside for installation and service work. This guide outlines practical, regulation-aligned safety steps. So you can help reduce risk, improve compliance, and protect both people and productivity.
Whether you run a factory or handle equipment buying, this article will help you ensure safe and efficient collating.
Collator machines pose several risks if not operated with care. The most common hazards include contact with moving belts or feed rollers and entrapment during jam clearance. In addition to this, we often hear reports of electric shocks from poorly maintained components. These risks increase when machines are used without training or are not subject to regular inspection.
Under the Provision and Use of Work Equipment Regulations (PUWER), employers must:
The Health and Safety Executive (HSE) note that inadequate safeguarding and a lack of training contribute to workplace injury across the manufacturing sector.
In print finishing, even small mistakes, such as missed interlocks or incorrectly set guards, can lead to big problems. That is why understanding and addressing these risks is the first step towards operational safety.
For more information, view the HSE’s official guidance on machinery safety.
Trained staff must inspect the collator machine before starting their shift. This includes both a visual check and a functional test.
The process should include:
These checks help prevent injuries caused by misalignment, unexpected movement, or mechanical failure. Operators should also ensure that the working area is clear of clutter, slip hazards, and any foreign objects that could be pulled into the feed.
Where applicable, Col-Tec offers machine-specific maintenance schedules and service agreements. These enable qualified engineers to review lubrication, power integrity, and system alerts on a regular basis. This helps ensure long-term operator safety and boosts machine performance.
Practical training helps ensure that collator machines are operated safely and consistently. All operators must receive instruction from qualified personnel. They must not only learn how to use the machine but also how to respond in the event of a fault or stoppage.
Operators must never turn off or bypass safety devices, such as interlocked guards and emergency stops. Doing so is a direct violation of PUWER and significantly increases the risk of injury. Operators should also avoid loose clothing, jewellery, or accessories that could get caught in moving parts.
At Col-Tec, we recommend that all staff receive refresher training when new machines are installed or when production requirements change. Failing this, supervisors and health and safety officers should reinforce protocols regularly anyway. They should also ensure that signage and safety instructions remain visible and up to date.
Should a collator machine jam or malfunction during operation, it must be stopped immediately. In such a situation, operators should use the emergency stop button. They should then wait for all moving parts to come to a complete halt before attempting any inspection or removal of material. Power must be isolated at the control panel before accessing internal sections of the machine.
Modern collator systems, like those from Col-Tec, incorporate numerous built-in safety features. These are designed to prevent and respond to such incidents and may include:
These engineering controls ensure the safe operation of the machine. They are vital for both Col-Tec horizontal collators and general ones.
Routine servicing is vital not only for performance but for sustained operator safety. As machines wear down, it’s essential to inspect and clean parts such as belts, motors, and control panels. Replace them when necessary.
Qualified engineers should handle all servicing. They must use original equipment manufacturer (OEM) parts. This ensures the integrity of the machine’s design is maintained and reduces the risk of future failure. Unrecorded changes or informal adjustments can lead to new dangers. They can also avoid safety systems without the operator being aware.
Col-Tec offers customised service and support agreements tailored to businesses. These agreements ensure reliable maintenance for all their equipment and include:
In high-speed print environments, procedural lapses can result in downtime or operator injury. Therefore, safety in collator machines is both a common-sense and regulatory requirement. It is what ensures reliable performance, keeps workers safe, and helps equipment last longer.
At Col-Tec, we take a comprehensive approach to safety. Our horizontal collators are engineered in the UK with advanced safeguards as standard. This includes emergency stop systems, guarded feeds, and easily accessible maintenance points. However, effective safety also depends on how machinery is used. That is why we support every installation with expert servicing and operator training to embed good practice from day one. Safe print finishing requires well-designed equipment and reliable procedures. Are you looking to enhance your collating process with systems designed to prioritise operator safety?
Call +44 ( 0 ) 1425 627755 or get in touch with Col-Tec today for a no-obligation consultation.
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