Workers in plastics and rubber products manufacturing face a considerably higher injury rate than the all-industry average. This sector consistently ranks among the most hazardous for workplace injuries, with tens of thousands of recordable cases each year. Behind these numbers are real people—machine operators, maintenance techs, forklift drivers—navigating high-risk environments where a single missed step can change lives.

The most common—and most severe—injuries in plastics and rubber products manufacturing are not random accidents. They're avoidable incidents: machine entanglements, chemical burns, thermal injuries, and noise-induced hearing loss. Each one disrupts families, operations, and bottom lines.

But here’s the real story: these injuries are not inevitable. A comprehensive safety approach—combining proven protocols, strong culture, and smart use of technology—can dramatically reduce risk. Video intelligence is now a vital part of that toolkit, offering real-time visibility, accountability, and operational insight.

In this guide, we’ll break down the top 4 avoidable injuries in plastics and rubber products manufacturing and, even more importantly, how to reduce their likelihood and impact.

The Cost of Safety Negligence in Plastics and Rubber Products Manufacturing

Workplace injuries carry a heavy financial price in addition to their human cost. In this sector, the combination of direct workers' compensation costs and indirect costs like retraining, downtime, and regulatory penalties adds up to billions of dollars annually. The cost of a single severe injury can be substantial, especially in cases involving long-term care.

These numbers represent stories of avoidable loss. The good news is that such incidents can be avoided with reliable safety systems, vigilant training, and live monitoring.

The Top 4 Avoidable Injuries in Plastics and Rubber Products Manufacturing

1. Machine Entanglement (Caught-in/Between Machinery)

Scenario:
A maintenance worker enters an injection molding machine to clear a jam, skips lockout/tagout, and the line restarts unexpectedly—resulting in severe crushing injuries.

Root Causes & Impact:
Machine entanglement is a leading cause of severe injury in the sector. Many of these incidents are linked to incomplete LOTO procedures and guards that are bypassed or removed. Production pressure and aging equipment without proper interlocks make matters worse. The results include severe injuries, fatalities, and substantial OSHA penalties.

How video intelligence supports:
Video analytics can detect when unauthorized personnel enter restricted zones around machinery. Real-time alerts allow supervisors to intervene before an incident occurs and provide clear video evidence for post-incident investigations.

2. Chemical Burns and Inhalation

Scenario:
During tank cleaning, a worker skips chemical-resistant gloves to “save time.” A splash of benzene or epichlorohydrin causes a severe burn—or the worker inhales toxic vapors, leading to chronic illness.

Root Causes & Impact:
Gaps in PPE use and training are recurring themes.

How video intelligence assists:
AI-powered video analysis can spot missing PPE, such as hard hats and safety vests, in designated areas. It also supports visual reviews to verify that proper chemical handling procedures are followed, helping teams identify gaps for coaching and retraining.

3. Thermal Burns

Scenario:
An operator reaches near a hot extruder or injection molding machine, not realizing the thermal shield is missing. A splash of molten plastic at 300°C causes severe burns on contact.

Root Causes & Impact:
Contact with molten plastic, steam, and hot equipment can result in serious burns requiring hospitalization. These risks are heightened when maintenance shortfalls mean protective shields are absent or emergency shower standards are not met.

How video intelligence assists:
Video analytics can monitor for unsafe proximity to hot zones by defining them as no-go zones and alerting teams when a person enters. In the event of a burn, rapid video review aids in clarifying exactly what happened—speeding up root-cause analysis and response.

4. Noise-Induced Hearing Loss

Scenario:
A technician works near the granulator, where noise hits 97 dBA. Hearing protection is “forgotten” or misused. Over time, the technician develops permanent hearing loss.

Root Causes & Impact:
Noise-induced hearing loss is common where engineering controls are missing. Gaps in PPE compliance and training are frequent, and long-term effects are often overlooked.

How video intelligence supports:
While video systems can monitor for some types of PPE compliance, such as hard hats and vests, they can also support visual reviews of work in high-noise zones to support coaching and reinforce a culture of accountability.

Hurdles and Impact of the Injuries

How Technology Strengthens Injury Mitigation

Machine Entanglement

Safety Obstacle:
Enforcing LOTO and guarding protocols every time, especially under production pressure, is tough. Even a small lapse can lead to a serious incident.

Tech solution: Video intelligence platforms like Spot AI offer live monitoring of restricted zones and machinery. AI-driven alerts flag when personnel enter these hazardous areas, allowing supervisors to intervene on the spot. As a result, post-incident reviews become faster and more accurate.

Chemical Burns and Inhalation

Safety Hurdle:
Ensuring every employee uses the correct PPE and follows chemical handling procedures, every time, is a persistent difficulty.

Tech solution: AI cameras can detect missing PPE, such as hard hats and safety vests, in designated areas. This allows managers to address unsafe behaviors in real time. Video evidence can also help identify training gaps and recurring issues.

Thermal Burns

Safety Obstacle:
Thermal shields can be removed for maintenance and not replaced, or operators may get too close to hot zones in a rush.

Tech solution: Video intelligence can monitor operator proximity to hot equipment by creating no-go zones. Teams can also use video to visually confirm that emergency showers and extinguishers remain accessible. This supports both compliance and rapid response if something does go wrong.

Noise-Induced Hearing Loss

Safety Obstacle:
In high-noise areas, it’s easy to become complacent or overlook proper hearing protection, especially on busy shifts.

Tech solution: Footage from cameras in designated high-noise zones assists safety teams in coaching workers and reinforcing the importance of hearing protection, building a culture where PPE is the norm, not the exception.

Practical implementation of safety technology

Integrating safety technology in plastics and rubber products manufacturing doesn’t mean starting from scratch. Video intelligence platforms are designed to work with your existing camera systems—old or new. Plug-and-play hardware connects on-premises cameras to a secure, cloud-native dashboard, allowing safety, IT, and operations teams to access operational data without overhauling infrastructure.

To get the most value, select solutions that:

• Offer open APIs for seamless integration with your safety management systems
• Include unlimited user access so every relevant team member can participate
• Deliver timely, relevant alerts—not just passive footage archives
• Support compliance reporting and easy searchability for incident investigation

Most importantly, technology should support—not replace—your existing safety programs. This technology supports training reinforcement, streamlines audits, and empowers frontline teams with the information they need to take action.

Partner for a safer plastics and rubber products manufacturing future

Effective safety is about more than avoiding penalties—it’s about creating an environment where every worker feels protected and every leader has the visibility to manage risk. Video intelligence is your ally for live insight, faster investigations, and stronger compliance. Want to see Spot AI in action? Request a personalized demo to discover how video AI can support safety in plastics and rubber products manufacturing.

Frequently asked questions

What are the biggest safety obstacles in plastics and rubber products manufacturing?

The biggest obstacles are machine entanglement, chemical burns, thermal burns, and noise-induced hearing loss. High-speed machinery, hazardous chemicals, and fast-paced workflows increase the risk of serious injury. Most incidents stem from lapses in protocol, skipped PPE, or production pressure.

How can video intelligence help reduce the risk of injuries in plastics and rubber products manufacturing?

AI-powered video platforms offer live monitoring for specific safety events, such as missing PPE (hard hats, vests), and people entering restricted zones. They generate real-time alerts for these events, enabling timely intervention. The ability to quickly review footage also makes incident investigation and root cause analysis much faster and more accurate.

Is it complex to integrate video intelligence with existing camera systems?

Not anymore. Leading solutions, like Spot AI, are designed for plug-and-play integration with your current cameras—whether analog or digital. They utilize on-premise hardware to securely connect video feeds to a cloud dashboard, making deployment simple and minimizing disruption.

How does video analytics support OSHA compliance for plastics and rubber products manufacturing?

Video intelligence assists in documenting compliance with certain OSHA standards by offering video evidence of events. For example, it can detect missing PPE (hard hats, vests) and unauthorized access to restricted areas (no-go zones). This video evidence is valuable for audits, incident investigations, and demonstrating due diligence in safety program enforcement.

What are common mistakes organizations make when implementing safety tech?

Common pitfalls include treating technology as a “set it and forget it” solution, failing to train staff on new workflows, or not involving frontline personnel in the process. The most successful implementations pair technology with strong safety culture, regular training, and ongoing improvement.

About the author

Joshua Foster is an IT Systems Engineer at Spot AI, where he focuses on designing and securing scalable enterprise networks, managing cloud-integrated infrastructure, and automating system workflows to enhance operational efficiency. He is passionate about cross-functional collaboration and takes pride in delivering robust technical solutions that empower both the Spot AI team and its customers.