Scaling machine safety and hazardous energy control across a large, multi-site manufacturing network is a complex challenge,  particularly when global compliance requirements must be met without disrupting production.

When Coca-Cola Europacific Partners New Zealand was required to complete comprehensive machine risk assessments and hazardous energy control reviews across more than 1,000 machines nationwide, they needed a scalable, structured approach that delivered consistency, clarity, and practical outcomes. TEG Risk was engaged to support the delivery of this programme, ensuring global policy alignment while maintaining operational continuity across CCEP’s New Zealand operations.

The Client: Coca-Cola Europacific Partners – New Zealand (CCEP)

Coca-Cola Europacific Partners – New Zealand (CCEP) is one of the country’s largest beverage bottling organisations and part of the global Coca-Cola network. Operating within the FMCG manufacturing sector, CCEP manages high-volume production and distribution across multiple sites nationwide.

In New Zealand, CCEP bottles and distributes leading brands including Coca-Cola (and its wider product range), Pump, Monster Energy, Keri Juice, and Jim Beam. Its operations span key facilities in Christchurch, Putaruru, Palmerston North, Mt Wellington (The Oasis), and Auckland (Keri Juice) .

As a large-scale manufacturer with a complex operational footprint, effective risk management and strong health and safety governance are critical to its ongoing performance and success.

 

The Goal: Machine Risk Assessments and Hazardous Energy Control Reviews Across Multiple Manufacturing Sites

The Coca-Cola Company (US-based) introduced a new global policy requiring all sites to complete comprehensive machine safety risk assessments and hazardous energy control including Lock Out Tag Out (LOTO) reviews across their operations.

For CCEP, this meant evaluating risks on more than 1,000 machines across multiple manufacturing sites. Beyond identifying hazards, the policy required all tasks that exposed personnel to risk to be clearly classified into defined operational modes and protected by appropriate safety functions or Lockout/Tagout (LOTO) procedures.

The scale and complexity of this requirement presented several key challenges:

• Developing a consistent, standardised assessment approach across all sites

• Producing results in a structured, usable data format for tracking and governance

• Conducting assessments during or around production schedules without disrupting operations

CCEP needed a scalable, practical solution that aligned with global policy requirements while maintaining production performance and operational continuity.

 

Why TEG Risk Was Selected to Deliver LOTO and Machine Safety Compliance at Scale

CCEP required a partner capable of delivering a large-scale machine risk assessment and hazardous energy control programme across more than 1,000 assets, without disrupting production.

TEG Risk was engaged because we brought the capacity, capability, and specialist tools required to deliver at scale. With experienced consultants based in Christchurch, Waikato, and Auckland, we were able to mobilise quickly and complete the programme in a timely manner across multiple sites.

We provided a consistent core delivery team, supported by additional specialists as required. This ensured standardised reporting, aligned methodology, and consistent engagement with site teams, critical for a programme of this size and complexity.

A key differentiator was our proprietary MinRisk platform, which enabled us to complete assessments in full alignment with The Coca-Cola Company’s US Global Headquarters requirements. MinRisk delivered:

• Structured, policy-aligned machine risk assessments

• Clear classification of tasks and safety control requirements

• Consistent, accessible, and data-driven outputs

• Scalable reporting across sites and assets
  

Importantly, CCEP’s Head of Health and Safety, Sam Rogers, was already familiar with TEG Risk’s expertise and approach. As one of the first female Certified Machine Safety Experts (CMSE), Sam has deep technical knowledge of machine safety and understood the scale and complexity of the assignment. She also recognised how MinRisk could efficiently meet the new global policy requirements.

TEG Risk was selected not simply for our resources, but for our ability to combine technical credibility, scalable systems, and practical delivery, ensuring compliance was achieved without compromising operational performance.

 

The Solution: Scalable Machine Risk Assessments and Hazardous Energy Control Implementation

Delivering more than 1,000 machine risk assessments across multiple manufacturing sites required a structured and scalable approach aligned to The Coca-Cola Company’s global policy requirements. TEG Risk integrated these policy expectations directly into our established methodology, ensuring assessments were both technically robust and compliant with US Headquarters standards.

Rather than assessing machinery in isolation, we focused on identifying every task that exposed personnel to machinery-related risk. Each task was classified by operational mode, such as production, cleaning, or maintenance,  and assessed against required safety functions or LOTO controls. This created a comprehensive, task-based risk profile across CCEP’s assets, giving the business clear visibility of exposure points and control requirements.

All findings were captured within TEG Risk’s MinRisk platform, providing CCEP with structured, consistent, and data-driven outputs. The system enabled site teams to analyse risks by machine, task, production line, or location, and supported mobile access for maintenance personnel needing hazard and isolation information in the field. Importantly, the outputs were not simply compliance records, but practical tools to strengthen day-to-day risk management, such as LOTO.

To minimise disruption, assessments were delivered in stages. Teams worked on site for defined periods, coordinating closely with production schedules. Reporting was released progressively by line and site, allowing CCEP to review findings, prioritise actions, and implement improvements without impacting operational performance.

This approach ensured global compliance requirements were met while maintaining production continuity and creating long-term visibility of machine-related risk.

 

The Challenges: Managing Complexity Across Scale, Sites, and Timeframes

Undertaking machine risk assessments and hazardous energy control reviews across more than 1,000 assets, multiple production sites, and active manufacturing environments is inherently complex. The scale of the programme, geographic spread of facilities, and requirement to work around live production schedules could have presented significant challenges in consistency, coordination, and data management. However, these factors were manageable due to three key enablers.

First, TEG Risk’s MinRisk platform provided the structure and data capability needed to handle a programme of this size. The system ensured consistency in methodology, simplified large-volume data capture, and enabled clear reporting across sites and production lines.

Second, the technical expertise of our team meant the policy requirements, machine safety standards, and hazardous energy control expectations were well understood from the outset. This reduced ambiguity, avoided rework, and ensured assessments were completed efficiently and accurately.

Finally, with experienced consultants located across Christchurch, Waikato, and Auckland, we were able to access sites nationwide and coordinate delivery without delay. This national footprint supported timely execution while maintaining a consistent core team approach.

While the programme was large in scale, the combination of specialist capability, digital tools, and geographic coverage ensured it was delivered in a structured and controlled manner.

 

The Results: Achieving Global Compliance and Reducing Machine-Related Risk

The programme delivered full alignment with The Coca-Cola Company’s global machine safety and hazardous energy control policy across CCEP New Zealand operations. Every machine within scope was risk assessed, and all tasks involving machinery-related exposure were clearly identified and classified by operational mode.

This provided CCEP with a complete, structured view of machine-related risk across more than 1,000 assets,  something that had not previously been consolidated in a single, accessible format.

Importantly, the outputs went beyond compliance documentation. TEG Risk delivered prioritised data files identifying remedial actions, ranked by risk level. This enabled CCEP to focus immediately on high-priority controls and quick wins, addressing critical gaps with urgency and minimising risk to staff.

The staged delivery of results allowed sites to begin implementing improvements as assessments were completed, rather than waiting for programme closure. This accelerated risk reduction, strengthened hazardous energy control practices, and enhanced overall machine safety governance.

As a result, CCEP not only met its global policy requirements but also gained a practical, data-driven foundation for ongoing risk management, continuous improvement, and safer production operations.

This project demonstrates how the right combination of technical expertise, national capability, and digital risk tools can turn complex global compliance requirements into practical, site-level safety improvements.

If your food and beverage manufacturing organisation is facing large-scale machine risk, hazardous energy control, or critical risk management challenges, TEG Risk can help you implement structured, data-driven solutions that deliver clarity, compliance, and measurable risk reduction. For machine safety consulting Contact Hamish or the TEG Risk team today to discuss how we can support your machine safety and risk management objectives.

 

FAQ’s

1. What is a machine safety risk assessment and why is it important for large-scale manufacturers?

A machine safety risk assessment is a structured process used to identify hazards, evaluate risk levels, and determine appropriate safety functions or control measures for machinery. For a large-scale manufacturer operating across multiple production sites, machine risk assessment is critical to ensuring machine safety compliance, protecting workers from harm, and aligning with recognised machine safety standards.

In high-volume environments such as food and beverage manufacturing, risk assessments must also consider different operational modes (e.g., production, cleaning, maintenance) and ensure that appropriate lock out tag out procedures and safety functions are in place.

2. How can organisations manage lock out tag out (LOTO) compliance across multiple sites?

Managing lock out tag out compliance at scale requires a consistent methodology, centralised data capture, and clear task classification. Each task involving hazardous energy exposure must be identified, assessed, and linked to defined lock out tag out procedures or engineered safety functions.

Digital tools, such as structured machine safety consulting platforms, enable organisations to standardise assessments, maintain accessible data records, and prioritise remedial actions. This approach is particularly important in food and beverage manufacturing and the wider safety in manufacturing industry context, where operational continuity must be maintained while improving risk controls.

3. What are the benefits of a data-driven machine safety compliance programme?

A data-driven machine safety compliance programme provides more than regulatory alignment, it creates visibility and control across complex operations. By consolidating hazard identification and risk assessment information into a structured system, organisations can analyse risks by site, machine, or task and prioritise critical improvements.

For large-scale manufacturers, this leads to faster implementation of safety controls, improved machine safety standards compliance, reduced exposure to hazardous energy risks, and stronger governance oversight. Over time, this structured approach supports safer production environments and more sustainable operational performance.