RISK ASSESSMENT AND CONTROL MEASURES FOR THE …From the HIRARC results, the medium risk level...

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International Journal of Civil Engineering and Technology (IJCIET) Volume 8, Issue 10, October 2017, pp. 41–55, Article ID: IJCIET_08_10_006 Available online at http://http://www.iaeme.com/ijciet/issues.asp?JType=IJCIET&VType=8&IType=10 ISSN Print: 0976-6308 and ISSN Online: 0976-6316 © IAEME Publication Scopus Indexed

RISK ASSESSMENT AND CONTROL

MEASURES FOR THE PRINTING INK

PRODUCTION PROCESS

Norazli Othman*, Liaw Lerk Lerk, Shreeshivadasan Chelliapan

*, Roslina Mohammad

and Noreen Mohd Ariff

Department of Engineering, UTM Razak School of Engineering and Advanced Technology, Universiti Teknologi Malaysia, Jalan Sultan Yahya Petra, 54100 Kuala Lumpur, Malaysia

Noor Shawal Nasri

Sustainable Waste-To-Wealth, UTM-MPRC Institute for Oil & Gas, Resource Sustainability Research Alliance,

Universiti Teknologi Malaysia, 81310, Johor Bahru, Johor, Malaysia

ABSTRACT

Safety and health are very crucial in the printing ink production process since it

consists of various chemical substances and heavy machines. Risk assessment for

printing ink production is vital as the raw materials used in the production process

exhibit various physical forms of chemicals such as gases, vapour, fumes, dusts, air

borne particles, and powders. This study investigates the assessment on the printing

ink production process in order to evaluate existing and potential hazards and risks

due to the raw material chemical substances. The study was conducted using

qualitative and quantitative approaches. Data were collected through observation of

the printing ink production process as well as Hazard Identification, Risk Assessment,

and Risk Control (HIRARC). Data were also collected from interviews with the

production workers. The result of the study identified nine types of activities that

contribute to the hazards and risks. From the HIRARC results, the medium risk level

hazard for the printing ink production process was 72.3% of the total hazards and

risks identified. However, about 27.3% of the total hazards and risks identified were

regarded as a high risk level hazards. In addition, the results also demonstrated that

the production workers in the printing ink production process were in the range of

moderate to high exposure to hazards and risks. A hierarchy of hazard controls based

on the Department of Occupational Safety and Health (DOSH) were proposed in this

study. The recommended control measures were elimination, engineering and

administration control, and personal protective equipment. This study provided a

comprehensive risk management and enhanced the precautionary and safety

knowledge of employers and employees in handling the chemical substances in the

production process based on Malaysian regulations.

Norazli Othman, Liaw Lerk Lerk, Shreeshivadasan, Chelliapan, Roslina Mohammad, Noreen Mohd Ariff and Noor Shawal Nasri


Keywords: Safety and Health, Control Measures, Risk Assessment

Cite this Article: Norazli Othman, Liaw Lerk Lerk, Shreeshivadasan, Chelliapan, Roslina Mohammad, Noreen Mohd Ariff and Noor Shawal Nasri, Risk Assessment and Control Measures for the Printing Ink Production Process, International Journal of Civil Engineering and Technology, 8(10), 2017, pp. 41–55 http://www.iaeme.com/IJCIET/issues.asp?JType=IJCIET&VType=8&IType=10

1. INTRODUCTION

In most of the industries today, safety and health have become part of the important elements, parallel in achieving the company goal. Safe working environment and practices are important to avoid the occurrence of accidents and ensure optimum work performance. However, accidents may happen any time in any circumstance. Thus, risk assessment in the workplace is important to identify potential risk. Risks and hazards mitigation can minimise the chance for accidents to happen. The implementation of appropriate control measures in the workplace that reduce accidents and contribute to zero loss time injuries record have also become one of the safety goals for most of the companies today.

Risk is defined as the product of the hazard probability resulting in the adverse event multiplied by the severity of the event [1]. Wijeratne et al. [2] reported that risk is simply the probability of a hazard happening. Milczarek and Kosk-Bienko [3] illustrated that risks can be categorised as physical hazards, physical workload, biological hazards, chemical hazards, and psychosocial hazards. Risk is a combination of a harm and the likelihood of the harm to occur [4]. Risk is not only a hazard, but an unsafe practice that can be evaluated [2].

Risk assessment can be defined as an intensive examination of the materials or articles related to or used in a job function that can cause harm. The articles in the workplace that may cause harm and injuries including any solid, liquid, gas or combinations of them [5]. Risk assessment in the workplace has become one of the important duties for an employer under health and safety regulations. The employer is responsible towards the safety, health, and welfare of the employees [6].

The employer is also responsible to assess the risks arising from the use or presence of chemical agents in the workplace [7]. The employer plays an important role to ensure that their employees are not over exposed to high hazard articles and the exposure should be under the permissible exposure limit [5]. For that reason, the employer is responsible to request for exposure monitoring when they suspect any occurrence of over exposures. In order to prevent accidents, emergencies, or work-related ill health, the employer is responsible to determine necessary precautions and control measures [7]. Thus, the protective devices designed to prevent serious bodily injuries to employee are important [6].

Assessing risks in the workplace can form the basis of safety requirements. Safety is the complement or antithesis of risk and risks reduce with the increase of safety [8]. Employees’ risks arise proportionally when the exposure and presence of hazards such as chemical agents or machineries increase. Hazards in the workplace include all articles that are brought into the working area for the purpose of processing or storage, such as raw materials, cleaning agents, machineries, and others. Besides that, substances generated by the work process activity, for instance, fumes, dust, solvent vapours, as well as by-products residues, are regarded as hazardous chemical agents emitted in the workplace. Hazardous chemical agents are considered harmful to workers due to their toxic chemical constituents and exposure severity to workers.

Control measures are the specified and identified writing with sufficient safety control to deal with accidents, emergencies, or ill health with the necessary details, and provide practical

Risk Assessment and Control Measures for the Printing Ink Production Process


procedures to manage health and safety issues in the workplace. The records of the risk assessment and the control measures are the employer and employees’ duties to be fully implemented [7]. Thus, control measures need to be specified to prevent harm. The exposure of hazardous chemical agents can cause serious illness to the extent of death if not properly controlled. However, the effect of chemicals agents can be classified as immediate effect such as eye irritation and long-term chronic illness, or acute effect such as lung cancer. Thus, adequate precautions and control measures are necessary to control any accident in the workplace. The employer is responsible to follow closely in taking the action to control employees' exposure to chemicals hazardous to health [7].

The occurrence of occupational accidents and incidents has increased in parallel with the growth of the industries that deal with heavy machines. Workplace accidents occur almost every day and they have become worse. Besides that, it is known to be a major concern in almost all types of industry [9]. Among all the occupational sectors, the manufacturing sector is listed to have the highest occupational accidents in 2013 and 2014 in Malaysia as reported by the Department of Occupational Safety and Health (DOSH), Malaysia. The occupational accidents cause death (D), non-permanent disability (NPD), and permanent disability (PD). In 2013, the total number of victims reported to be involved in the manufacturing sector accidents are 58, 1,469 and 128, respectively for D, NPD, and PD, as per DOSH report. However in 2014, the numbers of victims reported by DOSH in manufacturing accidents are 45, 1,510, and 112, respectively for D, NPD, and PD. The increasing figure of victims involved in 2013 from 1,655 victims to 1,677 victims in the year 2014 showed that occupational accidents are in an alarming stage.

According to the Malaysian Investment Development Authority (MIDA) [10], the printing ink industry is among the top ten industries that involve the highest number of workers. This is because the printing ink industry is seen as the supporting industry in the main media for knowledge and information to enhance the growth of the manufacturing sector [11]. According to Yon [11], many processes in the printing industry involve hazardous chemicals such as benzene, toluene, xylene, isopropyl alcohol, various inks, varnish consisting of solvents, kerosene, phosphoric acid, mineral oil, dichloromethane and volatile organic compounds (VOC), and many others. In the printing ink manufacturing plant, several huge size machines are involved such as the closed kettles, three roller mills grinding machine, bead mills grinding machine and others. The closed kettles are used to prepare varnish by the transesterification process at high temperatures of 120°C to 260°C for several hours. After varnish preparation, the next step involved is the dispersal of pigments in the varnish system, and followed by the grinding process to form ink [12]. The bulk storage tank used to hold large quantities of the solvent underground in the printing ink manufacturing plant increases the health and safety issue. Thus, risk assessment in the printing ink industry is important to prevent workers from health risks arising from the chemicals in the workplace.

Printing ink consists of dispersions of insoluble colourants or solutions of dyes in a varnish or vehicle system resulting in the combination forms of fluid, which can be distributed and transferred in the printing press. The raw material composition of printing ink is various as shown in Table 1. In the printing ink production process, two steps of the main processes are involved. The printing ink production processes are varnish manufacturing and pigment grinding [13]. Risk assessment for printing ink manufacturers is essential as the raw materials used in the production process exhibits various physical forms of chemicals such as gases, vapour, fumes, dusts, air borne particles, and powders. Volatile solvents that are largely used in the printing ink production process have contributed to great amount of vapour in the production area environment [14]. The high temperature in the varnish cooking process potentially emits hazardous gases and side products. Thus, all processes in the printing ink



production process have contributed to the generation and concentration of hazardous chemicals in the production area atmosphere. Moreover, the persons involved in the production process of printing ink are usually skilled in technical work and this limits their knowledge and awareness when dealing with hazardous chemicals [15]. Hence, to avoid possible employees’ health problems and failure of oversight hazards control in the printing ink production area, risk assessment for the printing ink production process is essential. For that reason, the aim of this study is to assess the risk present in the printing ink production process and increase the safety preventions and health precautions for production workers through appropriate control measures.

Table 1 The raw materials in printing ink [12]

Raw Materials in

Printing Ink Examples

Pigments Yellow pigments, Red pigments, Blue pigments, Black pigments, others

colour of pigments, extender, metallic pigments, fluorescent pigments, etc.

Dyestuff Acid dyes, basic dyes, solvent dyes, disperse dyes

Oils Drying vegetable oil – linseed oils, tung oils, palm oils, soy oils, etc.

Resins Natural resins, synthetic resins, etc.

Solvents Hydrocarbon solvents, petroleum distillates, esters, ketones, alcohols,

glycols, etc.

Waxes Synthetic waxes, petroleum waxes, natural waxes, etc.

Driers Liquid driers, paste driers, etc.

Miscellaneous additives

Chelating agents, antioxidants, surfactants, deodorants, defoaming agents, lacking agents, pure chemicals, etc.

2. MATERIAL AND METHODS

The study was conducted in the production department of the printing ink plant located in the state of Selangor in Malaysia. The plant produces three types of inks, namely sheet-fed ink, cold-set ink, and heat-set ink. The raw materials for these three types of inks are almost similar, but differ in terms of the composition that affects the printing ink drying properties. Risk assessment for hazardous raw materials was performed on the production workers, production supervisors, and any other personnel. They are involved in the production process and are exposed to all raw materials that are used in producing these three types of inks.

The methodology of this study involves data collection on the significant details of the printing ink production process flow. Existing hazards and risks in the printing ink production process were clearly observed and identified via an informative study on the printing ink production process. The data was also collected from interviews with the production workers. The interviews provided information on existing potential risks and hazards in the production process and previous accident records. Based on the observation in the production process, Hazard Identification, Risk Assessment, and Risk Control (HIRARC) were carried out accordingly. The procedure is based on the guideline for Hazard Identification, Risk Assessment, and Risk Control (HIRARC) from the Department of Occupational Safety and Health (2008). Based on the guideline of the HIRARC process, the work activities were classified according to the printing ink production process. Next, the hazards of the work activities were identified in each section along the printing ink production process. From the hazards identified, the risks of the hazards were assessed. The risk evaluation was assessed based on the 5 × 5 matrix calculation. According to Equation (1), the relative risk was calculated based on the likelihood and severity of the risks.



Relative Risk = Likelihood × Severity------ Equation (1)

Likelihood and severity rating depend on the hazards exposed. The values for the rating are shown in Table 2 and Table 3, respectively. The risk relative values obtained are evaluated with the risk matrix as shown in Table 4. The relative risks are classified into high, medium, and low. Table 5 shows the directive action to the relative risks.

The Hazard Identification, Risk Assessment, and Risk Control (HIRARC) are carried out to identify the hazards and risks at the production floor. This is to accomplish the objectives of this study in identifying and evaluating the hazards and risks exposed in the production process. The method proposed is based on the guideline for Hazard Identification, Risk Assessment, and Risk Control (HIRARC) from the Department of Occupational Safety and Health (2008). The entire printing ink production process on HIRARC was observed, identified, and evaluated.

Table 2 Likelihood rating [1]

Likelihood Example Rating

Most Likely The most likely result of the hazard/ event being

realized 5

Possible Has a good chance of occurring and is not unusual 4

Conceivable Might be occur sometime in future 3

Remote Has not been known to occur after many years 2

Inconceivable Is practically impossible and has never occurred 1

Table 3 Severity rating [1]

Severity Example Rating

Catastrophic Numerous fatalities, irrecoverable damage

and productivity 5

Fatal Approximately one single fatality major

property damage if hazard is realized 4

Serious Non-fatal injury, permanent disability 3

Minor Disabling but not permanent injury 2

Negligible Minor abrasions, bruises, cuts, first aid type

injury 1

Table 4 The risk matrix [1]

Likelihood (L) Severity (S)

1 2 3 4 5

5 5 10 15 20 25

4 4 8 12 16 20

3 3 6 9 12 15

2 2 4 6 8 10

1 1 2 3 4 5

Indications: High

Medium

Low

Table 5 The necessary action based on the relative risk value



Risk Description Action

15 – 25 High

A HIGH risk requires immediate action to control the hazard as detailed in the hierarchy of control. Actions taken must be documented on the risk assessment form including date for

completion.

5 – 12 Medium

A MEDIUM risk requires a planned approach to controlling the hazard and applies temporary

measure if required. Actions taken must be documented on the risk assessment form

including date for completion.

1 – 4 Low

A risk identified as LOW may be considered as acceptable and further reduction may not be

necessary. However, if the risk can be resolved quickly and efficiently, control measures

should be implemented and recorded.

3. RESULTS AND DISCUSSION

The printing ink production process is categorised into two steps, i.e. (1) cooking the varnish in the heating process to melt all the resins into paste form; and (2) mixing the cooked varnish cooked with all the colourants, solvents, and additives to form ink paste. The second step of the process includes mixing, grinding, and adjusting processes. The production process stage and the associated hazards and risks in the production process are summarised in Figure 1 and Figure 2.

Based on Figure 1, the procedure for the varnish process starts with the production card issued to the direct production workers that work in the varnish section. The production workers will request the required raw materials based on the production card from the warehouse. Next, the production workers will start weighing the raw materials in the varnish cooking tanker and mix all the raw materials. The varnish cooking tank is secured at the first floor of mezzanine floor. The varnish cooking tank consists of a vertical shaft and blade, which is powered by a motor. There are various sizes from 750kg to 3000kg to be used in the cooking process according to the batch formula. The raw materials are charged in a varnish cooking tank subsequently with the aid of a lifting equipment and a semi-automated machine. The next step is to heat up the varnish cooking tank to 180°C and hold for one hour. The heating process melts all the resins homogeneously in the oil and petroleum distillate system. As the resins are all melted and mixed homogeneously, the next step is cooling at 150°C and the product sample is taken from the piping for quality control check. Once the quality control check approves the varnish, the production workers will pack the varnish in the 200kg tank and label the tank. All the varnish packed in the tanks are recorded in the product inventory record and ready to be used in the standard ink preparation.

From the varnish production process flow, the hazards and risks are exposed to the direct production workers. The production workers who weigh and mix the raw materials are exposed to various types of chemical substances. These chemical substances can be classified as hazardous and non-hazardous. Besides that, the associate hazards and risks exposed to the production workers are the jumbo bags of resin falling from the hoist and the raw materials falling from the drum handle. Lifting during handling the raw material loads may cause posture disorder and ergonomics. Besides that, the rotating shaft of the varnish tank may potentially injure the production workers. Furthermore, the production workers are exposed to fire hazards from the flammable petroleum distillate solvents. Additionally, the production workers are also exposed to various types of chemical substances and the inhalation of



chemical substances in the chemical dust form or the organic vapour may cause health adverse effects. The handling of raw materials can also expose the production workers to skin contamination.

Figure 1 The first step of the varnish production process flow chart with associate hazards and risks

On the heating process of the varnish tank to melt the resin, the high temperature of the process evaporates the solvents and produces the fumes or vapour in the production floor. The chemical fumes that are released in the production floor are rapidly inhaled by the production workers. The high concentration of the organic vapour inhaled may cause lung irritation and respiratory system discomfort to the production workers. Moreover, the high temperature of the varnish cooking tank that heats up to 180°C may produce heat in the production floor. The high temperature causes thermal discomfort to the production workers and overload sweating induces dehydration. During the packing of the varnish, the open piping system to the tank highly exposes the fumes and vapour to the production workers. Besides that, the splashing of



the varnish in high temperatures may burn the skin. As the varnish is packed without cooling it first, thus the high temperature of the varnish may cause thermal discomfort to the production workers.

Based on Figure 2, the second step of the printing ink production process starts with the production card being issued to the direct production workers in the premixing section. The production workers proceed to request raw materials from the warehouse. Next, the production workers start weighing all the raw materials as per production card into the premixing tub. The raw materials, namely varnish, pigment, petroleum distillate solvent, and natural oil, are premixed in the premixing tub. The premix speed is initiated from 400RPM and increased to 1000RPM for about one hour. Next, the printing ink premix base undergoes the grinding process. The grinding process aims to grind all the rough particles of the premix base to achieve the fineness of the ink texture. Next, the production workers in the grinding section will collect the grinded printing ink for quality control check on the ink texture fineness. The process is continued with the adjusting process; at this stage, the additives are added subsequently in the ink to achieve the printing ink standard specification properties. The printing ink adjusting process proceeds with quality control check. Once the printing ink achieves the standard specification properties, the process proceeds to packing and labelling. The printing ink for export market is packed by vacuum packing.

The weighing and mixing processes expose high risks to the production workers. The hazards associated with these activities include the drums or the raw material packaging falling from the hoist. Besides that, the weighing and mixing processes may involve the heavy labour of carrying and moving the raw materials into the premixing tub. This may causes ergonomics to the production workers. Potential injury is involved in the rotating shaft during the premixing process under high speed due to the fact that the premixing tub is not covered with safety grills. The production workers in this section are also exposed to fire hazards from solvents; this is due to the high speed premixing process that produces heat. Under this circumstance, the organic vapour and chemical dust are concentrated on the production floor and inhaled by the production workers. Moreover, the production workers may face the problem of skin contamination as the weighing process is a manual process. Thus, the production workers are highly exposed to all the chemical substances.

The production workers in the grinding process are exposed to the high risk of hand injuries. This is due to the three-roller rotating machines that are operating at high speed and high pressure to crust the fine particles of the pigment. Under the high speed and high pressure process, the heat and fumes are highly formed and saturate the production floor. High concentration of organic vapour and fumes may irritate the respiratory system of the production workers. The production workers increase the risks to crust their hands in the machines when they collect samples for quality control checking. No proper collecting tools are provided to collect the ink samples.

During the adjusting process, the production workers are exposed to ergonomics hazards. This is because the weighing and charging of the additives is by manual process. During the weighing of the additives, the production workers may bend their body to scoop the additives from the drum. This is due to the fact that there are no proper design scoops provided to weigh the additives from the drums. Moreover, the adjusting process that involves the high speed stirring of the additives may expose the production workers to potential injuries from the rotating shaft.



Figure 2 The second step of the printing ink production process flow chart with associate hazards and risks

The work activities according to the first stage and the second stage of the printing ink production process and are shown in Table 6, Table 7, and Table 8. The hazard identification in the printing ink production process is shown in Table 6. The risk assessment for existing risk controls in the printing ink production process is shown in Table 7, while the recommended control measures are shown in Table 9. Table 8 summarises the risk level of the total hazards identified in the printing ink production process.

Referring to Table 6 and Table 7, nine work activities are classified. According to the nine work activities classified, there are 11 safety and health hazards that are identified in the study. Based on Table 8, the highest risk level identified is 20 and the lowest risk level is 6. From the risk analysis, the total risk matrix shows that the risks identified in the printing ink production process are medium and high risks. As stated in Figure 3, the medium risk level hazard is 72.3% and the high risk level hazard is 27.3% of the total hazards and risks



identified. This implies that immediate action for safety control and safety measures are necessary. The recommended control measures of the possible hazards and risks based on the work activities is illustrated in Table 9.

Table 6 Hazard identification in printing ink production process

No. Hazard Identification

Work Activity Hazards Possible Accident/ Health

Adverse Effect/ Person at risk

1. Discharge resin from jumbo bag

into tank

1. Static charge generated from resin and pvc beg

1. Fire caught in the plant

2. The resin fine dust clouds generated

2.The production workers inhaled the resin dust and caused lungs

irritations

2. Discharge solvents

from the tank

1. Static charge generated from the highly

flammable solvents

1. Fire caught in the plant

2. The highly evaporate solvent vapour

2. The production workers inhaled the hazardous or

carcinogenic chemicals solvent vapour

3.

Discharge resin / pigment / additives

to the varnish cooking tank / premixing tub

Loosen bag may entangled and hand draw

in the rotating shaft Hand injury

4. Handling the drums using drum handle

Drum fell and hit to production worker

Foot or bodily injury

5. Lifting the resin

bags Improper lifting technique

cause back pain Muscular lower back pain

(Ergonomic)

6.

Discharging of chemicals

(Pigments and additives)

Inhalation of air contaminants (organic vapour and particulate

dust)

Damage to the respiratory system and central nervous system

7.

Handling of chemicals and

contact of equipment

The contamination surface from the

equipment and also handling of chemical

Skin dermatitis through skin absorption

8. Handling varnish cooking process

High temperature of the production environment

caused thermo-discomfort

High blood pressure and dehydration

9. Packing of the high temperature varnish

High temperature of varnish

The high temperature of varnish splash can cause skin damage



Table 7 Risk assessment in printing ink production process

Risk Assessment

No. Work Activity Existing Risk Control

(If any)

Lik

elih

oo

d

Sev

erit

y

Ris

k L

evel


into tank

Administrative Control

1.Training on fire awareness, static discharge and flammable material

2.Training on bonding and grounding application

3.Safe operating procedures

4. Tool box briefing

5.In house ERT training

6. Fire suppression system inspection

PPE

7. Fire resistance PPE clothing.

3 4 12

PPE

1. Particulate respirators 5 2 10

2. Discharge

solvents from the tank


1.Training on fire awareness, static discharge and flammable material

2.Training on bonding and grounding application


4. Tool box briefing


6. Fire suppression system inspection

PPE

7. Fire resistance PPE clothing.

3 4 12

PPE

1. Chemical vapour valve respirator 5 3 15

3.

Discharge resin / pigment /

additives to the varnish cooking tank / premixing

tub

Engineering control

1.Provide shaft guarding on the rotating shaft Administrative control

2.Training on the safe operating procedures

2 3 6


Administrative control 1.Training on safe operating procedure

PPE

2.Wear of steel toe type safety shoes

4 3 12


bags Administrative control1. Training on the proper

lifting technique 5 2 10

6.

Discharging of chemicals

(Pigments and additives)

Elimination

1. List of chemical substances are banned from use

Engineering control

2. Suction ducting to reduce airborne contaminant Administrative control

5 3 15



3. Training on the safe operating procedures

4. Conduct yearly PPE training

5. Hazard communication

6. Conduct yearly chemical exposure monitoring

7.Conduct medical surveillance

PPE

8. Mask respirator

7.



Administrative control1. Regular housekeeping

2. Training on safe operating procedure

PPE

3.Chemical resistance glove

5 4 20

8. Handling

varnish cooking process

Not Applicable 5 2 10

9.

Packing of the high

temperature varnish

PPE

1. Cotton hand gloves 4 2 8

Table 8 The risk level of the total hazards identified in the printing ink production process

No. of Hazards

and Risks

Identified

Likelihood Severity Risk

Level

Risk

Matrix

1. 3 4 12 Medium

2. 5 2 10 Medium

3. 3 4 12 Medium

4. 5 3 15 High

5. 2 3 6 Medium

6. 4 3 12 Medium

7. 5 2 10 Medium

8. 5 3 15 High

9. 5 4 20 High

10. 5 2 10 Medium

11. 4 2 8 Medium

Figure 3 The risks level of the total hazards identified in the printing ink production process



Table 9 Risk Control (HIRARC) Assessment in printing ink production process

Risk Control Assessment

No. Work Activity Recommended Control Measures


into tank

Isolation

1.Electrical control beards to be isolated from the classified area

Engineering control

2.Conduct audit/inspection on the fire prevention practice

3.Regular check on the bonding clamp cleanliness

4.Conduct the quarterly conductivity check

5. Use antistatic net for jumbo beg

PPE

6. Static dissipative shoe

2. Discharge solvents

from the tank

Elimination

1.Electrical control beards to be isolated from the classified area

Engineering control

2.Conduct audit/inspection on the fire prevention practice

3.Regular check on the bonding clamp cleanliness

4.Conduct the quarterly conductivity check

5. Use antistatic net for jumbo beg

PPE

6. Static dissipative shoe

Engineering control

1. Auto piping system to discharge the solvents to the tank in a closed system


2. Conduct PPE Training

3.

Discharge resin / pigment / additives

to the varnish cooking tank / premixing tub

Engineering Control

1.Redesign and fabricate the full shaft guarding to accommodate all tank size

2.Design and fabricate opening lid with grill

Administrative control

3. Redesign the parameter setting by reduce the fast rotating speed 1000RPM to lower speed


Engineering control

1. Use safety strap to secure the drum

2. Redesign and fabricate the drum handle with stronger grip to hold variances size of drums


3. Inspect the drum handle grip daily

4. Refresh on the safe operating procedure


bags


1.Refresher training on proper lifting technique

PPE

Use of back safety belt

6. Discharging of

chemicals (Pigments and

Engineering control

1. Redesign and fabricate a tight lid to reduce organic vapour emission to the environment Administrative control



additives) 2. Monthly check on the suction effectiveness

3. Set up 5S team to have regular clean up at the work station

4. Trip on immediate spill clean-up if any

5. Retrain on the chemical handling procedures

7.



Engineering Control

1. Design and fabricate auto charging system to reduce chemical direct contact


2. Set up 5S team to improve the housekeeping

3. PPE training

4. Health talk

5. Hygiene awareness

PPE

6. Provide overall safety wears to the production workers

8. Handling varnish cooking process

Engineering Control

1. Install air-ventilation in the varnish cooking section to enhance the good ventilation and comfortable temperature


2. Scheduled frequent break time for the production workers in this section

9. Packing of the high temperature varnish

Engineering Control

1. Redesign the varnish packing system in automation line




PPE

4. Provide overall safety wears, chemical resistant hand gloves, goggles shield mask, and chemical respiratory

4. CONCLUSION

The Malaysian laws and the relevant authority acts enforcement will result in a marked increase of the information that is communicated to the chemical users. This will enhance the safety application of the chemical substances to the users. However, the communication of the information alone will not necessarily lead to improvements in the standards of workplace safety and health. Thus, in conclusion, the responsibilities of the employer and employees to maintain and obey the regulations in the workplace are essential. The relevant authorities shall take action to ensure the regulations and enforcement is up-to-date based on the industrial technology.

ACKNOWLEDGEMENT

The authors thank the Ministry of Education Malaysia and Universiti Teknologi Malaysia for all the supports in making the study a success. Vote: 4F814



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