UNIVERSITI PUTRA MALAYSIA

FACULTY OF ENGINEERING

(DEPARTMENT OF MECHANICAL AND MANUFACTURING)

EMM5616
Industrial safety, health and
environment
Case study proposal

Dr. Lecturer: Ir. Hj. Mohd Rasid Osman

By:
Alireza Rezanoori GS25338
Hamid Reza soltani GS26516
Amin Pouriran GS26201
Amir Sefidgaran GS26378
 Mohd Manfaluti Bin Ahmad GS27453

Contents
Introduction................................................................................................................3
1.1Company background........................................................................................3
1.2 Spinning process...............................................................................................3
1.3statement of the problem..................................................................................6
1.3.1 Justification of the problem.........................................................................7
1.4 Objectives.........................................................................................................7
Literature Review.......................................................................................................8
Machinery................................................................................................................8
Noise exposure........................................................................................................8
Exposure to cotton and other organic dusts (Occupational asthma).....................10
Fire........................................................................................................................10
Methodology.............................................................................................................10
3.1 Machinery........................................................................................................11
3.2 Noise exposure................................................................................................11
3.3 Exposure to cotton and other organic dusts....................................................12
3.4 Fire..................................................................................................................12
References...............................................................................................................13
Introduction

1.1Company background
Mashad Nakh Co. is one of Iran’s leading spinners, specializing in the fields of open-end and
ring. In the open-end field which was established in 1990, owner has combined technologies
from RIETER of Switzerland and SCHLAFHORST of Germany with our own ingenuity to
achieve high quality yarns, ranging from 1 Ne. up to 30 Ne. with variety of cotton, viscose,
acrylic, and polyester and their blends. [19]

Yarn Count (Ne): No of 840 yards yarn weighing in One pound

The ring spinning plant started production in 2003.The mill is capable of spinning ring yarn both
in short and long staple fiber ranging from 36-80 Nm in short, and 12-40 Nm in long staple
spinning. Having invested in the most updated technology from Rieter and Zinser of Germany,
Mashad Nakh is able to offer a variety of products to the market among which 40Nm 100%
Dralon acrylic suitable for the production of Channel, 64Nm dyed acrylic with lycra for the
making of socks, and dyed acrylic roving in all ranges for the production of fancy yarns are
reputable in the market. [19]

Figure 1: plant lay out [19]

The commitment to health and safety is an explicit part of the core values stated in Mashad
Nakh’s corporate responsibility report. A corporate health, safety and environment (HSE)
committee has been in place since 1990. This committee has been headed by the company
president, Reza Badamchi, as the OSHA assessment suggested that a commitment to safety,
health and environment would have to come from the very top of the company. There is also a
section dedicated to the safety of the manufacturing site, headed by a safety unit manager and
staffed with a senior safety engineer, a process safety engineer, a safety supervisor and a safety
technician. These five people are exclusively employed to improve Mashad Nakh’s safety and
report to the health, safety and environment manager. Safe Operating Committees at the
divisional level entrench commitment to these values throughout the hierarchy of Mashad Nakh.
Since 1990, Mashad Nakh has won awards by the National Forum for Environment and Health.

1.2 Spinning process

The process of spinning is essentially nothing more than taking the loose, tangled fibers, drawing
them into a smooth, uniform thread, and twisting the thread to give it strength. This process,
formerly done by hand, is now accomplished by long rows of complicated and expensive
machines in the spinning mill.

The cotton arrives at these mills in the bale. First the iron bands and the wrappings are removed
that the bales may be broken into pieces. Then the cotton is loosened pretty thoroughly, after
which any desired mixing of qualities or varieties is performed. The cotton is then passed
through machines that clean it, remove all impurities, and reduce every lump into a fine downy
mass. Next it is carded, and if of fine quality and intended for the finest goods, it is also combed.
From the carding and combing machines the cotton passes into drawing frames, machines that
begin to draw the cotton out into a thread. It is then ready for the spinning machines where the
final twisting of the yarn takes place. In an up-to-date plant human hands scarcely touch the
cotton from the time it enters the bale breaker until it comes out from the spinning machines a
finished yarn.[23]
Figure 2.Rotor System [20]

Figure 3.Ring System [20]

 Figure 4. Spinning process [22]

The important process stages involved in spinning a cotton yarn are

1. Blow Room

2. Carding

3. Combing Preparatory

4. Combing

5. Draw Frames
6. Speed Frames

7. Ring Spinning

8. Auto Winding

Blow Room process involves in-taking of raw cotton and opening and
cleaning it. Trash particles will be removed from the raw cotton to much of
extent.

Figure 20

Carding process involves again opening and cleaning of the cotton coming out
from Blow Room and carding machine will convert the cotton into a
continuous sliver form.
 Figure[20]

Comber Preparatory processes involves doubling and drafting of multiple card

slivers and converting them into a lap form. This lap will be fed to the next
process called Comber.[23]
 Figure [20]

Comber process involves removal of short fibres and neps from the comber
lap. In comber process, multiple comber laps are processed together, short
fibres and neps are removed and finally multiple slivers coming out from
each machine head are doubled and drafted to a single sliver called comber
sliver.[23]

Figure [20]

Draw Frame process involves doubling and drafting of multiple comber slivers
into a single sliver. In this process cotton fibres are more parallelized and
oriented.
 Figure [20]

In Speed Frame process, the draw frame sliver is drafted into a thin material
called Rove and a minor amount of twist is imparted to it to withstand loads
in further process.

Figure [22]

Ring Frame is the process where the actual yarn formation takes place. Here
the Rove material is again drafted to a very thin strand and considerable
twist is imparted to it to get the final yarn.
 Figure [20]

Auto Winding is the process wherein the single small yarn package formed at
Ring Frame stage is converted into a big package called cone. In this
conversion process, single yarn packages from Ring Frame are taken and
continuously unwound and wound on a package called cone and during this
winding process, faults in the yarn will be cleared with the help of electronic
yarn clearers.[23]

Figure [22]

Rotor Frame (OE Spinning) is the process where the actual yarn formation
takes place. Here the sliver, which drafted for two times, is fed to rotor
groove and considerable twist is imparted to it to get the final yarn.[23]
 Figure [20]

1.3statement of the problem

As machines became larger, speedier and more complicated, they also introduced new potential
hazards. As materials and processes became more complex, they infused the workplace with
potential health hazards. And as workers had to cope with mechanization and the demand for
increasing productivity, work stress, largely unrecognized or ignored, exerted an increasing
influence on their well-being. Perhaps the greatest effect of the Industrial Revolution was on
community life, as workers moved from the country to cities, where they had to contend with all
of the ills of urbanization. These effects are being seen today as the textile and other industries
move to developing countries and regions, except that the changes are more rapid While the
industry has been active in hazard reduction and safety education, spinning machines safety
remains a major concern. The reasons for the concern include the high frequency of accidents
and workers’ compensation claims, the large number of lost work days and the severity of the
accidents. The main reasons for problems that stated include:

• Machinery

• Noise exposure

• Exposure to cotton and other organic dusts

• Fire because the fiber are inflammable

Machinery: The cotton spinning industry, like other processing industries, has many hazards.
Information from workers’ compensation claims indicates that the number of injuries is highest
for the hand/fingers, followed by ear, lung, back/spine, eye, foot/toes, arm/shoulder, leg, trunk
and head injuries. Hazard in relation to a person, means anything with the potential to cause
injury, or harm to the health of the person. Current occupational safety and health legislation
places responsibilities to minimize hazards on everyone involved in the life cycle of the
machinery, from designers to the person finally disposing of the machinery. The most readily
available source of information pertaining to the safe operation of machinery is contained within
the operator‟s manual for the machine. Occupational safety and health legislation requires
(amongst other things) persons who supply machinery to, so far as is practicable, ensure that
persons properly using the machinery are not exposed to hazards. As part of this obligation
suppliers are required to provide adequate information in respect of any dangers associated with
the machinery, the proper maintenance of the machinery and how to correctly use the machinery.
Hazard identification is the process of identifying situations or events that could give rise to the
potential of injury or of harm to the health, of a person.

Noise exposure: Occupational noise exposure is the most significant health hazard present in the
modern industrial workplace. Noise is generally defined as unwanted or undesired sound we are
all expose to noise every day at home, at work and in traffic. If the noise level gets high enough
it can cause problems - including loss of hearing. High levels of noise have been observed in
most of the units engaged in the cotton spinning industry, particularly those in developing
countries. In the long run, exposure to high noise levels has been known to damage the eardrum
and cause hearing loss. Other problems like fatigue, absenteeism, annoyance, anxiety, reduction
in efficiency, changes in pulse rate and blood pressure as well as sleep disorders have also been
noted on account of continuous exposure to noise. Though it causes serious health effects,
exposure to noise is often ignored by spinning units because its effects are not immediately
visible and there is an absence of pain.

Exposure to cotton and other organic dusts: Cotton dust is defined as dust present
in the air during the handling or processing of cotton that result in lung disease, lung cancer,
allergic, sneezing attacks, asthma and related diseases. The workers engaged in the processing
and spinning of cotton are exposed to significant amounts of cotton dust. They are also exposed
to particles of pesticides and soil. Exposure to cotton dust and other particles leads to respiratory
disorders among the textile workers. The fatal disease of byssinosis, commonly known as ‘brown
lung’, is caused among people working in the textile industry on account of excessive exposure
to cotton dust. The symptoms of this disease include tightening of the chest, coughing, wheezing
and shortness of breath. In a study of cotton-mill workers in China, the workers were examined
for atopy, spirometry (forced expiratory volume in one second; FEV1) and airway
responsiveness before starting work and ten weeks and one year later. The major findings were
increased airway responsiveness, particularly among persons with atopy, and an increased
incidence of respiratory symptoms, ten weeks and one year after starting work. The present study
of the same cohort of workers was undertaken with the following major goals:
• to perform a follow-up for a longer period, and
• to compare the remaining workers and those who had stopped working in the mill. After the
termination of the initial study, the findings from a large follow-up study of cotton workers in
China over a 15-year period were reported.5 Results of the two studies are compared below.

Fire: Fire is a serious hazard in spinning company because fiber is inflammable, therefore; all of
the spinning company should have special instrument to protect their company.

1.3.1 Justification of the problem

Total economic costs for spinning machines injuries and health disorders include direct costs
(medical and other compensation) and indirect costs (time lost from work, downtime, loss in
earning power, higher insurance costs for workers’ compensation, loss of productivity and many
other loss factors). Direct costs are easier to determine and much less expensive than indirect
costs. Textile companies are interested to reduce these costs.

1.4 Objectives

The main objective for our case study is to study about the hazards issues for machinery, noise
exposure, dusts and general fire precautions that occur in textile industry especially at the
spinning process. Other objective is to find out some solution for those major problems.

Literature Review
Machinery

Many international safety and health regulations affecting cotton spinning are derived from US
legislation administered by the Occupational Safety and Health Administration (OSHA) and the
Environmental Protection Agency (EPA), which promulgates pesticides regulations.

Hazard Categories
There are many hazards associated with machinery. They fall into three principal categories:
✔ Hazards related to the machinery itself, such as shearing and abrasion and release of
hazardous substances.
✔ Hazards related to the location of the machine, such as stability (could it roll or fall over)
or its proximity to another structure.
✔ Hazards related systems of work associated with the machine, such as manual handling
injuries caused when putting material into the machine.

Common Injuries and Related Situations

The common injuries associated with machines are crushing, cutting, shearing, puncturing,
abrasion (or burns), and tearing (or stretching) or a combination of two or more of these.
However, electric shock, hearing loss, ill health form the release of hazardous substances or from
lack of oxygen and broken bones from falls (slippery or wet surfaces) are also relatively
common. Of course, some of these injuries or events cause amputation or death. The movements
of parts of machines consist basically if rotating, sliding or reciprocating motion or a
combination of these motions. The common situations which result in injury to persons are:
➢ Coming into contact or entanglement with a machine. This could include a person being
drawn into a machine or being drawn into a position where they might sustain further
injury.
➢ Being caught between a machine and material being used in the machine to manufacture
a product.
➢ Coming into contact or entanglement with material being used in the machine to
manufacture a product.
➢ Being caught between a machine or machine part and a fixed structure such as a wall,
column or fixed machine.
➢ Being struck by parts of the machine during failure or break-up of the machine.
 ➢ Being struck by material ejected from the machine.
➢ Being struck as a result of a release of potential energy. [24]

Many of the more modern textile yarn manufacturing mills find it useful to have some type of
occupational safety and health management system in place to control the workplace hazards that
workers may encounter. This can be a voluntary program like the “Quest for the Best in Health
and Safety” developed by the American Textile Manufacturers Institute, or one that is mandated
by regulations such as the US State of California Occupational Injury and Illness Prevention
Program (Title 8, California Code of Regulations, Section 3203). When a safety and health
management system is used, it should be flexible and adaptable enough to allow the mill to tailor
it to its own needs.

Activities related to the maintenance operations of industry specific equipment (e.g. cards,
spinning machinery, looms, and stenters) may expose workers to physical impacts, particularly
with reference to hot surfaces and moving equipment. Prevention and control of these impacts
include the implementation of general protection measures (e.g. machine guarding and lock-out-
tag-out systems and procedures), as described in the General EHS Guidelines.

Safety is a necessity for any textile plant. Around the world, the focus on the safety and health of
employees in the workplace is a growing priority for individuals and organization. In the U.S.,
for instance, the American Society of Safety Engineers (ASSE), the International Safety
Equipment Association (ISEA) and the American Industrial Hygiene Association (AIHA)
recently combined to express a commitment to safe work, which they say must be prominent in a
congressional jobs bill now under consideration. That concentration, first and foremost, protects
a company’s most valuable assets: the employees who knowledgeably keep a plant’s products
and services moving forward. When evaluating an operation for safety, a key area to address is
the mechanical equipment within the plant. There are three important facets of machinery
safety: Making appropriate use of machinery monitoring instrumentation; specifying machinery
design features that contribute to safety; and developing a rigorous machinery safety culture /
program with your staff. [1-8]
Noise exposure
Noise Pollution has been recognized as a major threat to human well being.
Much discussion and legislation has evolved in an attempt to recognize and
combat the problem of noise pollution. It has been recognized that noise, of
sufficient intensity, can damage hearing and be classified as a hazard. In
combating the problem of noise pollution it is necessary to use a means of
measuring noise levels and a system of classification. The decibel is a
number which relates sound intensity or sound pressure. When most people
use the term decibel or discuss noise levels in decibels they are referring to
decibels as related to the “A-weighted” scale or, dBA. [9]

The A-weighted scale parallels the sensitivity of the human ear and uses the
lowest audible sound that the human ear can detect as the reference point
for determining the decibel level of a noise. The reference intensities used
above represent the threshold of audibility where sound is just loud enough
to be heard. At 140 decibels or more acute pain is experienced. Some
common noise values are as follows:

Ordinary conversation – 60 dBA

Heavy traffic – 80 dBA
Cocktail Party – 90 dBA
Moving subway train – 100 dBA
Riveting gun – 130 dBA
Hard rock band – 100 to 138 dBA
Jet plane heard at close range – 150 dBA

Any noise rating above 80 dBA produces physiological effects and any long
term exposures at much or above 90 or 100 decibels will cause permanent
damage to a person’s hearing. An increase of 10 dBA is a doubling of
loudness with respect to the human ear.[10]
The hearing conservation program requires employers to monitor noise
exposure levels in a manner that will accurately identify employees who are
exposed to noise levels at or above 85 decibels (dB) averaged over 8
working hours, or an 8-hour time-weighted average (TWA). The exposure
measurement must include all continuous, intermitted, and impulsive noise
within an 80 dB to 130 dB range and must be taken during a typical work
situation. Two basic types of instruments are available to monitor noise
levels: Sound Level Meters and Noise Dosemeters.
Sound Level Meters: are direct reading instruments that provide a "snap
shot" measurement of noise levels at a particular time. They do not average
noise levels to provide the eight-hour TWA on which OSHA bases its
exposure levels. Noise Dosemeters: measure employee's TWA exposure,
they are physically worn by employees for an entire work shift in order to
record exposure levels. Instruments used for monitoring employee exposures
must be carefully checked or calibrated to ensure that measurements are
accurate. After the initial noise monitoring, OSHA requires that additional
monitoring be performed whenever there is a change in the production
process that may increase noise exposure.[24]
Occupational Noise exposure has been linked with a range of negative health
effects by various researchers. The resulting injury of occupational hearing
loss is also a well recognized and global problem. To protect workers from
hearing damage due to noise exposure and other related health effects, a
vast store of knowledge has been accumulated till date about its nature,
etiology and time course. There is still ignorance, amongst majority of people
working in industries in developing and third world countries including India
about ill effects of exposure to high values of noise. Equivalent sound
pressure level Leq has given in various sections of a plant with the help of a
digital sound level meter. The noise spectrum has been evaluated with the
help of 1/3 octave filter set. A cross sectional study involving 112 workers
exposed to different levels of occupational noise has been conducted. [11]
Meliksah ERTEM et al. [12] shows the comparison of the mean hearing
threshold levels (dB) of control subjects with carpet mill and cotton textile
factory workers. 4000 Hz notch was plotted in carpet mill and cotton textile
workers audiograms in the figure 1.

Figure 4.Mean hearing levels (dB) at different frequencies.

The results of the study establish the fact that noise level in certain sections
of the plants i.e. Loom Shed, Spinning, Ring Frame, and TFO Area is more
than the acceptable limit of 90 dBA for 8 h exposure stipulated by OSHA. The
noise level in other sections like carding, blow room, combing etc., although
is less than 90 dB (A), but is quite higher than limits used for assessment of
noise for community response. Octave band analysis of the noise shows the
presence of high sound level in 4,000 Hz frequency range, which can be a
major reason for causing occupational hearing loss. The results of the
interview questionnaire which included a number of parameters reveal the
following; (i) only 29% workers are aware about the effects of noise on
health (ii) 28% workers are using ear protectors (iii) the satisfaction with the
working environment is related to noise level, as workers exposed to
comparatively less noise level report better satisfaction (iv) 70% of the
workers reported that high noise level causes speech interference (v) 42%
workers report the noise to be annoying. The study thus demonstrates the
presence of gross occupational noise exposure in both the plants and the
author believes that occupational noise exposure and the related effects in
India is a widespread problem.
Audiometric Testing: Should the noise level monitoring determine that
employees are being subjected to levels equaling or exceeding a TWA of 85
dBA, the next step is to establish an audiometric testing program for those
exposed at no cost to the employee. The important elements of an
audiometric testing program include baseline audiograms, annual
audiograms, training, and follow up procedures.
Baseline Audiograms: The baseline audiogram is the reference
audiogram against which future audiograms are compared. Baseline
audiograms must be provided within 6 months of an employee's first
exposure at or above an 8-hour TWA of 85 dBA. Baseline audiograms must
be preceded by 14 hours without exposure to workplace noise.

Annual Audiograms: After a baseline audiogram has been taken, each

employee exposed to noise at the 85 dBA TWA level or above shall have an
annual examination. Annual audiogram must be conducted within 1 year of
the baseline. It is important to test hearing on an annual basis to identify
deterioration in hearing ability so that protective measures can be initiated
before hearing loss progresses. Annual audiograms must be routinely
compared to baseline audiograms to determine whether an employee has
experienced any recordable hearing loss. This hearing loss is reffered to in
the OSHA standard as a standard threshold shift (STS). OSHA defines an STS
as "a change in hearing threshold relative to the baseline audiogram of an
average of 10 dB or more at 2000, 3000, and 4000 Hz in either ear". [24]
If a STS has occurred, employees must be fitted with adequate hearing
protectors, shown how to use them, and required to wear them. Employees
must be notified within 21 days, the employee may be retested within 30
days if the professional determines that their test results are questionable or
if they have an ear problem of a medical nature that is thought to be caused
or aggravated by wearing hearing protectors. If the suspected medical
problem is not thought to be related to wearing hearing protection,
employees must be informed that they should see a physician. If subsequent
audiometric tests show that the STS identified on a previous audiogram is
not persistent, employees whose exposure to noise is less than a TWA of 90
dBA may discontinue wearing hearing protectors. [24]

Exposure to cotton and other organic dusts (Occupational

asthma)
Exposure to cotton dust in industrial environments causes an inflammation in
the airways. This may manifest as changes in respiratory function in terms of
decrease after the work shift and a decrease in baseline. Airway
responsiveness and symptoms are also increased. The most typical of the
symptoms is a sensation of chest tightness on the first day at work that
becomes progressively worse over the years. While many cross-sectional
studies have been done over the years, there have been relatively few
longitudinal studies in which the development of disease has been followed
in a group of individuals.
In a study of cotton-mill workers in China, the workers were examined for
atopy, spirometry (forced expiratory volume in one second; FEV1) and airway
responsiveness before starting work and ten weeks and one year later. The
major findings were increased airway responsiveness, particularly among
persons with atopy, and an increased incidence of respiratory symptoms, ten
weeks and one year after starting work. The present study of the same
cohort of workers was undertaken with the following major goals:
• To perform a follow-up for a longer period,
• To compare the remaining workers and those who had stopped working in
the mill. After the termination of the initial study, the findings from a large
follow-up study of cotton workers in China over a 15-year period were
reported. [13, 14]
Inhalation of the dust generated where cotton fibre is converted into yarn
and fabric has been shown to cause an occupational lung disease,
byssinosis, in a small number of textile workers. It usually takes 15 to 20
years of exposure to higher levels of dust (above 0.5 to 1.0 mg/m3) for
workers to become reactors. OSHA and the American Conference of
Governmental Industrial Hygienists (ACGIH) standards set 0.2 mg/m3
respirable cotton dust as measured by the vertical elutriator as the limit for
occupational exposure to cotton dust in textile yarn manufacturing. The dust,
an airborne particulate released into the atmosphere as cotton is handled or
processed, is a heterogeneous, complex mixture of botanical trash, soil and
microbiological material (i.e., bacteria and fungi), which varies in
composition and biological activity. The aetiological agent and pathogenesis
of byssinosis are not known. Cotton plant trash associated with the fibre and
the endotoxin from gram-negative bacteria on the fibre and plant trash are
thought to be the cause or to contain the causative agent. The cotton fibre
itself, which is mainly cellulose, is not the cause, since cellulose is an inert
dust that does not cause respiratory disease. Appropriate engineering
controls in cotton textile processing areas (see figure 89.8) along with work
practices, medical surveillance and PPE can, for the most part, eliminate the
byssinosis. A mild water washing of cotton by batch kier washing systems
and continuous batt systems reduces the residual level of endotoxin in both
lint and airborne dust to levels below those associated with the acute
reduction in pulmonary function as measured by the 1-second forced
expiratory volume. [17, 18]

Fire
An overview of an explosion that occurred in a textile industry, due to the deflagration of a
particular nylon fibre called flock. The evidence, the methods and the results of the inquiry are
reported. The explosion occurred in a plant that produced a characteristic kind of flocked thread
which is entirely made of a synthetic material. The explosion took place inside a dryer and
propagated to the connected suction plant. [15]
The aim is to use natural fibres as much as possible in order to provide flame retardant properties
in textile materials in order to reduce the hazards of fire during the manufacturing process and
final product. The approach is proposed to use blends of wool with high performance fibres (P-
Aramid) in order to investigate eventual synergistic effect. [16]
Diff. Kinds of Fire Extinguishing Agents
• Water
• Foam
• Dry Chemical
• Dry Powder
• Carbon Dioxide
• Halons (Halon Alternatives)
• Wet Dry Chemical
1- Water:
• Latent Heat Of Vaporization:
• Quantity of heat required to transfer one gram of substances from the liquid state to the vapor
state.
• When water is subjected to heat , temp starts to increase until reaching 100 degree C . Water
boils and starts to vaporize.
• At this temp. (100 C) water absorbs heat from the heating source without any change on its
temp.
• One gram of water can absorb 85 calorie when boiling, and 540 calorie when changed to steam.
• Water is used to extinguish class A fires.
• Water is used on oil tank fires: cooling , and fighting the fire with foam.
• Water is used in automatic sprinkler systems.
 Figure [24]

2- Foam:
• All foam systems consist of the same basic components.
1. The fire water supply
2. The foam concentrate
3. The proportioner (inductor)
4. The foam generator

Figure [23]

Dry Chemicals
• Sodium Bicarbonate
• Potassium Bicarbonate
• Ammonium Phosphate + Ammonium Sulphate.
• Monex (Potassium Bicarbonate + Urea).

Dry Powders
• To be used for extinguishing class D fire (metals).
• Tertiary Eutectic Chloride (T.E.C.)
• (Barium Chloride + Potassium Chloride + Sodium Chloride).
• Tricalcium Phosphate + Sodium Chloride for extinguishing Magnisium fires.
• Boron Trioxide.

Carbon Dioxide
• Pressurized at 750 psi.
• Heavier than air (1.5 times)
• When discharged – expands 450 times (volume) – temp. 80 degree below zero.
• Smothering effect & Cooling Effect.
• Ventilate the area after using Carbon Dioxide.[24]

Figure [24]
 Figure [24]

Methodology

Checklist of hazards in textiles

Mechanical hazards YES NO

Is work equipment and machinery regularly checked to ensure that it works

properly and that the guards and other protective measures are in good
condition and operating correctly?

Are there machines with unprotected or unguarded moving parts?

Are the emergency stops on the work equipment and machinery accessible
and working?
Are there machines where an unprotected or unintentional start-up is
possible?

Noise and vibration

Are there workers exposed to noise which is so loud that they have to
shout to communicate with a person standing 0.5-1 metre away?

Are there noise sources which are not dampened, enclosed effectively or
placed in a separate room?

Is there a lack of noise screens between sources of noise and work areas?

Are there workers who do not use ear-protectors, even when the noise
level is high?

Are workers carrying out tasks that expose them to vibration - either of
their hands and arms, or their whole body?

Does the employer purchase the lowest-noise machines available?

Does the employer purchase the lowest-vibration machinery available?

Chemical hazards

Do workers use hazardous chemicals; for example, those classified as toxic,

harmful, corrosive, irritant, sensitising, carcinogenic, mutagenic, or toxic to
reproduction?
Do workers use hazardous chemicals if material safety data sheets are not
supplied?

Do workers work with hazardous chemicals even if a set of safety

instructions for use has not been drawn up?

Can hazardous chemicals be substituted for ones less hazardous?

Are new workers told of the risks from the dangerous substances in the
workplace?

Are workers aware of the dangers posed by the chemicals they are using?

Do employees work with carcinogenic or mutagenic substances?

Are workers exposed to organic dusts; for example wool, cotton or yarns?

Are there workstations without appropriate collective preventive

equipment, such as local exhaust ventilation?

Are there workers who do not use personal protective equipment, such as
gloves, goggles, face shields or respirators, even if this is required?

Are there workers using hazardous chemicals who have not been trained in
Fire hazards

Are fire precautions in place, operational, and accessible?

Do workers use oxidising, or flammable materials, such as sometimes

found in paints, adhesives and solvents?

Are oxidising or flammable substances or preparations stored in

unventilated rooms?

Are there any sources of ignition; for example, open fire, electrical
equipment, electrostatic charges or high temperature?

Do explosive mixtures arise in work processes; for example, air and gases
such as hydrogen or methane, air and vapour of benzene or acetone?

Are there any areas where there is a risk of explosion; for example, rooms
in which paints or solvents, flammable liquids or gases are stored?

Are there any areas with a risk of explosion as a result of contamination by

stored flammable substances, increased storage temperatures or excessive
quantities of products?

Are there any fire/high temperature/electrostatic field sources in explosive

areas?

Manual handling of loads and prevention of musculoskeletal disorders

Are loads lifted in awkward working positions; for example, far from the
body, above shoulder-height or below knee-height?

Are heavy objects or loads lifted manually; for example, boxes containing
reels of yam, rollers or rolls of cloth?

Are trolleys or other equipment for moving loads kept in good condition?

Do workers have to carry out repetitive tasks, and cannot dictate their pace
of work?

Do workers stand or walk for a long period of time?

Does considerable force need to be used to push or pull equipment such as

trolleys?

Is the floor uneven, sloping, or in other ways likely to make the movement
of goods more difficult?

Are there areas where the pushing or pulling of loads has to be carried out
in cramped conditions?

Do people work in uncomfortable or awkward postures and positions?

Do workers have to make repetitive movements?

Psychosocial and other issues

Are there high levels of absenteeism and staff turnover that may suggest
that work-related stress is present in the workplace?

Is it often necessary for employees to work overtime?

Are workers showing abnormal behaviour such as drug and alcohol abuse,
lack of ability to concentrate, irritability, and depression that may indicate
an issue with work-related stress?

Are employees working under the threat of physical violence?

3.1 Machinery

To reduce machinery risks, the following actions were done by company:

1. Operators were trained, in particular to avoid attempting repairs while

the machinery is in motion, the cause of many of the accidents.

2. Sources of energy (electrical, mechanical, pneumatic, hydraulic,

inertial and so on) were controlled before any repair or maintenance
work is attempted (By maintenance group).

3. The facility was used to identify energy sources.

4. All hazardous energy sources are turned off while working on

equipment was ensured by necessary equipment and trained
personnel.

5. An inspection was performed on a regular basis to ensure that all lock-

out/tag-out procedures are being followed and correctly applied.
 6. Spacing of machinery: Minimum spacing standards were observed. The
risk of accidents is increased if insufficient space is allowed between
the machines.

7. Power transmission devices and most other pinch points were typically
guarded.

8. The machine lay, harnesses and other parts that must be frequently
accessed by spinner, however, are only partially enclosed.

9. Waste handling system is used by company (The central vacuum system is used for
cleaning of machinery, automatically collecting waste from under machinery such as fly
and motes from carding).

Figure 5. Waste disposal box for

discontinuous suction of waste from the
licker-in [22]
10. Emergency button was used around
the machine.

11. Safety sensor was installed on

doors.

3.2 Noise exposure

To reduce noise, company does the following action:

 1. Machinery was well maintained in order to reduce the level of noise. If necessary, certain
parts of machines were replaced.
In case the noise level could not be controlled, workers were provided with ear muffs, ear
plugs and ear canal so that exposure to noise can be reduced.
2. Administrative Controls: Workers were rotated within jobs so that they are not faced
with continuous noise exposure for a long period of time (Diagnosis is duty of company’s
doctor).
3. Medical examinations were conducted by the employers for the workers annually (A
hearing conservation program with periodic audiograms was used). If significant
occupational health problems are observed, appropriate measures were taken by the
management.
4. The workers were trained in the proper use of such protective equipment and supervised
to verify that they are using it (by OSHA officer).
5. Engineering Controls: Are defined as, "Methods of controlling employee exposures by
modifying the source or reducing the quantity of contaminants released into the
workroom environment" is used in company. Examples: installing noise-absorbing
acoustical foam or baffles to capture and deaden reverberating noise.
6. Training: Employees training is very important. All employees exposed to noise at a
TWA of 85 dBA or greater shall participate in a hearing conservation training program.
7. Recordkeeping: An accurate record is maintained of all employee exposure
measurements.

3.3 Exposure to cotton and other organic dusts

Inhalation of the dust generated where cotton fiber is converted into yarn and fabric has been
shown to cause an occupational lung disease, byssinosis, in a small number of textile workers.
To reduce dust risks, the following actions were done by company:

1) There has been proper ventilation at the place of work.

2) In order to reduce the exposure to dust, workers were provided with masks.
 3) In units where there is heavy
exposure to a lot of dusts, workers
were provided with safety
gloves.
4) Proper dust control equipment
was set up and maintained to
reduce the workers’
exposure to cotton dust.
5) Medical examinations should be conducted by the employers for the workers from time
to time. If significant occupational health problems are observed, appropriate measures
should be taken by the management.
6) Dust extraction system for a carding machines and other machine in spinning process

7) The central vacuum system was used for cleaning of machinery, automatically collecting
waste from under machinery.

Figure 6 [22]

3.4 Fire
Fire is a serious hazard, especially in cotton spinning mills.
1) The mill structure and layout was conformed to local regulations governing unobstructed
gangways and exits.
2) Fire-alarm systems are used by company.

Figure [24]

3) Fire extinguishers and hoses are used by company.

 Figure [24]

4) Emergency lights.
5) Cleanliness and good housekeeping will prevent accumulations of dust and fluff, which
encourages the spread of fire, is done weekly.
6) No repairs involving the use of flame cutting or flame-burning equipment is carried on
during working hours.
7) Training of all staff in procedures in case of fire was done.
8) Fire drills, conducted if possible in concert with local fire, police and emergency medical
services, were practiced at appropriate intervals.
9) The rectangular duct was prepared for installation of spark detectors.
References

1. Beck, GJ, LR Maunder, and EN Schachter. 1984. Cotton dust and

smoking effects on lung function in cotton textile workers. Am J
Epidemiol 119:33–43.
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Textile Plants. Bulletin No. 207. Washington, DC: US Public Health
Service.
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Weill. 1991. Exposure-related declines in the lung function of cotton
textile workers. Am Rev Respir Dis 144:675–683.
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Acoustics, pp377
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