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Process Safety - Printing/Coating Services
A major international Flexible Packaging Company experienced a catastrophic explosion on a coating process tunnel dryer causing damage to the plant and putting the operators at risk. This event was caused by a source of ignition occurring at the same time as a sudden release of solvent caused by loss of web tension and the web dipping into the coating tray.
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- Although this type of event is rare the consequences are substantial.
- The company owned a similar coating press to the one that failed and production was halted on this press until a full investigation was conducted.
- Following these investigations, Operational was tasked to upgrade the drying systems and install pro-active safety control systems to ensure the safe operation of the process.
- A series of airflow controls; process safety features including explosion relief designed to NFPA Standards and LEL solvent monitoring systems were installed.
- Due to the sensitivity of this situation the new process control and safety systems were inspected and verified independently by Veritas before production was resumed.
- Following these upgrades carried out by Operational both coating presses have subsequently operated without incident.
Outcomes
- Customer: Major International Printing Company.
- Initial Situation: Frequent loss of tension and web dips; Poor safety and process control.
- Solution: Process rationalisation; Dryer technology upgrades; Installation of safety systems.
- Client Benefits: Good process control achieved; High level of safety; Full compliance with Atex and other safety standards.