2.   Safe production of car chemistry

         - PPHU ProElite Andrzej Długosz

Summary

In order to reduce direct exposure to toxic substances used in the factory, PPHU ProElite equipped the station with the canister and bottle fillers. The employer also familiarised his employees with the substance safety data sheets and provide them with workplace and first aid training.

The company

PPHU ProElite is the dominant producer of chemical preparations mainly for cleaning and car care as well as specialist cleaning preparations and household chemicals for the office, catering and industry. It also has got a nationwide distribution chain covering such European countries as Germany, the Netherlands, Lithuania, the Czech Republic, Slovakia, Hungary and others. Customers include all kinds of car washes, garages, automotive and construction shops; transport, cleaning and industrial companies, catering businesses and offices.

The issue

PPHU ProElite is a small firm employing up to 30 employees. Workers often perform many different tasks, work in many positions and perform work entirely manually due to the costs incurred by the employer to maintain the facility.

The issue to be solved is the application of hydrofluoric acid and sodium hydroxide.

Hydrofluoric acid 70% is a very toxic substance. It’s inhalation has a strong caustic effect on the respiratory tract, it can cause sore throat, cough, difficulty in breathing and lung inflammation/embolism. In the tragic case it can cause even death. 

Sodium hydroxide in the form of dust, steam or aerosol causes pain and watery eyes, burning sensation in the nose and throat, coughing, a feeling of suffocation. Contamination of the skin causes pain, redness, chemical burn with blisters and necrosis. Extensive skin contamination can cause shock or collapse. Contamination of the eyes with dust or solution causes the destruction of the eye protection apparatus.

Action taken

The employer applied the optimal solution in consultation with employees and the workplace health and safety service. During internal inspections of the workplace health and safety services and conversations with employees regarding risks and organisation of the workplace, solutions were sought for the protection of employees against harmful (chemical) hazards and workplace ergonomics. Taking into account the STOP principle the workplace health and safety service recommended to apply technical measures before personal protective measures. In order to eliminate the exposure of employees to harmful substances – the employer equipped the station with the canister filler operated by pressing a button and containing a pneumatic screwdriver and bottle filler which takes the product by means of pistons and is controlled only with the foot.

The mixture of substances is prepared in a closed system, substances are delivered to the filler through hose pumps, then they are fed to the bottles with a pedal. At this stage, the substance contains a minimum concentration of acids, which means that the employee is not exposed in the event of contact with the substance. The amount of substance fed into canisters and bottles eliminates contact with the substance.    

Additionally the employees were familiarised with the substance safety data sheets and received workplace and first aid training for work with hazardous substances.

Results Achieved

1. Work in conditions without the direct exposure to dangerous substances as the risk of spillage of the hazardous substances is reduced to a minimum.
2. The assessment of occupational risk at the workplace is at an acceptable level.
3. The probability of poisoning with hazardous substances is low.