The Client
A major food manufacturing company undergoing an upgrade to their dust collection system for flour silos. The client needed to assess and mitigate the risks associated with combustible dusts to ensure a safer working environment.
The Goal
The goal was to conduct a comprehensive risk assessment in line with AS/NZS 4745-2012, evaluating the potential hazards of combustible dusts within the flour handling system. The client required actionable recommendations to minimise the risk of dust explosions and ensure regulatory compliance.
Why TEG Risk Was Chosen
TEG Risk was selected for their expertise in combustible dust risk management and deep knowledge of AS/NZS 4745. The client trusted TEG Risk’s experience in the food manufacturing sector and their ability to provide practical, safety-focused solutions for dust explosion risks.
Solution
At TEG Risk, our expert team specialises in addressing the complex challenges posed by combustible dusts, with extensive experience across industries like food and beverage, where the handling of materials such as flour introduces significant explosion hazards. For this project, we conducted a comprehensive risk assessment of the flour silo dust collection system, focusing on both the potential ignition sources and the explosive properties of flour dust.
To mitigate these risks, we recommended a suite of targeted safety solutions. One of the key recommendations was the implementation of explosion isolation systems, designed to contain and prevent the spread of explosions to adjacent areas of the plant. This crucial step minimises the risk of chain reactions, which can significantly increase the scale of damage. Additionally, we proposed explosion venting systems, which redirect the force of any explosion safely away from occupied areas, ensuring the protection of workers and critical equipment.
Beyond these physical safeguards, our assessment also included recommendations for ongoing safety procedures and maintenance practices. This included staff training on the dangers of flour dust and how to operate safely within potentially explosive environments. By implementing these comprehensive solutions, our client could mitigate the explosion risks associated with flour dust while maintaining their operational efficiency, ensuring a safer and more productive workplace.
Challenges
The primary challenge was ensuring that the upgraded system would fully address the risks associated with flour dust, which is highly explosive under certain conditions. Flour dust is highly explosive due to its fine particulate nature and the organic compounds it contains. When dispersed in the air, flour dust can form a cloud that, under certain conditions, becomes highly flammable. The key risk arises when the dust is exposed to an ignition source, such as a spark, flame, or even hot surfaces, in an enclosed or confined space. If the right concentration of flour dust is present in the air, it can ignite and cause an explosion.Our team’s expertise allowed us to identify multiple ignition risks within the facility, ranging from the mechanical handling of the flour to the electrostatic discharge from conveyors and fans. We carefully evaluated these risks, analysing how combustible dust could accumulate and potentially ignite under certain conditions.
The challenging conditions that make flour dust explosive include a high concentration of dust particles in the air, sufficient oxygen to support combustion, and an ignition source. Additionally, enclosed spaces, such as silos or dust collection systems, increase the risk of an explosion, as pressure can build up quickly when the dust ignites, leading to a rapid and powerful blast. Proper ventilation, dust control measures, and the elimination of ignition sources are essential to minimising these risks.
Another challenge was designing the mitigation systems, such as explosion isolation and venting, to seamlessly integrate with the existing plant infrastructure without causing significant operational disruptions.
Results
TEG Risk’s comprehensive risk assessment enabled the client to implement effective safety measures for their flour dust handling system. The recommendations, including explosion isolation and venting, significantly reduced the risk of explosions, ensuring the safety of both employees and the facility. The client achieved compliance with AS/NZS 4745-2012, and the upgraded system now operates with enhanced safety measures in place, reducing downtime risks and providing peace of mind.
Are you concerned about explosive dust at your manufacturing plant? Call us today for a full risk assessment, let’s get you safe and compliant.
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