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Safety in textile Industry. Shrikant Deshpande Asst Manager (Safety) Gammon India Limited. Departments of Spinning units. Cotton godown Blow room / Mixing Carding Combers Draw frames Speed frames Ring Frame Auto coners Packing Warehouse. Cotton Godown.
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Safety in textile Industry Shrikant Deshpande Asst Manager (Safety) Gammon India Limited
Departments of Spinning units • Cotton godown • Blow room / Mixing • Carding • Combers • Draw frames • Speed frames • Ring Frame • Auto coners • Packing • Warehouse
Cotton Godown • Cotton comes in the textile mills in the form of compressed bales which are stored in the godown and released to the process as and when required • Average weight of cotton bale is 200 to 250 kg • Dimension of bale is 0.75 X0.75X1.25 meter
Cotton Godown • Since the space is limitation so bales are stacked as high as roof height. Either manually and in few cases mechanically.
Hazards in cotton godown • Accidental falling of bales • At the time of stacking ensure that the stack is in adequate equilibrium means it should be such that when one bale is disturbed for unloading the stack should not collapse this is usually achieved by stacking them in along and across in alternate layers like bricks placed in the wall
Hazards in cotton godown • Accident by contact with sharp edges of the straps on the bales. • Fire due to improper wiring • Smoke in the godown due to moving of forklift • Chance s of accidents by fork lift
Cotton opening and blowing • Bales are transported from godown to blow room either manually , or by means of trolleys or by means of forklifts. • Blow room consists of • Hopper openers • Bale breakers • Beaters and condensers • Feeding unit assembly
Cotton opening and blowing • Through pneumatic line section lumped mass cotton in the form of bales is opened , beaten up, torn apart and converted into soft, fluffy lap of cotton. • Here major part is to remove • Stalk • Motes • Some sand • Dust • Etc.
Hazards • Transmission machine parts • Belts • Pulleys • Gears • Shafts • Revolving • Beaters • Spiced lattices or apron • Other moving parts
Cotton opening and blowing process • Generally blow room consists of units of hopper openers , bale breakers, beaters condensers and feeding unit assembly and cotton is transferred from one unit to other by pneumatic section. Using these units the lump mass of cotton in the bales is opened , beaten up, torn apart and converted into a soft fluffy lap of cotton. In this process the major part of impurities such as bits of leaves, stalk, motes some sand , dust etc get removed from the cotton
Hazards in Cotton opening and blowing • Sudden opening of cotton bale results into sudden disengage of steel strap and chances of accident. • Since all the machinery consists of belts , pulleys, gears, shafts and they are rotating so as per The Factories act 1948 all the transmission machinery and other dangerous parts should be made inaccessible by proper guards. • All gears and toothed wheels which do not required frequent adjustment should be fully enclosed.
Hazards in Cotton opening and blowing • Suitable and safe belt shifting device and emergency stopping device should be provided to all the machinery. • On all these machines the beater covers and other openings which provide access to the dangerous parts should be effectively interlocked. • Opening gibing access to dust chambers should be so fenced that while light is admitted to the chambers access to the beater guard is prevented.
Hazards in Cotton opening and blowing • Chances of accidents while releasing chokes and removing dirt from under casing of beaters and such opening must be interlock effictively. • Absence of ladder for reaching on certain points of machine may result into falling of person. • Improper housekeeping also may lead to accident and fire in the cotton textile industry.
Carding machine Carding Machine consists of • Cylinder • Doffer • Licker in • Calendar roll nip • Here cotton comes in the form of lap and leaves the machine as sliver. • Sliver rope is about an inch in diameter and made up of clean while fiber.
Hazards in carding machine • Accident due to cylinder • Interlock guard to be provided to the stripping door on cylinder. Door cannot be open without cylinder stopping and cylinder can not be start without securely closing the stripping door.
Hazards in carding • Accident in licker in • Access to licker in securely closed by panels • Gauging clearance • Clearance between cylinder, licker in or doffer or flat is done by using feeler gauges . AT the time of this activity following steps to be followed in order to prevent accident.
Hazards in carding • 1) Stop the machine before using filler gauge and should never be done when parts of machine is in motion. • 2) Operator should not remove fluff, lint, from moving parts of machine specially from cylinder, licker in doffer and flat.
Combers • In this process cotton in the form of ribbon laps is combed in short length of about 6mm by a series of needles placed on revolving cylinders. . The fiber become longer, straighter and brighter as compare to those in card sliver.
Hazards in combers. • To provide guard to the unguarded transmission parts and other gears • To provide interlock arrangement in order to avoid contact with cylinder needles. • To provide interlock guard to the nipper knife in order to avoid dropping of nipper knife.
Draw Frames • Sliver from comber and carding machine are passed through series of rollers which draw the sliver and render the fiber more parallel and blending and mixing also accomplished.
Hazards in draw frames. • Head stock gears. • Provide interlock arrangement to head stock gears such that machine can not be started without cover and covers can not be lifted without stopping the machine. • Calendar gears to be guarded properly. • Avoid jam to calendar rollers.
Fly Frame / Speed frame • Sliver is converted into roving in this process, sliver through two sets of rollers into a thick soft roving and also impart strength to it by twisting before the roving is wounded on the bobbins.
Hazards in speed frames. A) Gears. • There are large numbers gears which needs fencing on these machine • Lifter rack and pinion should be well guarded so that access to the nip is prevented both when rack lifts and fall. B) Flyers • Injury by hitting the flyer at the time of removing fluff and cleaning work. • Inter locking to be provided at the rotating zone of flyers.
Ring frames. • Roving converted into yarn in this process,
Hazards in ring frame. • Accident while piecing broken ends, operators usually hold the bobbin at its bottom end between their left hand fingers to stop it. Chances of accidents due to sharp edges on bobbin come in contact with fingers causes accident. • 1) Provide finger caps • 2) Educate workers to hold the running bobbins • 3) Provide stopping mechanism such as breaks for individual spindles.
Hazards in ring frame. • Falling of bobbins from creel tops: - While creeling average Indian workers may not reach to the bobbin holder easily and they tstep on the railing which expose them to the serious hazards. • Accidents at the time of handling of Knife. • To remove fluff or waste yarn on rollers operators do use knife. And improper use of knife result into serious cut injury to fingers.
Hazards in material Handling • Sharp edges of damaged cans • Cutting of bale hoop iron band by chisel and hammer may results into injury, proper bale opener should be used. • Maximum material is handled in the boxes and on the trolley so remove jams on the wheels of the trolley on regular intervals to avoid falling of trolley and material boxes to be kept in proper manner. • Wheels of trolleys provided with breaks in order to blocked them at the time of loading and unloading.
Hazards in material Handling • Over loading of trolleys , boxes and treys to be avoided. • material to be stored in proper and allocated position.
Housekeeping } • Nails from bales • Hoop iron strip • Ring travelers • Bobbins on the floor may create hazard and person may fall • Damaged floor may fall trolleys and cans at the time of material shifting • Cans trolleys kept haphazardly on the floor so chances of striking against these objects. May cause injury
Fire hazards • Maintain good housekeeping • Regular maintenance of electrical equipments and periodic checkup is necessary • Risk of overheating of bearings can reduced by providing efficient lubrication. • Day to day monitoring and maintenance of all moving parts • Smoking to be prohibited • Electrical equipments must comply Indian Standard and maintained in safe working condition
Fire fighting appliances • Metal detection and diversion system at blow room • CO2 Flooding system at beaters and carding section • Provision fire doors to maintain sepretion of two departments • Fire extinguishers • Fire hydrant system • Smoke detection and alarm system
Health hazards • Noise • Cotton dust • Exposure to chemicals • Exposure to UV rays • Working in Humid atmosphere
Medical checkup • Pre employment and periodical mediacl checkup • Colour blindness checkup • Noise induced hearing loss • Lung function test
PPE’s to be used • Ear plug • Nose mask • Safety shoes • Goggles for specific jobs • Hand gloves Etc
Safety system requirement • Safety policy • Recruitment of safety officer • Safety committee • Accident reporting investigation and analysis system • Safety audit , inspection and followup for action taken. • Identification of unsafe acts and conditions • Safety training and education • Safety campaign etc…..
