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5 Ways to Prevent Industrial Fires and Explosions

According to the NFPA, between 2011 to 2015, an average of 37,910 fires occurred at industrial and manufacturing facilities each year. These industrial fires resulted in 16 civilian deaths, 279 injuries and over $1 billion in direct property damage. While the fires occurred for many reasons, a key one was because managers and employees were not aware of the various risks within the facility. 

Fires are a serious issue, and prevention is key in avoiding injury, death and property damage. A major part of prevention is knowing the risks within your facility and how to manage them properly. Since fires and explosions are usually preventable, the consequences that facilities face for these incidents are severe. In one case, a worker was injured while working on a dust collector that caught fire, and OSHA fined the company nearly $150,000

Here are the common causes of fires and explosions within facilities — and how to avoid them.

Causes of Industrial Fires and Explosions

1. Combustible Dust

The biggest cause of fires and explosions within industrial facilities is combustible dust. Combustible dust can be found in many industrial facilities, from food processing plants to chemical plants. It is defined by OSHA as a solid material composed of particles that can present a fire or explosion hazard. The dust, when combined with oxygen and an ignition source, can result in a fire. 

If the dust is dispersed in an enclosed area, then there is also the potential for an explosion — which is difficult to contain and can lead to secondary, larger explosions. 

2. Hot Work

Traditionally, hot work is thought of as welding and torch cutting. However, it also includes other procedures, like brazing, burning, heating and soldering, which all create the potential for industrial fires. 

The risks occur due to the sparks that hot work equipment creates, and molten materials that can reach beyond 1,000ºF and travel more than 35 ft. The sparks and heat from hot work, combined with combustible dust, leads to many industrial fires and explosions. 

3. Flammable Products

Another common way for an industrial fire to occur is because of flammable liquids and gasses. These types of fire usually happen in chemical plants, as they work with highly flammable products such as fuel, acrylic acid and crude oil. 

When these products come into contact with an ignition source like electrical plugs, hot work and sparking equipment, it results in fire or combustion — and these are some of the most dangerous fires and explosions. 

In 2010, an explosion at Kleen Energy Systems power plant in Middletown, CT, was caused by natural gas, resulting in 6 deaths and 50 injuries. As a result of this massive explosion, OSHA proposed $16.6 million in penalties for an alleged 370 workplace safety violations.

4. Faulty Equipment and Machinery

Another threat to fire safety that industrial facilities face is from faulty equipment and machinery. Any equipment used to heat products or perform hot work can lead to an industrial fire, especially if the equipment doesn’t work properly. Furnaces are an especially big culprit for causing fires and explosions. 

When equipment is not installed or operated correctly, or properly maintained, it becomes a serious risk to industrial fire safety. Equipment with moving parts pose an extra risk as those parts can lead to friction and sparking, which can create a fire or explosion, especially if combined with combustible dust.

5. Electrical Hazards

Electrical hazards that can lead to industrial fires include things like:

  • Exposed wiring
  • Wiring that isn’t up to code
  • Overloading outlets and circuits
  • The use of extension cords
  • The presence of static discharge. 

Any of these hazards can result in sparking, which can become an ignition source for things like combustible dust and other flammable products. Any damage you can experience from electrical hazards can compound quickly, especially if more than one hazard is present at a time.

How to Prevent Fires and Explosions 

1. Conduct a Hazard Analysis

A Dust Hazard Analysis (DHA) is one requirement of NFPA 652, known as the Standard on the Fundamentals of Combustible Dust. It is a tool meant to help improve industrial plant safety by determining combustible dust hazards, so that facility owners and managers can improve their industrial fire safety. 

While it is a standard specified for NFPA 652, a DHA is useful for inspecting the entire facility for hazards. It will help to pinpoint what areas of the facility pose the greatest risks in safety, and help determine how to improve and eliminate those risks which will allow you to make your facility safer and help avoid serious fines and penalties from OSHA.

2. Train Employees in Fire Safety

Training, in general, is critical for employee safety, and especially to help avoid industrial fires. Industrial fire safety training should include general and job-specific safety. Employees should be educated in: 

  • Causes of fires and explosions
  • How they spread 
  • Spotting hazards
  • Handling and storing flammable materials. 
  • How to prevent fires 

Fire prevention should also cover the proper cleaning techniques to ensure that materials like combustible dust do not linger where they can pose a danger. Fire safety training should also include what to do in case of a fire, from extinguishing to safe evacuation of all personnel. 

3. Practice Good Housekeeping

The fire safety industry also states that good housekeeping is essential in preventing fires and explosions. OSHA has Good Housekeeping Guidelines that facilities are required to follow by law. These guidelines are for maintaining a clean, safe and sanitary facility. They include:

  • Keeping paper and other flammable goods away from electrical and heat sources.
  • Keeping flammable products safely contained.
  • Reporting problems or issues with equipment as soon as possible.

The use of the correct certified cleaning equipment is also a critical part of OSHA Guidelines. While there are different types of equipment, industrial vacuums are essential to keeping facilities clean, and HafcoVac offers high-quality, certified industrial vacuums ideal for preventing fires and explosions. 

Since housekeeping guidelines are mandatory, failure to comply can result in serious fines. 

4. Establish a Fire Prevention Plan and Emergency Procedures

It is critical to have a fire prevention plan and emergency fire procedures in place. An industrial fire safety plan needs to cover everything fire-related, and all employees must be educated in the prevention and emergency plans. 

It should include a detailed evacuation plan that explains what employees should do and where they should go in case of an industrial fire. The plan should be accessible to everyone, and it should be practiced so that employees can better understand what they should do in such situations. 

It is also vital to keep these plans and procedures up-to-date and always update employees on the procedures. 

5. Inspect and Maintain Your Equipment and Facility

Poorly maintained equipment is a large factor in industrial fires and explosions. A major part of what the fire safety industry calls for is inspecting and maintaining all equipment within the facility. 

Regularly scheduled checks and maintenance need to be done to ensure the equipment works properly and efficiently. Any motors or moving parts should be lubricated to ensure there is no friction that can lead to sparking and fires. 

Inspections should be done at least twice a year — or more, for frequently used equipment — and it should cover all parts of the facility, including sprinklers and fire extinguishers. Any needed repairs should be done immediately. 

Preventing Industrial Fires and Explosions

While industrial fires and explosions are unfortunately very common, they are usually entirely preventable. There are many potential risks, and when combined, like hot work and combustible dust, those risks become more serious. Preventing fires is critical to fire safety for industrial facilities. It helps to prevent serious incidents within the facility and also avoids fines and penalties from OSHA. 

The steps above are some of the most critical preventive measures you need to take in order to meet the standards of OSHA and keep your facility safe.

To help keep your facility clean and up to code, get in touch with HafcoVac for more information on explosion-proof vacuums.

The Most Overlooked Combustible Dust Risks in Food Facilities

Combustible dust is defined by the Occupational Safety and Health Administration (OSHA) as solid material comprised of distinct particles, regardless of their shape, size or chemical composition. 

Combustible dust is extremely hazardous and can create flash fires and explosions when it is suspended in the air and comes into contact with oxygen and a heat source. Depending on the severity, these fires and explosions can lead to serious worker injuries and even death. 

The risks from combustible dust are an issue in many processing industries, including the food industry. In fact, according to the 2019 MidYear Dust Incident Report released by DustSafetyScience, between January and June, 30 percent of all combustible dust incidents were related to the food industry.

What Are Combustible Dust Risks in Food and Grain Facilities?

Dust from flour, grain, sugar, alfalfa, herbs, hops, pulp and more are considered combustible in food facilities. Grain dust is particularly explosive when it becomes airborne or accumulates near an ignition source. 

According to OSHA, over 500 explosions have occurred in grain handling facilities across the US in the past 35 years. These explosions have resulted in 180 deaths and 675 injuries. According to DustSafetyScience, dust collectors, storage silos, elevators, conveyor systems and boilers also posed safety risks in facilities, due to accumulated dust. However, these are just the most common places to look for combustible dust: There are still many other overlooked dust risks within food facilities.

The Most Overlooked Dust Risks 

Food processing facilities, like most facilities, collect more dust than most people realize. It is when these risks are overlooked that potentially serious hazards may arise. Areas of high dust accumulation risk include:

Walls

Walls are likely the most overlooked risk in food facilities. Because combustible dust can be generated by a wide range of sources, anything from flour to pulp dust raises the risk of a hazardous situation. 

This dust can get into the air and stick to the walls very easily. If the walls are not cleaned regularly, that dust will steadily accumulate until it becomes a serious safety issue that can result in a fire or explosion.

Vents and Small Spaces

Another area of combustible dust accumulation risk often overlooked in food facilities are the vents and other small spaces. Like with walls, dust suspended in the air can travel and stick to vent covers, which can then push some particles back into the air if the vent gets clogged. 

Even if they are unclogged, dust can also travel through vents to other parts of the facility, which can lead to issues of cross-contamination. The dust can also end up near heat or electrical sources, which poses a serious fire and explosion risk.

Heat and Electrical Sources 

One of the key components to dust fires and explosions is a heat source. If dust penetrates these areas where heat is present, or where friction with moving parts can cause sparks, it creates the perfect environment for a dangerous situation. There are countless heat and electrical sources within food facilities, so the risk of dust penetrating these machines is incredibly high. 

Dust Collection and Storage Devices

Another area of overlooked dust risk is dust collection containers and storage devices, like dumpsters, storage containers and silos. These are areas of a facility that are sometimes poorly maintained and are rarely inspected. 

As a result, waste, products and dust can leak through and travel in the air to other areas of the facility. That airborne dust can end up anywhere, including an area where the risk of combusting is more likely, such as near heat or electrical sources.

Misaligned Conveyor Belts

A misaligned conveyor belt can also create a hazardous situation when combustible dust is concerned. When a conveyor belt becomes misaligned, it does not run as smoothly, which creates friction. 

Friction can end up leading to sparks, which can land on any of the material on the belt — products that may still have dust residue on them — resulting in a fire at best and an explosion at worst. 

In 2019, an explosion occurred at an Indian grain factory when raw material was being transferred from the boiler to the mechanical belt. The explosion left one person dead and nine others injured.

How HafcoVac Can Solve These Issues

Combustible dust risks in food facilities are plentiful. For that reason, it is important to maintain a clean, dust-free facility according to the guidelines set up by regulatory agencies like the National Fire Protection Agency (NFPA) and OSHA. 

Both of these organizations are dedicated to ensuring the safety of facilities, workers and products. They have various safety guidelines and regulations that facilities are required by law to follow. 

For combustible dust, OSHA and NFPA standards look at every aspect of facilities and determine the best safety practices possible from identifying hazards to management and minimizing risks. One of the key standards is NFPA 652: Standard on the Fundamentals of Combustible Dust. NFPA 652 requires facility owners and operators to make certain changes to minimize combustible dust hazards within their facility. 

While there are various requirements to meet compliance with these standards, one easy fix is to invest in the right industrial vacuum as part of your overall housekeeping plan for your facility.

HafcoVac offers various industrial vacuum models that are made in the USA and meet the strict NFPA and OSHA standards. The vacuums from HafcoVac are NFPA 652, 664, 484, 70 and 61 compliant, which cover different aspects of fire, dust and other combustible material safety. 

HafcoVac vacuums run on compressed air and are certified for combustible dust and use in hazardous environments. Compressed air vacuums are unique because they have no motor, so there are no moving parts inside and do not need electricity to run. As a result, there is no risk of a motor arcing, creating friction or sparking, which can lead to fire or combustion.

Avoiding Combustible Dust Risks

Food facilities have countless combustible dust risks–many of which end up overlooked in favor of other risks. However, each risk, no matter how small it may seem, has the potential to result in a very serious and hazardous situation. 

Identifying overlooked risks, correcting them, and managing them per OSHA and NFPA standards, will help ensure a safe and compliant facility. Recognizing the areas of risk and cleaning them appropriately, using an approved industrial vacuum, is just one of the many steps to take.

If you need a certified industrial vacuum, contact us today. Our representatives can answer all of your questions and provide recommendations based on your specific requirements. You can even get same-day shipping, so you can get started right away protecting both your workers and your business.

HafcoVac COVID-19 Statement

HafcoVac is an Essential Business and remains OPEN and PREPARED to keep your facility SAFE

We supply many essential industries, including the food industry, manufacturing and warehousing industries, and municipal rail industry. As such, we remain in operation during this complicated time. We are open and ready to handle your product inquiries and orders. We are shipping every day to make sure you get the certified safety equipment you require, and customer service and support you’ve come to expect.

We are keeping our own facility safe, with our on-site staff following the hygiene and cleaning standards set out by the CDC, and staff working remotely whenever possible. Our sales, customer service, warehouse, shipping and receiving teams are fully operational.

Hafco has been in business for over 50 years, and we have gotten through many difficult times by maintaining our commitment to our customers, and the quality of our products. We are here to receive your phone calls and emails. As always, you can rely on us to keep safety first.

Thank you for your business,
Basil and Billy Fornaci
Co-Presidents, HafcoVac

Cleaning Hard to Reach Spaces in Your Industrial Facility

All industrial facilities are subject to regulations and standards set by government organizations. The National Fire Protection Agency (NFPA) and the Occupational Safety and Health Administration (OSHA) are just two organizations dedicated to ensuring the safety of industrial facilities. 

While the NFPA focuses primarily on fire safety and prevention, OSHA covers a broader range of health and safety concerns. Both agencies share a common goal when it comes to industrial housekeeping standards, however: mitigating the risks caused by fugitive combustible dust. 

Failure to meet their combustible dust requirements can lead to the complete suspension of operational activities, hefty financial penalties, or both. As of January 15, 2020, OSHA reported an initial maximum penalty of $13,494 per violation

While dust accumulation in your facility may seem like a minor safety concern, it can pose serious health and safety risks if handled improperly. This is especially true when combustible dust collects overhead and in other hard-to-reach places. When fugitive combustible dust becomes suspended in the air in a confined area with sufficient concentration, it can quickly become a recipe for a dust explosion. 

In order to meet increasingly stringent safety regulations, these overhead locations must be thoroughly cleaned, a process that typically requires specialized high-reaching housekeeping tools such as pipe brushes and extension wands.

Why a Clean Facility Is Important

1. It’s a Safety Factor

In an industrial facility, any mess can become a safety hazard, no matter how small or insignificant it seems. This is especially true with dust, which can quickly become combustible under the right conditions and in the right environment. 

Combustible dust comes in many forms, from food dust like sugar and flour dust to metal dust and powder. When dust comes into contact with oxygen, heat and a fuel source, a fire can occur; and when that dust is dispersed in a confined space, it can lead to a potentially deadly explosion. 

If there is combustible dust in a facility, the risk of fire and explosion is much greater. As a result, there is a higher chance of accidents, worker injuries, and even possibly death. 

If any incidents occur, not only can your business find itself subject to a Worker’s Compensation lawsuit, but you can also count on being subjected to an OSHA investigated. This means that your business may have to suspend operations while the investigation occurs and, if found at fault, could be subjected to further fines and penalties. 

2. Keeps Employees Healthy

Without implementing proper housekeeping procedures, your facility can become an unhealthy environment for your employees. Dust, mold, chemicals and other forms of contamination can collect on surfaces and spread throughout the facility.

When dust is present in the air, it can land on the skin or be inhaled. This can lead to skin issues, respiratory problems and even allergies, and these health issues can worsen over time. While all dust can lead to these types of issues, it’s the fine dust often found in industrial facilities which pose the greatest risk.

3. Increases Productivity 

Maintaining a clean industrial facility also has the potential to increase employee productivity. When routine housekeeping procedures are followed, employees spend less time cleaning the facility before starting their work shift. A clean facility can also create an environment where workers are safer and happier and, as a result, are more efficient in meeting their responsibilities. 

A clean facility is an organized facility. Your workers will not struggle to find their equipment or materials — and clean them once found — which translates into work getting done easier and faster. 

4. Maintains a Well-Functioning Facility

When a facility isn’t clean, not only is it unsafe and unsanitary, but it also won’t run properly either. A dirty facility can lead to mechanical issues with equipment, where tools move slower or break down completely. 

Dust, in particular, can be problematic as fine dust particles get between gears and moving parts and cause them to stop working. 

Because fugitive combustible dust poses a fire or explosion risk in the right environment, it is critical to have the right tools to reach all areas that may accumulate dust. With an extension wand, curved brushes and small, round utility brushes, you can clean the taller machines, corners, overhead beams and pipes. All of these areas are prone to fine dust accumulation. 

Common Cleaning Issues In Industrial Facilities

Most industrial facilities have a cleaning plan in place already. However, it may not be sufficient or meet all of the NFPA and OSHA requirements, which become more stringent every year. In some cases, the housekeeping procedure currently in place can make the overall distribution of dust worse, rather than better.

Before vacuuming, some facilities perform the “blowdown and sweep” method of cleaning, where dust and debris are moved with compressed air, then swept into a pile. This method is explicitly prohibited by NFPA standards — unless the surfaces to be cleared using compressed air have been vacuumed prior to blowdown. Failing to follow the NFPA standard can cause dust and other debris to be dispersed back into the air and propelled into other hard-to-reach parts of the facility.

Certain areas of your facility may be overlooked when it comes to your housekeeping methods. Walls, corners, vents, lighting, overhead pipes and beams can all collect dirt and dust, and often don’t get the same attention as floors. This is also true for storage containers and inside equipment, where fine dust may build up. 

The most common cleaning issue is also one of the easiest to solve: having the right tools and equipment to properly contain and dispose of hazardous material. If your housekeeping procedures consist of blowing down, sweeping, and vacuuming with a shop vac, you are putting your workers, your facility and your business at risk. Unlike a residential building, industrial facilities require special equipment that is designed for use in industrial spaces. One key piece of industrial facility cleaning equipment is an industrial vacuum and its associated accessories. 

Industrial vacuums are specially designed to meet the stringent legal requirements set forth by organizations like NFPA and OSHA. They are effective for cleaning all types of industrial messes, including combustible dust, and there are certified explosion-proof models available powered by the same compressed air supply you already have. 

When paired with overhead cleaning tools, such as a vacuum extension wand for high ceilings and an overhead pipe cleaning attachment, it’s possible to clean all of these hard-to-reach places that normally don’t get enough attention. 

Choosing the Right Vacuum

While there are many different industrial vacuums on the market, they don’t all offer the same quality. For the safest and most effective vacuums, look at HafcoVac, which offers industrial vacuums made in the U.S.A. and powered by compressed air that’s already available in the facility. 

HafcoVac’s certified compressed air vacuums do not have moving parts that can get damaged by things like dust and debris, and because there are no moving parts, there’s no worry about arching, friction or sparking leading to a fire or explosion. 

These vacuums are certified for use with combustible dust, and some models are also certified for use in hazardous environments. 

HafcoVac vacuums meet the strict OSHA Housekeeping Guidelines and NFPA Standards, such as Standard 484, the Standard for Combustible Metals and 652, the Standard for the Prevention of Fires and Dust Explosions. HafcoVac has also gone the extra step and earned ATEX Certification — a European rating similar to the OSHA and NFPA seal of approval.

If you need a certified, industrial vacuum, contact us today. Our representatives can answer all of your questions and provide recommendations based on your specific requirements. You can even get same-day shipping, so you can get started right away protecting both your workers and your business.

Does My Industrial Vacuum Cleaner Need to Be ATEX Certified?

Industrial facilities all have different safety requirements that they are expected to follow. The right safety precautions and cleaning methods are essential for creating safe, clean facilities. 

Part of following these requirements is choosing the right equipment and, more specifically, choosing certified equipment. Certified equipment has met the standards necessary to be sold and used by industrial facilities in the country. 

While there are several certifications that you will see on equipment, today we want to talk about ATEX certification: what is it and will it work for your facility? 

What Is ATEX Certification? Why Is It Important?

ATEX, short for “atomosphères explosibles,” is a European Union directive from the European Committee for Standardization. The directive covers the regulations for equipment and protective systems that are made for use in potentially explosive atmospheres within Europe. 

According to the European Committee for Standardization, an explosive atmosphere can be caused by things such as flammable gasses, mists, vapors or combustible dust. ATEX certification refers to the process of testing equipment and systems to ensure that they are safe for use within industrial environments. Vacuums are one type of equipment that is required by EU law to be ATEX certified. 

ATEX certification requirements are similar to the Occupational Safety and Health Administration (OSHA) and the National Electrical Code (NEC) requirements in the United States. Products are sent to a third-party organization called a “Notified Body” for certification. 

ex logo

Once a product has been ATEX certified, it is branded with an “Ex” symbol. This means that the product has passed the required tests, and it is safe for use in explosive atmospheres.

Does It Apply to the U.S.? What Does It Mean for Industrial Vacuums?

Although ATEX certification requirements are very similar to those of the National Fire Protection Association (NFPA) and OSHA, ATEX is not a U.S. standard. ATEX applies specifically to the countries within the European Union and nowhere else. Therefore, U.S.-based facilities are required to have equipment that meets OSHA and NFPA requirements. 

More specifically, equipment has to go through the Nationally Recognized Testing Laboratory (NRTL) — a third-party organization created and recognized by OSHA — for evaluating, testing and approving equipment for use. The U.S. certification process is based on the safety standards developed by the American National Standards Institute (ANSI) and Underwriters Laboratories (UL) in conjunction with OSHA and NFPA. It is required by U.S. law for all electrical equipment, both consumer and industrial. 

Although ATEX certification is not officially recognized by U. S. standards, that doesn’t mean manufacturers cannot seek it out in addition to U.S. certifications. While ATEX is very similar to what the U.S. requires, offering products that have not only U.S. certifications but EU certifications as well shows a company’s commitment to creating quality products. It will build additional trust between facility managers and owners and the company whose products they are considering. 

When there is the option of a certified ATEX vacuum cleaner that also meets OSHA and NFPA legal requirements, facility owners and managers are more likely to choose that option to ensure they are buying the safest and best quality equipment possible.

Benefits of ATEX Certified Vacuums

Although the ATEX directive is different from OSHA, it is equally as strict since many of the requirements are similar. For example, ATEX directives 99/92/EC and 94/9/EC, or ATEX 137 and 95, outline the same requirements as NFPA 652, the Standard on the Fundamentals of Combustible Dust. Because of these similarities, American manufacturers of industrial vacuums and other equipment can submit their products for ATEX certification. 

By choosing to have an ATEX certified vacuum cleaner, American facilities will have extra assurance that the vacuum is safe not only by U.S. standards, but also by EU standards. It also shows a deeper dedication from companies to create safe and reliable products for industrial facilities.

Who Needs an ATEX Certified Vacuum?

It is vital to stress that in the U.S., a certified ATEX vacuum cleaner also needs to meet the certifications required by OSHA and NFPA. An ATEX vacuum cleaner is ideal for facilities with explosive atmospheres; that is, facilities that contain dust that is flammable when combined with heat or an ignition source, such as a spark, in an enclosed space.

(Click here to read more about combustible dust explosions and how to prevent them.)

Facilities that should consider ATEX certified products include petroleum plants, chemical manufacturers, and facilities that deal with combustible dust, like powder, agricultural, food, pharmaceutical, pesticide, rubber, plastic, textiles, chemical, recycling, coal-fired power, wood and more.

Choosing an ATEX Certified Vacuum

Not all industrial vacuums in the U.S. have earned ATEX certification. HafcoVac is a line of industrial vacuums are all proudly made in the USA, and feature NRTL approval, NFPA compliance and ATEX certification. They also abide by OSHA’s Housekeeping Guidelines, which help satisfy both NFPA and NRTL requirements.

HafcoVac has many different models that are all ATEX certified and can serve in a wide range of facilities. HafcoVac models include Explosion-Proof Vacuums, Anti-Static-Vacuums and Pneumatic Vacuums. Each of these models is powered by compressed air already available in the facility, which means there are no moving parts and no risk of arching, friction or sparking that can lead to fire or combustion within an explosive atmosphere. 

While U.S.-based agencies such as OSHA do not formally recognize ATEX as an official standard, it is still very similar to OSHA standards covering material handling in hazardous environments. HafcoVac is dedicated to creating high-quality products and having them thoroughly tested for various markets. 

The ATEX certification can provide facility owners and managers with an added sense of security, as a certified ATEX vacuum cleaner has gone through more testing than an industrial vacuum that only has NFPA and OSHA certification. HafcoVac is a U.S.-based company that is dedicated to providing the safest and most reliable industrial vacuums for all types of facilities. 

For more information on ATEX certified industrial vacuums, contact an expert at HafcoVac today.

Is Your Industrial Vacuum Cleaner NFPA 652 Compliant?

As inconspicuous as dust may seem, it can be incredibly hazardous, especially in industrial and commercial facilities. Over that past decade, dust has been one of the leading causes of serious flash fires and explosions in processing facilities. 

The Occupational Safety and Health Administration (OSHA), an agency within the U.S. Department of Labor, has recognized the hazards that dust poses and stresses the need to deal with them appropriately. As a result, the National Fire Protection Agency (NFPA) introduced NFPA 652: the Standard on the Fundamentals of Combustible Dust. 

NFPA 652 has set the standard for dust safety for the processing industry, defining what combustible dust is and how to best manage it to prevent serious safety issues. 

NFPA

What Is NFPA 652 Compliance? What Does It Mean for Industrial Vacuums?

NFPA 652, Standard on the Fundamentals of Combustible Dust, is a standard that was created to promote and define the hazards of dust, creating awareness and directing facilities on how to properly manage and reduce dust hazards. More specifically, it provides requirements for dust management in facilities where combustible dust fires and explosions can be an issue. 

When necessary, and based upon the industry in question, NFPA 652 also directs facility owners and managers to other NFPA standards, like NFPA 61, NFPA 654, NFPA 484, NFPA 655 and NFPA 664, which are concerned with combustible dust from various commodity-specific industries. 

The foundation of NFPA 652 — and the related standards — focuses on creating a safe environment where combustible dust is concerned. Specifically, this means that the fuel source — dust — is properly managed, ignition sources are controlled, and the potential for explosion is limited through proper facility design, protection, isolation and proper housekeeping. Meeting all NFPA 652 requirements earns facilities NFPA 652 Compliance. 

NFPA 652 Compliance is a recognition given to facilities that have complied with the standard and met all necessary safety rules and requirements. Without meeting these requirements, facilities will fail to earn NFPA 652 Compliance. This can result in steep fines and production being stopped until all non-compliance issues are corrected.

One requirement outlined by NFPA 652 is determining the combustibility and explosivity of various materials within the facility, particularly dust. To do this, you need to conduct a Dust Hazard Analysis (DHA), which is used to identify the specific combustible dust hazards associated with a process. 

Once the DHA has been completed and hazards identified, facility owners and operators must take the proper steps to deal with these hazards and manage the risks posed by combustible dust. From there, owners and operators need to establish a written safety management system that enforces NFPA 652 and explains to employees how to properly handle combustible dust.

The requirements and guidelines above are meant to create safe operating facilities and equipment. By following the guidelines, you minimize the risk of serious combustible dust hazards within the facility. All working parts and equipment within the facility are required to meet these requirements to earn NFPA 652 Compliance. Even industrial vacuums, which are often overlooked, need to meet NFPA 652 compliance.

Why Is It So Important?

According to a 2007 dust hazard study conducted by the U.S. Chemical Safety and Hazard Investigation Board (CSB), there were nearly 280 dust fires and explosions over a 25-year period. These fires and explosions resulted in 119 worker fatalities and over 700 worker injuries. 

The incidents happened in a wide range of industries that produce various types of combustible dust. While good housekeeping is an essential part of preventing dust explosions, proper facility design and engineering is also vital. This includes using the appropriate electrical and ventilation equipment, keeping this equipment in working order and covering pipes, while embedding cables into walls to prevent surface dust.

It is especially important to manage potential ignition sources — anything that can generate flames or sparks or that can create static electricity: one of the key components to combustion. 

There are three main components needed for combustion: the presence of combustible dust, oxygen and a heat source. Two additional components are required for an explosion to occur: the dispersion of dust particles in a sufficient concentration and the confinement of that dust cloud. 

All of this knowledge has led to new safety standards, like NFPA 652, meant to protect structures, people and products from harm. These standards are regulated and enforced by various agencies, including the U.S. Department of Labor, OSHA and the NFPA.

Compliance with these codes, including NFPA 652, is not optional. Failure to comply can lead to severe consequences like the facility being shut down until the standards are met, which can cause significant financial loss. In addition, facilities can be hit with substantial fines for noncompliance, which creates an additional financial burden on facility owners and operators.

Which Industries Require NFPA Certification

NFPA 652 compliance is required by any facility whose processes produce any amount of combustible dust. Major industries that fall into this category include powders, agriculture, food, pharmaceutical, pesticides, rubber, plastic, textiles, chemical, recycling, coal-fired power, wood and more. 

There is a wide range of combustible dust produced by these various facilities, each posing serious risks to safety. Anything from flour dust in the food industry to epoxy dust from the chemical industry is considered dangerous, combustible dust. 

What to Look for in an NFPA 652 Vacuum 

Keeping a facility free from combustible dust is essential. However, doing so requires NFPA 652 compliant equipment, including an approved NFPA 652 vacuum. The standard has seven requirements that industrial vacuums have to meet to be compliant:

  1. Except for certain circumstances, an industrial vacuum should be made using conductive materials.
  2. In addition to a conductive build, the vacuum’s hose should either be conductive or static dissipative.
  3. All the conductive parts of the vacuum must be bonded and grounded.
  4. When working, dust-laden air should not pass through the fan or blower.
  5. For vacuums with electrical motors, the motor should not be in the dust-laden air stream, unless it is listed for Class II, Division I locations.
  6. There should be no paper filter elements in the vacuum for picking up liquids or other wet materials.
  7. In addition to meeting NFPA 652 requirements, vacuums used for metal dust must also meet NFPA 484: Standard for Combustible Metals.

HafcoVac’s NFPA 652-Certified Vacuums

Finding an NFPA 652-compliant vacuum that meets all the necessary requirements can be difficult. Fortunately, there is HafcoVac. 

HafcoVac has been servicing various industrial industries for over 15 years, specializing in NFPA and OSHA-certified industrial vacuums that are made in the USA. They offer explosion- and dust ignition-proof industrial vacuums that are energy-efficient and have variable power.

Industrial Pneumatic Vacuums 

HafcoVac’s industrial pneumatic vacuum is powered by compressed air rather than a motor with moving parts. For that reason, it does not require any electricity to run, which makes it easy to use in any part of the facility. 

HafcoVac’s pneumatic vacuums can handle not only combustible dust waste, but dry and wet material recovery as well. Aside from being NFPA 652 compliant, this vacuum also meets NFPA compliance for standards 664, 484, 70 and 61. 

It has the option of either an anti-static or static conductive hose, per NFPA requirements. These types of hoses help to ensure that any static electricity dissipates, so there is no risk of fire-causing sparks. 

Another benefit to pneumatic vacuums is that they require little maintenance since there are no moving parts that need cleaning. The only maintenance workers would need to be concerned about is changing filters when necessary. 

All of HafcoVac’s Explosion-Proof industrial vacuums come with a High-Efficiency Particulate Air (HEPA) Filtration system. These filters are 99.97% effective at keeping fine dust particles from entering the air, keep workplaces and the air cleaner. 

Areas such as asbestos abatement, lead paint recovery, healthcare facility cleaning and pharmaceutical manufacturing require HEPA filters for their work. Additionally, food processing, mining, power generation and facilities dealing with combustible dust all should use industrial vacuums with HEPA filtration systems.

While it is already an incredibly versatile vacuum that can clean any virtually part of a facility, there are accessories that help make it an even more efficient machine for eliminating combustible dust within a facility.

Ensuring NFPA Compliance

Processing facilities must maintain a safe, dust-free facility. Dust, especially within these facilities, can cause serious safety hazards for the facility, its employees and its products. Combustible dust poses a risk of fires and explosions that can lead to injuries and even death. 

To create a safe facility, you need to follow the OSHA Housekeeping Guidelines and NFPA’s Standards for safety, particularly NFPA 652. This includes using an NFPA 652-compliant vacuum, like those provided by HafcoVac. These are made to those strict standards and are rated for use with combustible dust, even in hazardous environments.

If you need an industrial vacuum, contact us today. Our representatives can answer all of your questions and provide recommendations based on your specific requirements. You can even get same-day shipping, so you can get started right away protecting both your workers and your business.

Why Industrial Vacuum Cleaners Are a Must-Have for All Metalwork Shops

Metal and Machine Shop Industry Metal Working and Machine Shop

Metalworking shops, like any other industrial workplace, are home to several by-products as a result of the production process. However, one waste product, in particular, is a cause of several safety and efficiency issues: metal chips.

Metal chips appear in several forms — filings, dust or shavings — and they present a consistent threat to the metalworking shop. Additionally, metalworking shops are home to several other raw elements used in the process, such as oil.

When these metal chips get covered in oil, the result is a safety hazard: a highly sticky waste product that clings to machines and finished products. Not only does that contribute to an unclean, dirty workplace, but it also diminishes the appearance of the final product.

In order to ensure a tidy working shop that adheres to industry regulations, as well as preserving the health of the workers, metal shops need to invest in a comprehensive cleaning solution.

Metalwork And Machine Shops Need to Optimize Their Cleaning Routines

In a robust metalworking environment, an effective cleaning mechanism remains an inevitable requirement to ensure the health and efficiency of the workplace.

In the absence of such a system, the metal and dust particulates pose a grave threat to the well-being of all people in the proximity of the workplace.

Proper Handling of Metal Chips for a Safer Work Environment

Metal chips are dangerous for everyone who comes into the facility, but particularly for people that work in close proximity. There are several reasons why they pose a threat, the major among them being:

  • They are extremely sharp, which can lead to severe injuries.
  • The especially fine particles can be inhaled, leading to serious lung problems.

Typically, in shops where power tools and machinery are extensively used, employees are advised to handle metal shavings with utmost precaution and care.

Lackluster cleaning mechanisms for metal shavings can result in cuts, breathing problems and medical complications for your lungs. The occurrence of such problems can adversely affect the entire production – from the health of your employees to your company’s productivity.

It is crucial to invest in the right safety equipment, such as specialty gloves and masks, that can alleviate the chances of injury and harm caused by metal shavings. 

But above all, it’s essential that removing metal chips should be handled with specialized machinery. As metal and machine work has become more specialized, it is only rational that the cleaning techniques and equipment follow suit.

Productivity and Product Quality Is Augmented

In addition to harming the health of people in their close proximity, metal chips present additional threats to metalworking shops.

Metal chips and dust floating in the air or resting on solid surfaces can compromise the quality of end-products as well. This is because:

  • Metal chip infused fluids can lead to diminished results when used.
  • Metal shavings and dust particles can attach to power tools, large equipment and finished products, either ruining them or resulting in expensive repairs.

In order to preserve the quality and visual brilliance of the finished product, as well as to ensure optimal health of your workforce, metalworking shops need to invest in comprehensive metal shaving cleaning options: shop vacs for metal shavings.

How Industrial Vacuum Cleaners Keep Your Metalwork Shop in Top Shape

An industrial vacuum cleaner is the most effective solution for the metal industry, as it can clean machines and power tools from metal shavings after each production cycle.

Vacuums for metal shavings can also remove all evidence of metal clippings, even if they are within liquids such as emulsions, coolants and oil. Once the solids and liquids are separated, the solid can be processed for its scrap value and the fluid can be reused. 

Metalworking shops and facilities need to have an industrial vacuum always available on-site to clean up after spills, accidents that occur in every production cycle.

The best shop vac for metal shavings not only ensures that every minute particle is cleaned up but also guarantees an extended lifetime and performance value.

HafcoVac Industrial Vacuum Cleaners

If you want the best vacuum cleaner for your metal shop, you want to choose one of HafcoVac’s industrial vacuum cleaners

They can handle even the most demanding environments, and come with a lifetime warranty. 

Let’s look at the benefits of HafcoVac industrial vacuum cleaners: 

Works on a Variety of Materials

Not only do HafcoVac’s industrial vacuum cleaners collect volatile and combustible dust, but they also clean up a variety of dry and wet materials. Moreover, these machines are powerful enough to collect metal shavings and dirt from all kinds of industrial surfaces.

Hafco Vac’s best shop vac for metal shavings provides a powerful solution for cleaning every aspect of a metalworking shop – from dust, sludge, fiber, grindings to turnings, metal chips, lubricants and abrasive materials.

All Industry-Relevant Compliances Are Met

Compliance and standards are set in place to ensure that everything is done efficiently and safely. As one of the leading cleaning solutions for the metal industry, HafcoVac adheres to all relevant industry thresholds to ensure maximum compliance.

This is why all HafcoVac’s industrial vacuum cleaners are certified and abide by NFPA and OSHA standards and regulations for clippings safety, metal dust and shavings. These include:

  • NFPA Class I Division 2 Group E
  • OSHA -Certified for Class 1, 2, 3, Division 1 and 2, Groups A, B, C, D, Zone 1 and 21 E, F, G

Considerable Savings on Electrical Expenses

HafcoVac’s industrial vacuum cleaners are not reliant on electricity as their pneumatic vacuum design does not need an electric motor to function, ensuring they are intrinsically safe.

Instead, these units harness energy from compressed air to power air motors, control valves and rotary actuators. The means the chance of electric shortages, burnouts or overheating vacuum cleaners are non-existent. 

Why HafcoVac Has the Best Shop Vac for Metal Shavings

Here are some reasons why customers are so fond of HafcoVac’s industrial vacuum cleaners:

  • All products are made at par with NFPA and OSHA standards.
  • Maintenance costs are reduced and fire hazards reduced as there is no electric motor.
  • All vacuums come with a lifetime warranty.
  • Your product will reach you within 24 hours of placing the order.
  • Vacuum Performance is exceptional at up to 400+ CFM.
  • They use a certified HEPA filtration system and just one filter that can last you up to a year.
  • They are a holistic cleaning solution as they seamlessly handle metal shavings, liquids and dust.
  • The body contains no moving parts and uses no electricity, so there is less chance for breakdowns or sparks to start a fire.
  • They come with either a 30-gallon or 50-gallon drums, so you can get the size that works for your shop.

Metal dust and pieces can be dangerous. It is vital for companies belonging to the metal industry to keep their workspace clean and free from metal chips for employee safety, better product quality and production efficiency. 

Interested in learning more about HafcoVac’s pneumatic vacuums? Get in touch with us today!

An Introduction to Combustible Dust Explosions

Combustible dust explosions are one of the most underestimated hazards in industrial settings. This is simply because people are not aware of how common and dangerous combustible dust can be.

Consider this: According to a study by the Chemical Safety Board (CSB), there have been 111 dust-related fires that resulted in 66 deaths and 337 injuries between 2006 and 2017.

In this article, we will discuss the causes of these dust explosions and shed light on how to prevent them.

Let’s start by discussing what combustible dust is and why it is so dangerous.

What Is Combustible Dust?

Combustible dust is any type of fine substance that has the capability to burn, which can then lead to an explosion hazard under the right circumstances.

Metal PowderDust can accumulate from conveying, handling and storing the following materials:

  • Organic materials like sugar, grain, wood, etc.
  • Synthetic materials like plastic, pesticides, etc.
  • Peat and coal
  • Metals like aluminum, bronze, etc.
  • Nonmetallic and inorganic substances like rubber

While these materials may be non-combustible when settled on a surface, they can pose an explosion risk when the dust particles are dispersed in air in the correct concentration.

What Is a Dust Explosion?

A dust explosion occurs when fine particles, suspended in the air in a confined area with sufficient concentration, combust rapidly. Simply put, when too much combustible dust accumulates and is exposed to a spark, that dust will explode. 

In general, the dust cloud that results from the processing of raw materials in some industries is extremely combustible and only requires a light ignition source. If this rapid burning of dust particles takes place in an enclosed room, pressure could build up and cause equipment to explode. Ultimately, this could result in serious damage to the facility and loss of limb or life to the workers.

Here are some industries that face an increased risk of dust explosions:

  • Food products
  • Lumber and wood products
  • Chemical manufacturing
  • Primary metal industries

How Do Dust Explosions Occur?

A fire needs three elements to ignite: oxygen, heat and fuel (dust). Also known as the fire triangle, when these three combine with dust particles dispersed in abundance, they can cause violent combustion called deflagration. If another element – confinement – is introduced to this equation, the result is a deadly explosion due to an immense rise in pressure.

These five elements (oxygen, heat, fuel, dispersion and confinement) combined are called the “Dust Explosion Pentagon,” and exclusion of any one of them can prevent a fire or an explosion.

What Makes Dust Explosions So Destructive?

Dust explosions are divided into two types:

Primary Dust Explosions

This usually occurs in smaller spaces like rooms, containers or inside equipment. It happens due to the accumulation of dust in these confined spaces which reacts to an ignition source and starts a fire.

Secondary Dust Explosion

Vibration caused by the primary explosions may result in more dust being dislodged into the air or may simply damage a containment system like a container or a vessel. As a result, more dust becomes airborne that may result in another explosion.

In contrast to primary explosions, these can be far more deadly due to an increased concentration and quantity of combustible dust. It is believed that this type of explosion is the real culprit that has caused so much destruction and casualties in the past.

Now that we understand the causes and types of dust explosion, let’s look at the possibilities of preventing them.

How to Prevent Dust Explosions

As we have learned earlier, the exclusion of even a single element from the “Dust Explosion Pentagon” can eliminate the risk entirely; hence, the primary goal should be implementing a safe housekeeping regimen focusing on disposing of the fuel and safeguarding against any ignition source.

To do this, first and foremost, you have to reduce the accumulation of dust from all locations within the factory. This process consists of three essential tasks:

  • Identifying problem areas
  • Identifying if dust accumulated in these problem areas is combustible
  • Getting rid of the dust

1. Identifying Problem Areas

In plants and industrial sites where powder processing takes place, some dust is bound to escape from the conveyors or other equipment. Naturally, this dust settles on horizontal surfaces near the source.

When this dust becomes dislodged, it is referred to as fugitive dust. The amount of fugitive dust is measured by OSHA and must be under a certain level for the facility to be compliant. 

To reduce the amount of fugitive dust in a facility, you need to remove dust as soon as it settles onto all surfaces, even those that are commonly overlooked such as roof support, support steel, piping and cable trays.

2. Identifying if Dust Accumulated in These Problem Areas Is Combustible 

Conducting a thorough analysis of the various types of dust present in the vicinity is crucial, especially since not all types of dust are considered to be combustible. While it is preferable to clear out all types of dust from a facility, identifying problem areas can further help reduce the risk of a fire.

As part of the most recent update to NFPA 652, all chemical, wood processing, metals, and agricultural industry facilities must have a DHA (dust hazard analysis) completed by September 7, 2020, with a follow-up analysis done every five years. 

3. Getting Rid of the Dust

The elimination of combustible dust requires regular cleaning, but just sweeping it away will not be enough; this will simply make it accumulate in some other place. 

This is where vacuums come in handy as they draw up the dust from various surfaces with efficiency. And this is why intrinsically safe vacuums are highly recommended for these types of applications where there is an increased risk of combustion.

Per NFPA 652 standards, when using a vacuum to draw up dust, the vacuum and its tools must be grounded and bonded to avoid static discharge. Make sure when choosing a vacuum, you choose one with built-in grounding to comply with NFPA’s standards for portable vacuum cleaners.

It’s also important to note that if you choose to remove dust using the compressed air blowdown method, you will still need to use a vacuum to clean the area first, per section 8.4.2.6.2.

HafcoVac’s Explosion-Proof Vacuum Cleaners

Anti-Static - Explosion-Proof

These explosion-proof vacuums are certified which means that they are designed to be used under possible explosive conditions. They are also NRTL approved, ATEX certified and recommended for use in OSHA’s hazardous environments. 

Being air-powered, they do not contain any motors or mechanical moving parts that can generate an electric charge. This makes them safe for use in many conditions where there is risk of a possible fire, compared to traditional shop vacs where the electric motor can create a spark or charge due to friction.

HafcoVac’s explosion-proof vacuums are cost-effective, non-electric vacuums that are renowned for their reliability, and are an excellent long-term solution to getting rid of combustible dust.

Key Advantages of Using Hafcovac’s Explosion-Proof Vacuum

  • No electricity
  • Fully grounded
  • No moving parts

This vacuum comes with advanced safety features; where electrically powered vacuums generate heat and static charge buildup, HafcoVac’s pneumatic vacuums ensure that the charge is properly grounded so as to prevent combustion.

Some applications of this vacuum include:

  • Operation in hazardous locations
  • Removing combustible dust
  • Recovering flammable by-products
  • Recovering hazardous by-products
  • Safe removal of static-prone materials

All-in-all, explosion-proof vacuums are an excellent preventive measure for dust explosions. Get in touch with HafcoVac today for more information on explosion-proof vacuums.

Reducing the Risk of Explosions in Flour Mills

Flour mills are the backbone of the American economy and an essential part of the agricultural industry.

These mills are responsible for breaking down the cereal grain obtained from wheat into flour quickly and at a low cost — but this poses a serious threat to labor and flour mills which we will discuss in this article.

Ever since the flour explosion of Washburn mill in 1878 that claimed 18 lives, the milling industry has worked tirelessly to develop preventative reforms. However, problems are still prevalent. For instance, despite numerous technological advancements, a recent grain mill explosion in South Sioux City, Nebraska claimed a life and decimated the structure.

What Causes Flour Mill Explosions?

Flour dust combined with factors like an ignition source, confined space, dispersion and oxygen are the main culprits behind flour dust explosions.

The process of flour production can create an environment where all these elements unite. As such, flour dust acts as a fuel source when mixed with oxygen which can result in a fire when confined in a limited space.

Is Flour Combustible?

So, can flour explode? As astonishing as it may sound, the fact is that flour dust is more explosive than gunpowder and 35 times more combustible than coal dust.

However, it is not explosive in small, non-dispersed quantities. For example, if you burn a small pile of flour sitting on top of your kitchen counter, it won’t explode since it’s not dispersed in a cloud-like form.

The case is different when dealing with airborne flour particles, as they have ample oxygen to fuel combustion. Combine that formula with multiple secondary dust sources in a confined space, add an ignition source, and you have a recipe for a chain reaction that could lead to an explosion. 

Poor Operations at Flour Mills

Eliminating one of the five elements responsible for a flour dust explosion (dust, ignition source, confined space, dispersion and oxygen) will prevent this problem, but due to the operating environment in flour mills, eliminating any of these elements can be difficult.

Several ignition sources are at play in flour mills such as rubbing pulleys, static electricity and sparks from friction.

Plus, almost all flour mills have flour handling systems like transfer bins, bucket elevators, hammermills, headhouses and baghouses. These provide the required confinement and pressure, and ultimately, increase the risk of an explosion.

Risks Associated With Flour Dust

U.S. flour mills generated a revenue of $22.8 billion in 2019 and currently employ more than 22,532 people. With so much at stake, it’s crucial to identify potential risks and hazards involved for the safety of both workers and the mill.

Following are some risks associated with flour mills:

Respiratory System Damage

Dust from flour mills can cause serious damage to the respiratory system as it contains various contaminants such as fungi, silica, bacterial endotoxins, mammalian debris and pesticides.

Flour processing produces airborne dust that is regularly inhaled by mill workers. This causes serious respiratory ailments like irritated rhinitis, wheezing, coughing, lung fibrosis and even asthma.

Suffocation is also a major issue that many workers experience; it is a major cause of death in storage bins. According to a report issued by Purdue University, 51 workers were buried under grain stored in bins, out of which only 25 survived, the most catastrophic incident on record in terms of the number of deaths. In other words, these bins act like quicksand for workers trying to walk in them.

Dust Explosions

Many people believe that since a mill has been running for years without an explosion or fire, it must be safe. Sadly, this is simply not true as combustible dust particles can accumulate anywhere and at any time.

Flour explosions are known to cause serious damage from worker casualties to the destruction of the facility. The explosions typically start in equipment like dryers, classifiers, mixers, conveyors and hoppers.

During the past 35 years, more than 500 incidents have been reported in flour mills across the U.S., which have caused more than 180 deaths and 675 injuries. This represents an accurate picture of how destructive exploding flour can be.

How to Mitigate Risks Related to Flour Dust   

One key factor to prevent these risks is to stop the accumulation of dust in different areas of the mill(s). This is easier said than done; this process requires serious maintenance and dedication from everyone involved in the facility.

Here are some tips to reduce the risk of flour dust explosions and other health issues:

Preventative Maintenance – Ongoing Education and Training

Lack of preventative maintenance, poorly managed grain handling and conveyance equipment can cause an increased buildup of flour dust. Hence, one primary responsibility of safety supervisors is to educate all workers about the serious consequences of dust buildup and to ensure they are doing everything possible to mitigate these risks.

Elimination or Substitution of Hazards

This step involves the elimination or substitution of hazardous materials where possible. In other words, owners of flour mills and factories must decide if they can implement a process that uses or generates less flour dust.

Changing Work Policies

A major aspect of creating a safe and healthy work environment is changing the work policies to limit the risk of flour dust exposure or explosions.

For this, managers must create a written plan for controlling exposure, posting warning signs in and around the factory and improving the overall cleaning practices.

Building a Safer System – Physical Modifications

To further reduce the risk of flour dust explosions, it is important to make physical modifications to the equipment and factory.

For instance, factories are encouraged to improve their ventilation and install a dust extraction system. A major part of this is using a HEPA vacuum to efficiently clean up 99.8% of the combustible dust. In fact, as per safety code NFPA 654, factories should only use vacuums that are properly approved and certified for dust collection.

Using Vacuums to Eliminate Dust

An industrial vacuum is an ideal solution for cleaning out flour storage facilities and getting rid of accumulated dust. They are highly capable of minimizing the risk of flour mill fires while eliminating the hazards related to food safety.

Popular Types of Vacuums Used in Flour Mills

Specially designed for flour mills, these vacuums come in different sizes and are used for different applications.

Dust, Fumes Extractors

These are designed to eliminate dust, fumes and mist from different areas of flour mills.

Certified Explosion-Proof Industrial Vacuum Cleaners

They are built to work in hazardous zones and designed to prevent sparks, charge or any type of electric tension through special technical features.

Industrial Air Powered Vacuum Cleaners

With no moving mechanical parts, these are extremely durable and are used in flour mills to extract dust without providing an ignition source. Instead, they use compressed air to run, a power source easily found in flour facilities. 

HafcoVac Vacuum Explosion-Proof Vacuums

Explosion-proof vacuums, like the HafcoVac Vacuum, that run on compressed air rather than a motor are necessary to eliminate the risk of static charge that can ignite a fire. 

HafcoVac’s intrinsically safe vacuums are ATEX Certified and are cleared for use in locations with excess dust or other combustible materials by the National Fire Protection Association (NFPA). They also meet OSHA’s housekeeping standards. 

These cost-effective vacuums are capable of running for an extended amount of time (with no motor to burn out) while maintaining high levels of suction. They are available in stainless steel, so they match the rest of your equipment. 

If you need an industrial vacuum, contact us today. Our representatives can answer all of your questions and provide recommendations based on your specific requirements. You can even get same-day delivery, so you can get started right away protecting both your workers and your business.

Reducing the Risk of Explosions in Flour Mills

Flour mills are the backbone of the American economy and an essential part of the agricultural industry.

These mills are responsible for breaking down the cereal grain obtained from wheat into flour quickly and at a low cost — but this poses a serious threat to labor and flour mills which we will discuss in this article.

Ever since the flour explosion of Washburn mill in 1878 that claimed 18 lives, the milling industry has worked tirelessly to develop preventative reforms. However, problems are still prevalent. For instance, despite numerous technological advancements, a recent grain mill explosion in South Sioux City, Nebraska claimed a life and decimated the structure.

What Causes Flour Mill Explosions?

Flour dust combined with factors like an ignition source, confined space, dispersion and oxygen are the main culprits behind flour dust explosions.

The process of flour production can create an environment where all these elements unite. As such, flour dust acts as a fuel source when mixed with oxygen which can result in a fire when confined in a limited space.

Is Flour Combustible?

So, can flour explode? As astonishing as it may sound, the fact is that flour dust is more explosive than gunpowder and 35 times more combustible than coal dust.

However, it is not explosive in small, non-dispersed quantities. For example, if you burn a small pile of flour sitting on top of your kitchen counter, it won’t explode since it’s not dispersed in a cloud-like form.

The case is different when dealing with airborne flour particles, as they have ample oxygen to fuel combustion. Combine that formula with multiple secondary dust sources in a confined space, add an ignition source, and you have a recipe for a chain reaction that could lead to an explosion. 

Poor Operations at Flour Mills

Eliminating one of the five elements responsible for a flour dust explosion (dust, ignition source, confined space, dispersion and oxygen) will prevent this problem, but due to the operating environment in flour mills, eliminating any of these elements can be difficult.

Several ignition sources are at play in flour mills such as rubbing pulleys, static electricity and sparks from friction.

Plus, almost all flour mills have flour handling systems like transfer bins, bucket elevators, hammermills, headhouses and baghouses. These provide the required confinement and pressure, and ultimately, increase the risk of an explosion.

Risks Associated With Flour Dust

U.S. flour mills generated a revenue of $22.8 billion in 2019 and currently employ more than 22,532 people. With so much at stake, it’s crucial to identify potential risks and hazards involved for the safety of both workers and the mill.

Following are some risks associated with flour mills:

Respiratory System Damage

Dust from flour mills can cause serious damage to the respiratory system as it contains various contaminants such as fungi, silica, bacterial endotoxins, mammalian debris and pesticides.

Flour processing produces airborne dust that is regularly inhaled by mill workers. This causes serious respiratory ailments like irritated rhinitis, wheezing, coughing, lung fibrosis and even asthma.

Suffocation is also a major issue that many workers experience; it is a major cause of death in storage bins. According to a report issued by Purdue University, 51 workers were buried under grain stored in bins, out of which only 25 survived, the most catastrophic incident on record in terms of the number of deaths. In other words, these bins act like quicksand for workers trying to walk in them.

Dust Explosions

Many people believe that since a mill has been running for years without an explosion or fire, it must be safe. Sadly, this is simply not true as combustible dust particles can accumulate anywhere and at any time.

Flour explosions are known to cause serious damage from worker casualties to the destruction of the facility. The explosions typically start in equipment like dryers, classifiers, mixers, conveyors and hoppers.

During the past 35 years, more than 500 incidents have been reported in flour mills across the U.S., which have caused more than 180 deaths and 675 injuries. This represents an accurate picture of how destructive exploding flour can be.

How to Mitigate Risks Related to Flour Dust   

One key factor to prevent these risks is to stop the accumulation of dust in different areas of the mill(s). This is easier said than done; this process requires serious maintenance and dedication from everyone involved in the facility.

Here are some tips to reduce the risk of flour dust explosions and other health issues:

Preventative Maintenance – Ongoing Education and Training

Lack of preventative maintenance, poorly managed grain handling and conveyance equipment can cause an increased buildup of flour dust. Hence, one primary responsibility of safety supervisors is to educate all workers about the serious consequences of dust buildup and to ensure they are doing everything possible to mitigate these risks.

Elimination or Substitution of Hazards

This step involves the elimination or substitution of hazardous materials where possible. In other words, owners of flour mills and factories must decide if they can implement a process that uses or generates less flour dust.

Changing Work Policies

A major aspect of creating a safe and healthy work environment is changing the work policies to limit the risk of flour dust exposure or explosions.

For this, managers must create a written plan for controlling exposure, posting warning signs in and around the factory and improving the overall cleaning practices.

Building a Safer System – Physical Modifications

To further reduce the risk of flour dust explosions, it is important to make physical modifications to the equipment and factory.

For instance, factories are encouraged to improve their ventilation and install a dust extraction system. A major part of this is using a HEPA vacuum to efficiently clean up 99.8% of the combustible dust. In fact, as per safety code NFPA 654, factories should only use vacuums that are properly approved and certified for dust collection.

Using Vacuums to Eliminate Dust

An industrial vacuum is an ideal solution for cleaning out flour storage facilities and getting rid of accumulated dust. They are highly capable of minimizing the risk of flour mill fires while eliminating the hazards related to food safety.

Popular Types of Vacuums Used in Flour Mills

Specially designed for flour mills, these vacuums come in different sizes and are used for different applications.

Dust, Fumes Extractors

These are designed to eliminate dust, fumes and mist from different areas of flour mills.

Certified Explosion-Proof Industrial Vacuum Cleaners

They are built to work in hazardous zones and designed to prevent sparks, charge or any type of electric tension through special technical features.

Industrial Air Powered Vacuum Cleaners

With no moving mechanical parts, these are extremely durable and are used in flour mills to extract dust without providing an ignition source. Instead, they use compressed air to run, a power source easily found in flour facilities. 

HafcoVac Vacuum Explosion-Proof Vacuums

Explosion-proof vacuums, like the HafcoVac Vacuum, that run on compressed air rather than a motor are necessary to eliminate the risk of static charge that can ignite a fire. 

HafcoVac’s intrinsically safe vacuums are ATEX Certified and are cleared for use in locations with excess dust or other combustible materials by the National Fire Protection Association (NFPA). They also meet OSHA’s housekeeping standards. 

These cost-effective vacuums are capable of running for an extended amount of time (with no motor to burn out) while maintaining high levels of suction. They are available in stainless steel, so they match the rest of your equipment. 

If you need an industrial vacuum, contact us today. Our representatives can answer all of your questions and provide recommendations based on your specific requirements. You can even get same-day delivery, so you can get started right away protecting both your workers and your business.