Keeping staff safe and WEL
September 1st 2005 Here IP&E reports on how Wolstenhome International’s relationship with 3M is helping to ensure its workers respiratory safety
At Wolstenholme International’s manufacturing site in Darwen, Lancashire, around ninety employees are involved in the production and packing of speciality metallic inks, pigments, flakes and powders. To find a range of respiratory protection solutions that help protect its employees from the potentially harmful effects of solvents and fine dust particles used and created during the processes, Wolstenholme International chose to work with 3M.
Best Practice in Health and Safety
The health and safety of Wolstenholme’s workforce is paramount. A number of steps are taken to ensure that employees are aware of the hazards found in the workplace and are aware of their health and safety responsibilities - both in the foundry and in the other workplace areas.
Every precaution is taken with a view to reducing the risks of exposure to the hazards of the workplace, including the provision of personal protective equipment (PPE) as a last resort. Everyone exposed to the hazards of the job is fit tested when provided with respiratory protection equipment, and Is additionally Issued with ear defenders, hard hat, safety goggles, gloves and safety footwear where necessary. In addition, computer-based training on COSHH requirements and the use of PPE is provided to each employee.
Following this training, the employee must demonstrate a certain level of competency before he or she is permitted to work on the shop-floor, and these competencies are kept on record.
The production of metallic powders and flakes creates a large amount of dust, with particles ranging from 1 micron upwards.
Although there are local exhaust systems in place, there is potential for exposure to solvents, gases, fumes and fine dust particles. John Maynard, Wolstenholme International’s health and safety manager, explained, "The solvents, dusts and gases present within the three main processes all have differing Workplace Exposure Limits (WELs).
"WELs are set under the Control of Substances Hazardous to Health Regulations (COSHH). They are set by the Health and Safety Commission and published in EH40. WELs are the airborne concentration of hazardous substances averaged over a time period. WELs should not be exceeded and for certain substances identified in EH40 exposure should be reduced to as far as is practicable. During all the foundry processes, there is a requirement for workers to wear respiratory protective equipment. In the main, our risk assessment requires a level of P2 protection, however some operations in the foundry require P3 protection."
The three levels of disposable respirators available; FFP1, FFP2 and FFP3 offer different levels of protection.
FFP1s have an assigned protection factor (APF) of 4, FFP2s an APF of 10 and FFP3s an APF of 20. This means they may be used in concentrations of solid and nonvolatile liquid particles up to 4 x WEL, 10 x WEL and 20 x WEL respectively.
Protection from dusts and powders
John continued, "Currently, we use the 3M 8822 cup shaped, valved disposable respirator and the 3M 9320 foldable, unvalved disposable respirator to protect workers from fine dusts and powders in the bronze, inks and aluminium processes.
Each person has a different shaped face and varying comfort level requirements, so not everyone is suited to the same face piece. The valve on the 8822 respirator reduces heat and moisture inside the mask, making it especially easy to breathe through. The foldable 9320 mask allows employees to step in and out of a hazardous area, fold up their mask and put it in their pocket for re-use on re-entry. Both are low weight, comfortable and compatible with other PPE such as safety goggles. Workers pick up a fresh respirator at the beginning of each shift, and may use more than one mask per shift if required."
Protection against fine dusts, mists, organic gases and vapours
For protection against gases and vapours in the solvents areas workers are provided with the 3M Maintenance Free Gas/Vapour & Particulate respirator 3M 4251. The 3M 4251 respirator provides protection against the effects of fine dusts, oil and water-based mists, organic gases and vapours with good warning properties and boiling points above 65°C. Offering all round vision and comfort, the 3M 4251 respirator is CE marked and approved to EN404: 2001, Class FFA1P2D. The adjustable head harness cradle aids ease of fitting, while the textured face seal prevents slippage and improves comfort and fit. In addition, with built-in filters integral to the mould, the 4000 series requires no spare parts or replacement filters. It provides maximum usage limitations of: gases/vapours: APF - 10 x WEL or 1000ppm, whichever is the lower; and particulates: APF - 10 x WEL. All the 3M 4000 Series respirators are designed to be re-usable, but should be disposed of within one month, or when gas/vapour filters are saturated, or when the particulate filter clogs, (whichever situation occurs first), or as dictated by the company respirator change policy.
As part of its customer service, 3M can help employers select the appropriate level of protection, using the 3M "4-step" guide to selection. This includes hazard identification, risk assessment, product selection and training on fitting, use and maintenance, with a comprehensive after sales service to complete the package. More articles from 3M UK PLC: | 
