Minimizing Fires in Production

Fire Safety in Production: From Risk Acceptance to Systemic Control

In the context of growing production capacities and an expanding equipment fleet, fire safety issues require rethinking. The speaker examines the evolution of the approach to fire risk management using the example of a disposable tableware and packaging manufacturing enterprise. Initially, fires inside cup-making equipment were considered a minor risk; however, the increase in fire load and incidents necessitated a transition from a reactive model (waiting for operator response) to a proactive one (modernization of equipment and control systems).

Incident Analysis and Root Cause Identification

The presentation details real cases of fires. The key cause of most incidents was paper blanks falling onto heating elements, the temperature of which reaches 400°C. Analysis of video materials showed that the human factor plays a significant role: operators do not always react correctly to abnormal situations, ignore personal protective equipment (high-temperature gloves), and make mistakes when using fire extinguishers. In addition, technical flaws in the equipment were identified, such as the failure of optical sensors and the continuation of movement cycles after the machine was stopped.

Technical Solutions: In-House Equipment Modernization

Faced with an insufficient response from equipment manufacturers to the identified defects, the company was forced to seek solutions independently. The speaker demonstrates by example how the following technical changes were implemented:

• Software Reconfiguration: The machines were reprogrammed so that if a blank is placed incorrectly, an immediate stop occurs, and the heating elements automatically shift or rise, preventing direct contact with the paper. This is critically important for preventing fires when blanks jam.
• Equipment Synchronization: Communication between the first and second wall machines was set up. If there is a shortage of cups on one of the machines, the other switches to idle mode, which reduces the risk of overheating and fire.
• Installation of Protective Guards: Additional guards prevent smoldering blanks from falling out of the machine into waste bins, localizing a possible fire inside the equipment.
• Installation of Exhaust Hoods: Installing hoods over the machines ensures the removal of dust and excess heat, reducing the overall fire hazard in the area.

Organizational Measures and Personnel Training

The technical solutions were supplemented by a set of organizational measures. A zonal fire alarm control system using flame detectors was implemented, allowing for prompt localization of the fire source. Control over the condition of limit switches, optical sensors, and temperature conditions was strengthened. Special attention was paid to personnel training: a skills matrix was developed, and regular practical training sessions are held using fire extinguishers (carbon dioxide ones to minimize equipment damage) and fire blankets. The right to stop work by any manager upon detecting a potentially hazardous situation was introduced.

What you will learn from this webinar:

• How to independently modernize imported equipment to prevent combustible materials from contacting heating elements?
• What mistakes do operators most often make during local fires and how to prevent them?
• Why are carbon dioxide fire extinguishers preferable to powder ones when extinguishing production equipment?
• How to organize effective practical fire safety training in an active production facility?
• How to build a control system for the condition of sensors and limit switches using the mechanical service?