Occupational Hazards in The Plastics Industry (Blow Molding)

Applied Occupational Safety
Training
Occupational hazards
In the plastics industry
(Blow molding)
Name: Mohamed Salem Mahmoud Salem
Code No: 0905 – 2 -004
1
Occupational hazards in the plastics industry
Introduction
The plastics industry is divided into two major sectors.
The first sector comprises the raw material suppliers who manufacture
polymers and molding compounds from intermediates which they may
also have produced themselves. In terms of invested capital this is
usually the larger of the two sectors.
The second sector is made up of processors who convert the raw

materials into saleable items using various processes such as blowing,
extrusion and injection moulding.
Other sectors include machinery manufacturers who supply equipment

to the processors and suppliers of special additives for use within the
industry.
2
In this article, we will look at occupational risks related to the second
sector (blow-molding plastic).
Summarize the process
Blow moulding
This process can be regarded as a combination of the process of

extrusion and thermo-forming.
A tube is extruded downwards into an opened mould; as it reaches the

bottom the mould is closed round it and the tube expanded by air
pressure.
Thus the plastic is forced to the sides of the mould and the top and
bottom sealed. On cooling, the article is taken from the mould.
This process makes hollow articles of which bottles are the most
important.
The compression and impact strength of certain plastic products made

by blow moulding can be considerably improved by using stretch-blow
moulding techniques.
This is achieved by producing a pre-form which is subsequently

expanded by air pressure and stretched biaxially.
This has led to such an improvement in the burst pressure strength of

PVC bottles that they are used for carbonated drinks.
3
Major processes
1- Feed the raw material (Polyethylene granules).
2- Softening the resin by heating, using an extruder to heat the plastic to

the melting state and push it to the top of the die (this stage is very
similar to the extrusion process).
3- Configure the parison cylinder so that it is ready to enter between the

two halves of the mold.
4- The cylinder is inflated inside the mold by compressed air that spreads
the molten parison material onto the walls of the mold cavities in the
shape of a bottle (for example, a bottle). Note that when the two
halves of the mold are closed, the hydraulic pressure used in closing
closes the ends of the parison cylinder.
2
4
4
Subjective Hazards
And Control measures
A- Physical Hazards
1- Noise
 RISKs
- Occupational hearing impairment.
- Communication interference and safety.
- Effects on job performance.
- Annoyance.
 SOURCEC
- The rise and fall of the bearing car forming molds.

- Close the mold to complete the forming process.
- Air blowing process inside the forming mold.
- Scrap crushing and recycling equipment.
 Control measures
* Engineering control;-
- placing sound-blocking enclosures around equipment
- constructing an enclosure around the employee’s workstation
*Administrative controls;-
- Replacement of old equipment with quieter new models

- Adherence to equipment maintenance programs
- reduce noise doses by limiting exposure time
- PPE
- Pre- employment and periodic medical examination
- Record Keeping
5
2- Heat
 RISKs
- Systemic Disorders.
- Heat syncope.
- Heat oedema.
- Heat cramps.
- Heat exhaustion.
- Heat stroke.
- Skin Disorders
 SOURCEC
- Heaters on the injector screw.
 Control measures
- Enclosure the source by heat-resistant shields.
- Ventilation
- Pre- employment and periodic medical examination.
- PPE.
- Proper nutrition.
6
B- Chemical Hazards
 RISKs
- Respiratory Disorders.
 SOURCEC
- Fumes to be generated from the thermal degradation of

polymers during hot processing.
- Volatile dust from scrap grinding.
 Control measures:-
- Local ventilation.
- Periodic measures.
- PPE.
7
C- Accident factor
1- Mechanical hazards
 RISKs
- Amputation or crushing injuries.
- Burns injuries.
 SOURCEC
- Compression, transfer, injection and blow moulding

machines all have press platens with a locking force of
many tonnes per square centimeter.
- the plastics processing machines operate at high
temperatures and severe burns may be sustained if parts
of the body come into contact with hot metal or plastics.
- Adequate guarding should be fitted to prevent amputation

or crushing injuries.
- The design of the feed openings on large machines should

be such as to prevent whole body entry.
- Adequate lockout/tag out program.
- PPE
- The rotors operate at high speed and covers should not be

removed until they have come to rest. Where interlocking
guards are fitted, they should prevent contact with the
blades until they have completely stopped.
8
2- Fire and explosion hazards
 RISKs
- Burns injuries.
- Death.
- Destruction of installations and equipment.
- Loss of products.
 SOURCEC
- Plastics are combustible materials, although not all

polymers support combustion. In finely divided powder
form, many can form explosive concentrations in air.
- Products are stacked next to machines.
- Flammable liquids are commonly used in this industry, for
example, as paints, adhesives, cleaning agents and in
solvent welding
- The powders should be controlled, preferably in an

enclosed system, with sufficient relief panels venting at
low pressure (about 0.05 bar) to a safe place.
- Storage areas should include safe places in the open air or a

fire resisting store
- Cleanliness is essential to prevent accumulations in the

workrooms.
- Stocks of such liquids should be reduced to a minimum in

the workroom and stored in a safe place when not in use.

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Applied Occupational Safety

Name: Mohamed Salem Mahmoud Salem

Code No: 0905 – 2 -004

The plastics industry is divided into two major sectors.

The second sector is made up of processors who convert the raw

Other sectors include machinery manufacturers who supply equipment

Summarize the process

This process can be regarded as a combination of the process of

A tube is extruded downwards into an opened mould; as it reaches the

The compression and impact strength of certain plastic products made

This is achieved by producing a pre-form which is subsequently

This has led to such an improvement in the burst pressure strength of

1- Feed the raw material (Polyethylene granules).

2- Softening the resin by heating, using an extruder to heat the plastic to

3- Configure the parison cylinder so that it is ready to enter between the

And Control measures

- Occupational hearing impairment.

- Communication interference and safety.

- Effects on job performance.

- The rise and fall of the bearing car forming molds.

- Air blowing process inside the forming mold.

- Scrap crushing and recycling equipment.

- placing sound-blocking enclosures around equipment

- constructing an enclosure around the employee’s workstation

- Replacement of old equipment with quieter new models

- Heaters on the injector screw.

- Enclosure the source by heat-resistant shields.

- Pre- employment and periodic medical examination.

- Fumes to be generated from the thermal degradation of

- Volatile dust from scrap grinding.

- Amputation or crushing injuries.

- Compression, transfer, injection and blow moulding

- Adequate guarding should be fitted to prevent amputation

- The design of the feed openings on large machines should

- Adequate lockout/tag out program.

- The rotors operate at high speed and covers should not be

- Destruction of installations and equipment.

- Plastics are combustible materials, although not all

- The powders should be controlled, preferably in an

- Storage areas should include safe places in the open air or a

- Cleanliness is essential to prevent accumulations in the

- Stocks of such liquids should be reduced to a minimum in

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