Prepared by Tarun Kumar Cheddy Risk Assessment In Dyeing Section at CMT La Tour Koenig

2. TARUN KUMAR CHEDDY

3. Definitions:
 Hazard is any thing that has the potential
to cause harm. e.g chemicals
 A Risk is the chance high or low that
somebody could be harmed by these or the
other hazard.
• A risk assessment is simply a careful
examination of what, in your work could
cause harm to people, so that you can weigh
up whether you have taken enough
precautions or should do more to prevent
harm. an important step in protecting
workers & workplace as well as complying
with the law.

4. Hazards in dyeing Section
Chemical Hazards
Physical hazards
No evidence suggests that dyestuffs are harmful to
human health at the level of exposure that workers
generally face in the factories.
However, long-term, accidental or over exposure can
be a potential health hazard. Thus, all dyes
&chemicals must be therefore be treated with
reasonable care.

5. Chemical Hazard
Reactive dyes cause respiratory problems due to the
inhalation of the dye particles It can also affect a worker’s
immune system.
Exposure to chemicals acts as irritants that can cause
dermattis as a result of skin exposure.
 Some chemicals used in dyeing are: chlorine,
ammonia,caustic soda ,HCL,H2SO4,Rhodamine
B,magenta & others.
Corrosive chemicals can cause serious burns&and may
react dangerously with other chemical.
Hot liquids can lead to scalding accident

6. Carcinogenic
Certain dyes such as rhodamine B ,Magenta have
been found to be carcinogenic.

7. Physical hazard
Exposure to loud noise of the machine can result in
permanent hearing damage , such as noise-induced
hearing loss and tinnitus.
According to the noise regulations 2012 the noise
level should be less than 85 dB
Noise causes fatigue, anxiety & low productivity
Wet floor in the dyeing section can cause the risk of
slip &falls.
 long exposure to heat can cause heat stress.
Note : The noise level at CMT is less than 85 db.

8. Fire hazard
A fire hazard may arise from the use of flammable
liquid that are easily ignited.
The presence of large quantities of dry fabric can
increase the risk of fire.

9. Effluents
Effluents from dyeing may cause alteration of the
biological ,chemical &physical properties of aquatic
environment

10. Different types of dyes used in
dyeing factories

11. Process flow diagram of dyeing
industry

12. Preparation of fabrics
Singeing
WHAT IS IT?
Singeing machines burn off short fibres
protruding from cotton fabrics.
WHY IS IT DONE?
To make fabric smoother and reduce pilling
Preparation
This means getting the fabric ready for
dying, printing or finishing.
You need to have a basic understanding
of these 5 techniques:
• Singeing
• Scouring
• Shrinking
• Bleaching
• Mercerising
These treatments are done on large
machines in textile factories worldwide,
many of them in the Far East.

13. Preparation of fabrics
Shrinking
WHAT IS IT?
Natural fabrics are washed and allowed to
relax on a vibrating table so they can shrink
in both width and length.
WHY IS IT DONE?
So the fabric will not shrink during later
processing or in use.
Scouring
WHAT IS IT?
A washing treatment to remove fats and
waxes which occur naturally (i.e. in wool)
or have been applied during spinning,
weaving or knitting.
WHY IS IT DONE?
To clean and relax the fabric and
make it take up dye easier.

14. Preparation of fabrics
Mercerising
WHAT IS IT?
A chemical process used for cotton yarn or
fabric which is held under tension in a
solution of caustic soda. This causes the
fibres to swell and become rounder.
WHY IS IT DONE?
To make cotton textiles stronger, more
lustrous and take up dye more easily.
Bleaching
WHAT IS IT?
Chemical process using hydrogen peroxide
to destroy natural colour and make the
fabric white.
WHY IS IT DONE?
Easier to produce pastel shades when dyed
(or enhances ‘whiteness’ if being left white)

15. Dyeing fabricsTypes of Dye
 Natural dyes – used for 1000s of years, hardly
ever used commercially today.
 Synthetic dyes – since 19th
C, used almost
exclusively today.
Chemical dyes can pollute rivers
when wastewater is released.
WHEN ARE TEXTILES DYED?
 Fibre stage
 Yarn stage
 Fabric stage (piece, batch, continuous, over-dyeing)
 Product stage (garment dying – piece or batch)
Piece/Batch/Continuous
Dyeing
HOW IS IT DONE?
 The open width of fabric in a greige state
(un-dyed) is passed through a bath of dyestuff.
 It is then squeezed between rollers to ensure
even and consistent dyeing
Continuous fixation machinery fixes the dye in
the fabric.
WHY IS IT DONE?
 To produce rolls of plain coloured fabric in any
length to any colour shade.
Cheaper than setting up machines to produce
woven fabrics from different coloured yarns.

16. Five steps in risk assessment
Step 1
Identify the hazard. To collect appropriate H&S data ,
literature such as MSDS of dyestuff and a visit to the
factory (CMT)

17. Cont’d
Step 2
Decide who might be harmed& how.
The dyeing operators ,supervisors, maintenance
workers, visitors ,cleaners and contractors.
How
By exposure to chemicals and dyestuffs.

18. cont’d
Step 3
Evaluate the risks & decide on precaution
Dyeing operators should wear the following PPE:
(1)chemical suit to avoid burns or scalds
(2) Safety shoes to protect against chemicals and falls
(3)Goggle to protect the eyes from chemical splash
during sampling
(4)Respirators to protect the respiratory system from
inhalation of dyes particles
(5) Protective gloves during handling of dyestuffs

19. Cont’d
Provide sanitary facilities
(1) First aid
(2) washing facilities
for removal of contamination

20. Step 4
Record your findings & implement them
The results of the risk assessment are shared between
the dyeing staff
High risk is unacceptable
Small or medium risk is acceptable

21. Cont’d
Elimination-complete elimination of a process or potential
source of emission from the dyeing section
Substitution-replace by a less hazardous chemicals or dyes
Engineering control-at design phase e.g (1) placing guards
or fencing near hot pipes in dyeing section(2)Improve
maintenance procedures(3)LEVS
Administrative (1)-job rotation (2)reduction in working
hours
Behaviour (1)-safe handling of chemicals and dyestuff with
gloves.(2) avoid eating or drinking during sampling of
chemicals
PPE-(1)helmet (2)respirator (3)Chemical suit (4)Safety
shoes (5)gloves (6)

22. Step 5
Documenting risk assessment
Record basic information
For e.g Compagnie Mauricienne de textile at La Tour
Koeing
Name of workplace Dyeing section
hazard: Burns from hot pipes
Record preventive or protective measures used to limit
risk arising from the hazard i.e guarding or fencing
the machine

23. SOME EXAMPLE OF HAZARDS
AND RISK ASSOCIATED .

26. Severity of harm
Catastrophic
Critical
Marginal
Negligible-Minor injury e.g burn in contact with hot
pipe

27. Likelihood of harm
Issued to be considered:
Number of personnel exposed to the hazards-25
Frequency & duration of exposure to the hazard- 40Hrs
per week
Failure of services e,g electricity& water- short
circuit,overload ,no regular test of safety devices e.g
RCD, electrical installation according MS 063. Lack of
maintenance of the water system e.g fail to detect a
leak of hot water
Unsafe acts –e.g Not wearing safety gloves during
sampling of chemicals

28. Risk Level estimator
3 points scale
likelihood Explanation Remarks
Highly unlikely Chance of
occurrence
virtually nil
Risk exists in
dyeing section
Unlikely Could occur
sometime
acceptable
Likely Could occur
repeatedly
acceptable

29. Determining the level of risk for
hazard
Hazards Likelihood
Manual handling Likely
Fabric dust unlikely
Exposure to steam likely
Bursting of steam pipes Likely
Slips, trips and falls unlikely
fire likely
Electrical hazard likely
Psychological hazard likely

30. Tie line
1

31. How these control measures will reduce the risk to a level
which is ALARP
Manual Handling
 Job rotation – allows the employee to rest and reduce
repetitive movement
Remind employees on standing position, awkward
postures to prevent work related musculoskeletal
disorders especially upper and lower limb disorders.
 monitoring the employees to distress during breaks

32. Recommending any further control measures
Exposure to steam and bursting of steam pipes
Review of all steam pipes after a predetermined period to
make sure that the pipes are not defective
Electrical hazard
Replacing frayed cords to avoid contact with employees to
eliminate the risk of electrocution or fires
Psychological hazard
stress management to prevent absenteeism due to fatigue
and prevent turn over
Appraisal methods to appraise workers on their way they
work(other than remuneration) ,giving them importance
and make sure that they are socially active

33. Further recommendation (ALARP)
 Engineering control at the design stage
 Local exhaust ventilation is essential in dyeing section to dissipate heat &
flammable range (limits of flammability)
 Use effluent treatment plant (ETP) to treat the waste water
 Use eco-friendly chemicals &dyes
 Job rotation –even when all protective measures have been some workers are
found to be so sensitive to the effects of these chemicals that transfer to other
work is the only alternatives
 Regular maintenance of machine
 Keep floor dry to prevent slip and falls
 Regular inspection of ppe by supervisors
 Training in the proper use of ppe
 A fire drill be carried out once yearly as stipulated in OSHA 2005
 Risk assessment to be carried by a competent person
 Medical surveillance

34.  Question ?
Thank you for kind attention