The Polyolefin Company (Pte) Ltd

Our

Product

IMPROVEMENT IN FLOSS MANAGEMENT FOR

PELLET CONVEYING WATER (PCW) SYSTEM

To look safety in 360 degree view

Implement an innovative solution

To eliminate/reduce the At

Risk activities & Conditons

To protect the health, safety and the

environment of our employees,

contractors, customers and the

communities through integrating the

HSEQ management practices into all

aspects of our business activities and

upholding the Responsible Care

guiding principles of sustainable

development in conserving our

resources including energy, water and

raw materials

The Polyolefin Company’s commitment to

Health, Safety, Environment and Quality

Occurrence

At Risk Activity

At Risk Condition

Occupational Hazard

Ease of Implementation

Criteria Low Medium High

Occurrence 1 2 3 4 5

At risk activity 1 2 3 4 5

At risk condition 1 2 3 4 5

Occupational

hazard 1 2 3 4 5

Ease of

implementation 1 2 3 4 5

Back Injury:

Awkward body posture during

pushing/scooping floss

Pinch Point:

Hand/Fingers when open/close

filter cover lock

Slipping Hazard:

Floss overflow causing

surrounding area wet

Falling Hazard:

Scooping at 2nd Wastewater Pit

(much bigger & deeper compared to 1st

Wastewater Pit)

Toppling Hazard:

During forklift operation,

floss cart can topple and hit

worker

PCW Water

What is Polymer Floss ?

Tiny hair like polymer generated

during Pelletizing process or by

attrition of Pellets in Pellet

Conveying Line.

Accumulated Polymer Floss gets

degraded due to prolonged

exposure to high temperature

causes product quality issues.

New Floss with no

Degradation

Old Floss with signs

of Degradation

Plate & Frame Heat Exchanger

Floss Deposition on Exchanger Plates

Why do we need to remove the floss?

2nd Wastewater Pit 1st Wastewater Pit

PCW Water Tank

Floss Management System

Purge Stream Filter

To drain

PCW Return

Floss Accumulation in PCW Tank

PCW Tank

To Extruder

Water Pump

PCW Return

Previous Scenario

PCW Tank

To Extruder

Water Pump

Floss overflow out from

the tank is being

collected by the purge

stream filter

PROBLEM

Floss Accumulation in purge

Stream Filter

Clearing Floss Accumulated in

Purge Stream Filter

Wastewater Pit

Solution 1 - Modification to the

Purge Stream Filter

Existing Proposed to Extend

Or

Enlarge Filter

Solution 2 - Pelletiner with

floss bag

Solution 2 – Pelletiner with

floss bag

PCW Tank

Solution 3 – Pelletiner with Modified

floss bag

Containing Floss using PCW

Overflow tank

1ST SECTION 2ND SECTION 3RD SECTION

Deflector

1st separator

2nd separator

Box-like

opening

Containing Floss using PCW Overflow Tank

Eliminate the likelihood of sustaining

back injury due to using long floss

scoop or spade to remove floss

Reduced forklift operation to minimal

as there was no need for clearing floss

cart

Eliminate floss scooping activities at 1st

and 2nd Wastewater Pit

Eliminate the hazards associated to

scooping from both Wastewater Pit like

- Risk of falling over leading to possible

drowning

Recognition from

Management

Recognition

from

Management

Met team objective to

reduce Risk Score from

above ‘Substantial’ to ‘Low’

Improve Morale

Less manual work for worker

1) Operating procedure updated.

2) Manuals updated, revised & documented

3) Training to all concern

1. Valuable experience and knowledge gained

2. Most importantly safety hazards relating to Floss

Management System has been significantly

reduced

3. Floss handling activities is reduced to minimum.

4. Manual work load of technicians and

contractors has been reduced significantly

5. Close to 40 man hours saved monthly