SAFETY AND HEALTH ISSUES DURING PRINTING INK PRODUCTION PROCESS · 2017-09-27 · supervisors, and any other personnel. They are involved in the production process and are exposed

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International Journal of Civil Engineering and Technology (IJCIET)

Volume 8, Issue 9, September 2017, pp. 942–954, Article ID: IJCIET_08_09_105

Available online at http://http://www.iaeme.com/ijciet/issues.asp?JType=IJCIET&VType=8&IType=9

ISSN Print: 0976-6308 and ISSN Online: 0976-6316

© IAEME Publication Scopus Indexed

SAFETY AND HEALTH ISSUES DURING

PRINTING INK PRODUCTION PROCESS

Norazli Othman*, Liaw Lerk Lerk, Shreeshivadasan Chelliapan

*,

Roslina Mohammad

Department of Engineering, UTM Razak School of Engineering and Advanced Technology,

Universiti Teknologi Malaysia, Jalan Sultan Yahya Petra, Kuala Lumpur, Malaysia

Noor Shawal Nasri

Sustainable Waste-To-Wealth, UTM-MPRC Institute for Oil & Gas, Resource Sustainability

Research Alliance, Universiti Teknologi Malaysia, Johor Bahru, Johor, Malaysia

ABSTRACT

Occupational accidents may occur due to several reasons, such as the workers are

unaware of the rules, the workers are aware but do not understand the rules, they

mistakenly apply the rules, they ignore the rules, they lack sufficient educational

background, and they received no proper training. The lack of safety awareness in the

workplace has become one of the reasons for the occurrence of occupational

accidents. Consequently, the knowledge of safety is very important in order to create a

safe working environment and increase the awareness of safety among workers.

Hence, the study aims to identify the factors that influence the safety and health issues

during printing ink production process. For this study, the data was collected through

observation and distribution of survey questions to the printing ink production staff.

Thirty sets of questionnaires were distributed to the respondents, who include the

production workers, production supervisors, and any personnel working in the

printing ink production process. The results showed that more than half of the

production workers are uncertain with the safety instructions. The study revealed that

a low education background of the production workers also contribute to safety and

health issues. For that reason, employers should provide sufficient training to the

production workers. The findings of this study can contribute to the development of

awareness and control measures for the printing ink production process by the

employees and employers.

Key words: Safety and Health, Ink Production Process, Hazardous; Chemical

Substance.

Cite this Article: Norazli Othman, Liaw Lerk Lerk, Shreeshivadasan Chelliapan,

Roslina Mohammad and Noor Shawal Nasri, Safety and Health Issues During Printing

Ink Production Process. International Journal of Civil Engineering and Technology,

8(9), 2017, pp. 942–954.

http://www.iaeme.com/IJCIET/issues.asp?JType=IJCIET&VType=8&IType=9

Norazli Othman, Liaw Lerk Lerk, Shreeshivadasan Chelliapan, Roslina Mohammad and

Noor Shawal Nasri


1. INTRODUCTION

Safety knowledge is the mediating factor which contributes in creating a good safety

environment at the workplace. The safety knowledge of workers may determine the

probability of accidents happening. However, the contribution of occupational accidents at the

workplace may be due to insufficient rules and regulations [1]. Occupational safety and health

procedures that have no proper preventive actions or control measures could potentially incur

a personal injury, disease or death [2]. Thus, employers and employees are responsible to

prevent accidents by adapting the occupational safety and health practices in the workplace.

According to Lind et al. [3], working tasks and working environment vary in the industrial

sector especially for maintenance. Thus, identifying, selecting, and managing the most

essential hazards help the occupational safety and health management to prevent and mitigate

the occurrence of accidents.

According to the report from the Department of Occupational Safety and Health (DOSH)

[4] on the Occupational Accident Statistics by sectors for 2013 and 2014, the total number of

accident cases are 2825 and 2805 accidents, respectively. In total, manufacturing shows the

highest occupational accidents of 1655 cases (58.58%) in 2013 and 1667 cases (59.43%) in

2014 [4]. The total number of accident cases in the manufacturing sector increased by 12

cases within a year. Thus, this implies that the manufacturing sector has become the most

dangerous sector among the listed sectors and it highly requires safety control measures for

accident prevention.

The chemical industry is considered as a high risk industry, and failure or accidents can

cause major environmental impacts [5]. Reliability is important for the environmental safety

in chemical industries. Thus, printing ink can be summarised as a high risk industry as it is a

manufacturing industry that involves all kinds of chemical materials. Hence, a comprehensive

control measure in the printing ink manufacturing sector is needed. In the printing ink

production process, a large proportion of cleansing solvent is used in the production cleaning

process. The solvents involved are hazardous and flammable. The solvents have increased the

health risk of the production workers and enhance the risk associated with fire [6]. The

printing ink manufacturing site is important to install the necessary safety tools for safety

management. The safety management tools are sprinkler systems, portable extinguishing, and

electrical system with explosion proofing and static control [6]. Besides that, the safe work

environment for the production workers in the safety management system is important. It

involves machine guards, safety programmes training such as chemical spillage handling,

emergency response training, safety showers, eye washes, first aid kits, providing appropriate

Personal Protective Equipment (PPE), and medical surveillance [7]. In a comprehensive

safety management system, employers are responsible in providing training to the employees

for appropriate raw materials, chemical, and mixture handling techniques. In manufacturing

industries, the implementation priorities for safety management elements are client

requirement, insurance company requirement, employee requirement, cost effectiveness,

production rate effects, competence and expertise requirement, and employees’ safety and

health. The efficiency of an organisation is influenced by the quality of facilities and

maintenance. In maintaining the safety management and environmental impact in the

industry, retaining system inherent safety is done by effective maintenance [7].

Risks of accidents are coupled with time pressure, defects in work planning, and poor

safety management [8]. The implementation of practical risk reduction measures is related to

the risk assessment method that is emphasised to organisational safety and health

performance. Unsafe act is the most dangerous as it can become the risks or the causes for

Safety and Health Issues During Printing Ink Production Process


risks [9]. In addition, the pressure of time and workload are identified as the risks. This is

because employees who work under pressure tend to omit aspects which induce the

occurrences of hazards.

Accidents are considered as an organisational problem. It occurs unexpectedly and

suddenly, causing injuries and losses. Accidents are grouped under two categories, namely

fatal and severe non-fatal accidents. Fatal accidents involved falling and falling objects that

are generally caused by working environment and structures [10]. However, severe non-fatal

accidents are caused by machinery or devices. The typical problems that cause accidents are

poor work planning and scheduling, ergonomics problems, occupational hygiene issues, and

the workers are taking risk consciously and unconsciously [11].

For any safety management system implementation, it depends on the resources allocated

[12]. Limited resources and the adaption for the new management concepts rate are

considerable for implementation. The difficulties for the implementation of the safety

management system are lack of resources and lack of relevant expertise [13]. Besides that,

monitoring, auditing, corrective action, and regular management review are important for the

safety management system performance [14]. There is a need for regular safety reviews and

safety audits as well as for reports to be submitted for each of the review and audit with

recommendations. The common safety management system that stresses the safety policy,

planning, implementation, and performance evaluation also stresses Occupational Health and

Safety Advisory Services (OHSAS) 18001 [15]. The top management’s responsibility is to

establish a safety policy and the objective is to commit a safety and health performance [16].

Employers should formulate a safety policy that is relevant to the business activities and

demonstrate the commitment approaches towards the safety and health performance.

Employers should be committed to form a safety organization in order to facilitate the

achievement of the safety policy by allocating the adequate resources and the safety

organisation responsibilities in implementing the safety practices and procedures.

The self-regulatory and safety management system enables the organisation to achieve

high standards of the safety and health aspects in the workplace. In implementing the safety

and health management, the employer is committed to allocate employees in various levels

with adequate resources that is required for the safety and health performance. The safe

person approaches focused on the individual and the control of behaviours such as safety

training and Personal Protective Equipment (PPE) application. However, the safe place

approaches stressed on the hazard and the mitigation of the hazards such as job hazard

analysis and inspection programme. The most effective way to enhance safety performance is

by prevention of accidents and reducing uncertainties before accidents happen [17, 18].

The Occupational Safety and Health Act 1994 is an enactment that shall be applied

throughout Malaysian industries as stated in the First schedules per Appendix I [19]. The

manufacturing industry is listed as one of the industries that should apply OSHA [19]. This

act aims to secure the safety, health, and welfare of persons at work and persons at the

workplace other than persons at work against risks to safety or work health arising from

activities. Besides that, OSHA [19] aims to promote an occupational environment for

physiological and psychological needs for persons at work as well as improving the standard

of health. It emphasised the responsibilities of employers to provide and maintain the safety,

health, and welfare of the employees at work. As a manufacturer, it shall be their

responsibility to ensure that the plant (Regulation 20) and substances used at work

(Regulation 21) are safe and without risks to health. Hence, the duties of the employer to

formulate the safety and health policies in the workplace are necessary (Regulation 16). It also


Noor Shawal Nasri


emphasised on the Safety and Health Organisation function which are as a competent person

to ensure the workplace and working process are conducted under regulatory. For this paper,

the objective of this study is to identify the factors that influence the safety and health issues

during the printing ink production process.

2. METHODOLOGY

The study is conducted in a selected printing ink manufacturer. This research study is carried

out in the production department of the printing ink. The production plant of the manufacturer

includes the production processes of three types of inks, namely sheet-fed ink, cold-set ink,

and heat-set ink. The raw materials for these three types of inks are almost similar; their only

difference is in the raw materials composition that affect the printing ink drying properties.

The scope of the study is to focus on the awareness of the production workers, production

supervisors, and any other personnel. They are involved in the production process and are

exposed to all the raw materials used in producing these three types of inks.

The methodology of this study involves the data collection on the significant details of the

printing ink production process flow. Thirty sets of questionnaires were distributed to the

respondents. The respondents of this study are the production workers, production

supervisors, and any personnel who works in the printing ink production process. The data of

the survey questions, which were collected from the production workers, were analysed using

the Cronbach-Alpha Reliability Test. The Cronbach Statistical Analysis value must be greater

or equal to 0.7 to be reliable and acceptable [20].

The aims of the survey questions to be carried out are to understand the existing hazards,

risks, and previous accidents records in the production process. The survey questions are

based on the Likert scale to determine the agreement level of the production workers towards

their safety and health knowledge in the daily production activities. The survey questions are

prepared accordingly into two sections, namely Section A and Section B. Section A is about

the respondents’ demographic. There are five parameters on the demographic information,

namely gender, age, educational background, working experiences, and health conditions.

Sub-Section B contains the survey questions on the respondents’ safety and health

knowledge. There are 12 questions in this section and the survey questions are based on these

categories, namely chemical knowledge, personal protective equipment, personal hygiene,

health adverse effects, ergonomic, and accidents or chemical spillage incidents. The survey

question is distributed to 30 production workers from the morning shift and night shift

production workers. The printing ink production floor comprises of six sections. The sections

are varnish cooking section, premixing section, grinding section, adjusting section, packing

section, and labelling section. The number of production workers from each of the section

who contributed in answering the survey questions are as shown in Table 1.

The feedback received from the production workers through a set of questionnaire surveys

were analysed and discussed. The production workers successfully completed and returned

the questionnaire survey within three working days. In total, 30 copies of the survey question

distributed are all completed and returned. The response rate was 100%. The data was

analysed using the Statistical Package for Social Science, Predictive Analytics Software

(SPSS PASW) 18 and Microsoft Excel 2013.



Table 1 The number of production workers from each of the section contributes in the survey

questions findings

Production

Floor Section

Production Workers

Morning Shift Night Shift

Varnish cooking

section

2 2

Premixing

section

4 4

Grinding section 3 3

Adjusting

section

3 3

Packing section 2 2

Labelling section 1 1

Total 15 15

3. RESULTS AND DISCUSSION

The summary results of the reliability analysis are summarised in Table 2. The Cronbach-

Alpha analysis scored 0.877 for the 12 questions on the safety and health knowledge of the

production workers. The Cronbach-Alpha score of the analysis indicated good internal

consistency, repeatable, and stable over time on the safety and health knowledge of the

production workers. Figure 1 until Figure 5 show the results of a demographic study. The

parameters in the demographic are gender, age, education background, working experiences,

and health conditions. Each of the parameters are compared and analysed accordingly. The

gender parameter showed that the production workers in the printing ink production floor are

all males. Figure 1 showed that 100% of the production workers are male. None of the female

workers are designated to work in the production floor. This is due to the heavy work tasks in

the production floor, in which female workers may have less strength to carry out the work

activities.

Table 2 Summary results of reliability statistics analysis

Variable Number of

Items (N)

Cronbach-Alpha

Coefficient

Safety and

Health

Knowledge

12 0.877

Besides that, the production environment consists of many mechanical types of

machinery, which are generally more suitable for the male workers to work in the printing ink

production floor. Figure 2 showed that 50% of the production workers are between 36-45

years old and 20% of the production workers are between 18-15 years old. The rest of the age

group, namely workers between 26-35 years old, 46-55 years old, and 56 years old and above

are all averagely 10%, respectively. The age range of the production workers with the highest

percentage is between 36-45 years old. This may imply the sufficient working experience to

support the work activities.

Figure 3 shows the education background of the production workers. From the data, 60%

of the production workers have completed primary school, 30% of the production workers

completed secondary school, and 10% of the production workers achieved high school or

technical or vocational level of education. From the total number of 30 production workers,

none of them graduated from college or university. The results of the survey showed that the

production workers’ education background is at the lower side.


Noor Shawal Nasri


Figure 4 shows the working experience of the production workers by years. 30% of the

production workers possessed a working experience of less than 5 years, while 40% of the

production workers have 6–10 years working experience. 20% of the production workers have

11-15 years of working experience and only 10% of the production workers have the longest

working experience which is by 16-20 years. None of the production workers possess a

working experience of more than 21 years. The highest working experience of the production

workers are in the range of 6-10 years.

Figure 5 shows that 30% of the production workers have not encountered any illnesses in

the past. 30% of the production workers have hypertension in their medical history, 20% of

the production workers have asthma, 10% of the production workers have allergic dermatitis,

and 10% of the production workers have diabetes. To summarise the data, 70% of the

production workers possess medical illness records. The high medical illness record of the

production workers may be due to the living lifestyle of the production workers. Thus, an

unhealthy living lifestyle and stressful working environment contributed to the high illness

record among the production workers.

Figure 1 The gender of the production workers

Figure 2 Percentage of the production workers by age

Male Female

Percentage 100% 0

100%

0 0%

20%

40%

60%

80%

100%

120%

Per

centa

ge

Gender of the Production Workers

0%5%

10%15%20%25%30%35%40%45%50%

18 - 25

years

26 - 35

years

36 - 45

years

46 -55

years

56 years

and

above

20% 10% 50% 10% 10%

20%

10%

50%

10% 10%

Num

ber

of

the

Pro

duct

ion W

ork

ers

Age range

Nu

mb

er o

f th

e P

rod

uct

ion W

ork

ers



Figure 3 The educational background of the production workers

Figure 4 Frequency of the production workers by working experiences

Figure 5 The health conditions of the production workers

Figure 6 until Figure 10 show the survey findings of the safety and health knowledge of

the production workers. Referring to Figure 6, the survey on chemical knowledge showed that

80% of the production workers are uncertain with the raw materials’ of the Material Safety

0%10%20%30%40%50%60%

70%

Primary

SchoolSecondary

SchoolHigh

School /

Technical /

Vocational

College /

University

60%

30%

10%

0

Per

centa

ge

The Qualification Level

0%

10%

20%

30%

40%

≤ 5

years

6 - 10

years

11 - 15

years

16 - 20

years≥ 21

years

30%

40%

20%

10%

0

Per

centa

ge

Working Experience (Years)

30%

10%

0

20%

10%

30%

0% 5% 10% 15% 20% 25% 30% 35%

Hypertension

Diabetes

Overweight

Asthma

Allergy Dermatitis

No Diseases

Number of the Production Workers

Typ

e o

f Il

lnes

s


Noor Shawal Nasri


Data Sheet (MSDS) and safety instructions from their supervisor before handling the

chemicals. However, 10% of the production workers agree and 10% of the production

workers disagree. This shows that a majority of the production workers do not understand the

MSDS and the safety instructions from their supervisor. This is due to the lower education

background of the production workers; they may have difficulties in understanding the

chemical knowledge. Besides that, the employer does not take full responsibility in ensuring

that the production workers understand the risks of the chemicals and the correct handling

method before starting the work activities.

Figure 6 Production workers understanding level on the material safety data sheets (MSDS) and the

safety instructions from the supervisor by percentage

The survey findings for the Personal Protective Equipment (PPE) relevant questions are

on Figure 7. Referring to Figure 7, 30% of the production workers agree that they are

provided with sufficient PPE, 20% are uncertain, and 50% disagree. A high percentage of the

production workers disagree that they are provided with sufficient PPE. This is due to the

employer who do not supply the sufficient full set of necessary PPE to the production

workers. This may be due to the fact that the employer is less concerned and is not

responsible on the safety and health of the production workers. Besides that, 50% of the

production workers agree that they can put on the PPE appropriately, although the other 50%

of the production workers are uncertain on this. This result implied that the employer may

have not given a full PPE training to all the employees. From the data, 30% of the production

workers agree that the method of putting on PPE is checked by the supervisor frequently.

However, 70% disagree. The production workers’ PPE not checked by the supervisor implied

that the supervisor in the production department does not take responsibility and this may be

due to the fact that the production workers are not trained including the supervisor. Moreover,

20% of the production workers agree on the practice of changing PPE when it is spoilt, while

the other 80% disagree. These results may imply that the production workers have not been

instructed that the PPE can be replaced after being spoilt, or the employer have a limited

supply of the PPE for the production workers. Besides that, this may be due to the production

workers’ attitude that is care-free on the spoilt PPE. Generally, the employer of the printing

ink manufacturer is less impressed in providing sufficient PPE and adequate training to the

production workers.

Figure 8 emphasised on the Personal Hygiene of the Production Workers. Referring to

Figure 10, 50% of the production workers strongly agree that they wash their hands after

0%

10%

80%

10%

0%

0% 20% 40% 60% 80% 100%

Strongly Agree

Agree

Uncertain

Disagree

Strongly Disagree

Percentage

Lik

ert

Sca

le



handling the raw materials or before break time. Yet another 50% of the production workers

agree. The data shows that the majority of the production workers is positive with personal

hygiene issues and they show concern in cleaning up their hands after contact with various

chemicals in the production floor. This result implied that, the production workers are

minimally aware that the chemical substances contacted in their hands may be transmitted

when they eat with their hands and the chemical substances are not good for their safety and

health.

Figure 9 shows that the health adverse effects reflected from the daily production

activities are skin dryness, breathing difficulties, dizziness or drowsiness, and muscle pain.

Based on Figure 9, 40% of the production workers strongly agree that their skin dryness

problem becomes more severe after being exposed to the chemicals, 20% agree, 30% are

uncertain, and 10% disagree. The results showed that a majority of the production workers are

highly exposed to the petroleum-based solvent that causes skin dryness. This may be due to

there being no appropriate PPE used when handling the chemicals. Besides that, 60% of the

production workers are uncertain with breathing difficulties at the production floor, 20%

agree that they have encountered such problems, and another 20% disagree. For the dizziness

or drowsiness issue, 10% of the production workers strongly agree that they have encountered

this health adverse effect at the production floor, 60% agree, 20% uncertain, and 10%

disagree. Moreover, for the health adverse effects on the muscle pain, 40% of the production

workers strongly agree that they have encountered muscle pain issues, 30% agree, 20%

uncertain, and 10% disagree.

Figure 7 Survey findings on personal protective equipment (PPE) by total production workers

0%

30%

20%

50%

0% 0%

50% 50%

0% 0% 0%

30%

0%

70%

0% 0%

20%

0%

80%

0% 0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

Strongly Agree Agree Uncertain Disagree Strongly Disagree

Nu

mb

er o

f P

rod

uct

ion

Wo

rker

s

Likert Scale

Provide with Sufficient PPE Put on PPE Appropriately

Method of putting on PPE check by Supervisor Change PPE when spoilt


Noor Shawal Nasri


Figure 8 Production workers practice on taking care of personal hygiene

Figure 9 The health adverse effect of the production workers by percentage

Figure 10 shows the accidents or chemical spillage incidents that happened in the printing

ink production process. Based on Figure 10, the results showed that 50% of the production

workers agree that they have experienced accidents in the production floor, whereas 40% of

the production workers are uncertain and 10% of the production workers disagree. This result

shows that the accidents and chemical spillages are very common to happen in the production

floor. The chemical spillage happening frequently may be due to the manual handling method

in the entire printing ink production process floor. Besides that, production workers with a

lack of experience may have less skill in handling the chemical substances and cause the

spillage to happen very frequently. Besides that, 30% of the production workers strongly

agree that they have sufficient knowledge in handling the chemical spillage when it happens,

while 40% agree and 30% are uncertain with this question. These results implied that a

majority of the production workers have knowledge in handling the chemical spillage in the

50% 50%

0 0 0

-20%

-10%

0%

10%

20%

30%

40%

50%

60%

Strongly

Agree

Agree Uncertain Disagree Strongly

Disagree

Per

centa

ge

Likert Scale

0%

50%

100%

150%

Stron

gly

Agree

Agree Uncer

tain

Disag

ree

Stron

gly

Disag

ree

Muscle Pain 40% 30% 20% 10% 0

Diziness or Drowsiness 10% 60% 20% 10% 0

Breathing Difficulties 0 20% 60% 20% 0

Skin Dryness 40% 20% 30% 10% 0

Per

centa

ge

Likert Scale

The Health Adverse Effect of Production Workers

Skin Dryness Breathing Difficulties Diziness or Drowsiness Muscle Pain



production floor. The frequent chemical spillage in the printing ink production process has

enhanced the practical skill in handling the chemical spillage.

Based on the survey, more than half of the production workers are uncertain with the

safety instructions. The low education background of the production workers is also related

and they probably need more training in handling the chemical substances. The employer

should always provide sufficient and intensive on-the-job training to the production workers.

Besides that, the employers should also consider the health conditions of the employees and

rearrange the working environment that are suitable such as assigning the older production

workers to work in the morning shift instead of night shift. Administration control should be

alert of the employees’ health conditions according to their job scope.

On the other hand, employees play equally important roles in the safety of the printing ink

production process. Employees should be focused in their work tasks and report frequently on

any hazards found. Besides that, the employees should apply the knowledge learned and

practise the knowledge they have in their work scope for safety purposes. It is very important

for the employees to follow a safe work operation and apply the PPE correctly. Moreover,

employees should always be alert that the working environment they work in is safely

secured.

Figure 10 Accidents and chemical spillage happened in the production process and the capability of

the production workers to handle the accidents or chemical spillage by percentage

4. CONCLUSIONS

Printing ink production process floor consist various hazards and risks. The job handling and

work tasks in the printing ink production process floor is considered risky thus it must be

handle with extra care and alert to the safety requirement. This is to ensure all the unwanted

accidents to be minimized. The employees that currently work in the printing production

process are exposed to the hazards and risks of the chemical substances and process.

Immediate action must be taken by the employer to avoid more accidents and health adverse

effect cases in the near future.

ACKNOWLEDGEMENT

The authors wish to express their greatest appreciation and utmost gratitude to the Ministry of

Higher Education Malaysia and Universiti Teknologi Malaysia for all the supports in making

the study a success. Project vote number: 4F814.

0 0

50% 40%

10% 0

30% 40%

30%

0 0

0.10.20.30.40.50.6

Strongly Agree Agree Uncertain Disagree Strongly

Disagree

Per

centa

ge

Likert Scale

Encountered accidents in production floorKnowledgeable in handling chemical spillage


Noor Shawal Nasri


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SAFETY AND HEALTH ISSUES DURING PRINTING INK PRODUCTION PROCESS · 2017-09-27 · supervisors, and any other personnel. They are involved in the production process and are exposed