Implementation of New Flame-Resistant PPE for Handling Flammable Liquids

Initially, in the liquid blending sector, no flame-resistant protective gear was used by our client during the production of alcohol-based batches, a flammable liquid. These batches are produced approximately once a month in pre-mixing tanks exposed to ambient air. The presence of alcohol vapors near unprotected operators posed a burn risk associated with handling flammable liquids or vapors.

Genipro was mandated with implementing a new flame-resistant protective suit covering the entire body (coveralls) and face (hood) to shield operators' skin from burn risks in the event of a flash fire. The equipment had to meet the CGSB-155.20 Standard (or its American equivalent, NFPA 2112) for flash fire protection to ensure compliance with the client's GMP installations. This new Nomex PPE is intended for operators working in the production of pre-mixes involving alcohol handling.

The main challenge was managing resistance to change among operators in the liquid blending sector. Throughout the implementation process, we faced difficulties in decision-making, adoption, and integration of the new equipment. These obstacles stemmed from employees directly affected by the changes. The operators' deeply rooted culture, mindset, and working methods posed significant opposition, but the implementation of this new safety measure was ultimately successful.