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Copyright© 2015 DuPont. “ This material is only intended for this (webinar) and may not be used for any other purpose without the expressed written consent of DuPont”
1
Webinar July 29, 2015
Dennis L. Mater
dennis.l.mater@dupont.com
FR Apparel Sales Technical Leader – North America
2 Copyright© 2015 DuPont. “ This material is only intended for this (webinar) and may not be used for any other purpose without the expressed written consent of DuPont”
Introduction
Flame Resistant PPE Life Cycle Assessment
Durability
Launderability
Appearance
Repair/Replacement Considerations
Actual PPE Evaluations - Life Cycle Expectations
Life Cycle Cost Calculator – Actual Example
Total Cost of Ownership Summary
Total Cost of Ownership
Webinar Overview
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Total Cost of Ownership
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Pressure to save money on the front end
decision for short term gains
The cheaper alternative is not always the
least expensive to own.
Total Cost of Ownership
Introduction
Value – the material or monetary worth of something…the
worth of something compared to the price paid or asked for it.
Identify key considerations to choose a FR PPE program with the
best long term value; save more money over time than is possible
through initial purchase price considerations alone.
GOAL
Conditioned to look at initial procurement cost
Quality
Total Life Cycle Costs
Long Term Performance
Wearer Safety
Must Consider
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By choosing a garment with a higher
initial cost but lower replacement
costs, you can potentially save close
to 30% over the life of the program
Total Cost of Ownership
Introduction Value – the material or monetary worth of something…the
worth of something compared to the price paid or asked for it.
Primer on Costs Replacement Component
A key factor in Total Cost of Ownership is Garment Life Cycle Repair and Replacement Costs Are Significant
Key assumption: 200 wearer program
$
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Total Cost of Ownership
Durability Launderability
Appearance Repair
Replacement
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Field Trials and Actual Use
Fabric/Garment Testing
Durability
FR Protection Durability
Fabric and Garment Wear Durability
Repair/Replacement Frequency
Launderability
Soil Release Properties
Ease of Care
Appearance
Total Cost of Ownership
PPE Life Cycle Assessment
In Order to Calculate the Total Cost of a PPE Program, We Must
Determine the Expected Life Cycle of a Garment
A key factor in Total Cost of Ownership is Garment Life Cycle
Repair and Replacement Costs Are Significant
What Tools Exist to Determine Garment Life Cycle?
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Flame Resistant Protection Durability
Total Cost of Ownership
Durability Flame Resistance
PPE Life Cycle Assessment
Inherent (e.g. Nomex®, Kevlar®, PBI®, Kermel®, etc)
FR performance is present in the chemistry of the fiber at the
time of production
Fiber molecular structure does not support combustion
Inherent Blends (e.g. Nomex® MHP , Tecasafe® Plus, etc)
Synergistic effect of FR and non-FR fibers
No chemical treatments
Blend dependent, may produce gas to inhibit combustion
Chemically Treated (e.g. Ultrasoft®, Proban®, Dale Antiflame®, etc.
After fabric is manufactured, it is treated with flame retardant
chemicals to impart flame resistance to the fabric
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Total Cost of Ownership
PPE Life Cycle Assessment
Durability Wear Key Metrics for Evaluating Textile Fabrics for
Wear Durability
These Evaluations Help Determine a Fabric’s Resistance to Tears, Rips,
Worn Areas, etc. That May Occur Through Use.
Breaking Strength and Elongation of Textile Fabrics - ASTM D5034
Elmendorf (Falling Pendulum) Tear Strength ASTM D1424
Trapezoidal Tear Strength ASTM D5587
Taber Abrasion ASTM D3884
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Break Strength – Grab Method
Breaking Strength and Elongation of Textile Fabrics -
ASTM D5034
• Force required to elongate or break a fabric sample
• Measures relative strength of a fabric
• Evaluate as new and after laundering
Total Cost of Ownership
PPE Life Cycle Assessment
Durability Wear
Stronger and More Durable Fabric or Garment Can
Provide a Longer Service Life, and Reduce
Replacement Costs.
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Abrasion Resistance
Taber Abrasion ASTM D3884
• Abrasive discs rubbing against a fabric sample with a
known pressure
• Indication of a fabric’s relative resistance to
weakening and wear through.
Total Cost of Ownership
PPE Life Cycle Assessment
Durability Wear
Stronger and More Durable Fabric or Garment Can
Provide a Longer Service Life, and Reduce
Replacement Costs.
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Elmendorf Tear and Trap Tear
Elmendorf (Falling Pendulum) Tear Strength ASTM D1424
– Trapezoidal Tear Strength ASTM D5587
• Measures force required to tear a fabric
• Indication of a fabric’s relative resistance to tearing.
Total Cost of Ownership
PPE Life Cycle Assessment
Durability Wear
Stronger and More Durable Fabric or Garment Can
Provide a Longer Service Life, and Reduce
Replacement Costs.
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Upstream oil and gas exploration is a great
example
Care should be taken not to use FR PPE with
residual stains or contaminates that could be
flammable
Even small amount of residual contaminates
could be problematic
Ease of laundering is a key consideration to
ensure a PPE garment does not have to be
discarded before reaching the end of its useful
life; thus increasing replacement costs
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Total Cost of Ownership
Launderability PPE Life Cycle Assessment
Embedded Soil, Stains and Unremoved Contaminates Are
a Common Reason Garments are Disposed of
Prematurely.
Soil Release Properties and Ease of Cleaning Can
Lengthen the life Cycle of a Garment
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Total Cost of Ownership
Launderability
Special laundering Procedures
Bleach
Hard Water
Launder Similar Fabrics Together
Contaminate Removal vs. Redistribution
PPE Life Cycle Assessment
Launderability Considerations
Laundering Costs
Soil Release Properties
Drying Time
Ease of Laundering
Consistency of Care
Individual Home Laundering
Industrial Laundering
Garments Discarded Before Full Wear Life Achieved
Effect of Laundering on Physical Properties
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Total Cost of Ownership
Appearance
PPE Life Cycle Assessment
Importance of Worker Appearance
Company Image
Professionalism
Wearer Pride
Less Resistance to PPE Use
Perceptions
Evaluation Techniques Ability to Maintain Original Appearance
Wash Shrinkage
Percent shrinkage after laundering at preset intervals
Wash Color Fastness
Delta E* color change evaluations after multiple launderings
Light Fastness
Xenon Arc – Accelerated light exposure
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Total Cost of Ownership
Repair
Replacement When Should FR PPE Garments be Repaired
or Replaced?
PPE Life Cycle Assessment
ASTM F 1449 Guide for Industrial Laundering of Flame, Thermal and Arc Resistant Clothing,
covers maintenance of garments by industrial laundries.
ASTM F 2757 Guide for Home Laundering, Care, and Maintenance of Flame, Thermal and
Arc Resistant Clothing provides information for home care and maintenance of flame resistant
protective garments.
OSHA requires regular inspections of FR garments to ensure it is
not in need of cleaning, repair or replacement before being used
as protective apparel.
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Total Cost of Ownership
Repair
Replacement When Should FR PPE Garments be Repaired
or Replaced?
If damage is repairable, remove the garment from service until repaired. Repairs should be
made using the same FR fabrics, inherent FR thread and components used in the original
garment’s. FR garment repair kits are available. Garments that are properly repaired can be
safely worn again.
PPE Life Cycle Assessment
Thin or Worn Through Areas
Holes
Excessive wear or abraded areas
Elbow regions
Knee regions
Rips, cuts, tears, broken zippers, or torn seams
Garment no longer properly fits the wearer
Garments should not be modified from the original design
Residual soil and/or contaminates
Garments That Cannot Be Repaired Should Be Replaced and Not Used.
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Total Cost of Ownership
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Nomex® IIIA 6.0oz
FRTC 88/12 (cotton/nylon) 7.0oz 19
Total Cost of Ownership
Actual FR PPE Evaluation
A Company Has Many Different Choices of FR PPE Garments
There are certainly other criteria, rather than cost alone, that must be considered
when specifying a FR PPE program.
Durability Launderability Appearance
Step through a representative process of
evaluation using the metrics we have
discussed. Goal
From a cost prospective, we will evaluate two possible choices and relate
the results to a projected average life cycle and subsequent total cost of
ownership.
Evaluate
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Total Cost of Ownership
Durability
Greater Durability Should
Provide Better Wear Life
Actual FR PPE Evaluation
Potential for Lower
Life Cycle Costs
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When considering wear, it is
important to have a strong fabric in
the garment that retains a high
percentage of original performance
after multiple launderings.
Total Cost of Ownership
Durability
Actual FR PPE Evaluation
∆ = 4.4%
∆ = 39.4%
∆ = 58.7%
∆ = 18.7%
Launderability
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1) The independent study was conducted by the Department of Human Ecology, University of Alberta.
2) Mettananda, C.V.R. & Crown, E.M. (2009). Quantity and Distribution of Oily Contaminants Present in Flame-resistant Thermal-protective Textiles.
Textile Research Journal 2010 80: 803. Published Online. DOI: 10.1177/0040517509346439.
CAUTION: This particular contaminant may not mimic soils in every situation. Flame-resistant protective garments need to be free from any flammable contaminant.
Total Cost of Ownership
Launderability
The contaminant in the study is new motor oil with tritiated-triolein as a tracer.
Residual oil amount and decontamination efficiency is the percent of contaminant removed
by each method measured by radiotracer analysis and scanning electron microscopy.
Decontamination was performed in a 10-minute small load heavy duty wash cycle at 60°C
in 400ml of water and 4g of detergent, followed by 2 rinse cycles at 30°C at 5 minutes
and 3 minutes.
Actual FR PPE Evaluation
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Nomex® Coveralls after
10 washes FRT Cotton Coveralls
after 10 washes
Total Cost of Ownership
Appearance
Actual FR PPE Evaluation
Nomex®
Coveralls after
100 washes
FRT Cotton
Coveralls after
100 washes
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Total Cost of Ownership
Scenario 1 Scenario 2
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Initial Garment Cost
Administration Costs1 Initial procurement and continued PPE program administration
Repair Cost Assumption2 (Per Garment-Year)
Laundering Costs3
Replacement Rate4 (launderings)
Wear Factor
25
Total Cost of Ownership
Life Cycle Cost Calculator
Water cost per load
Energy cost per load
Detergent cost per load
Utility Consumption Factor
Nomex® IIIA
6 oz FRTC 88/12
7 oz
$100.00
$5.00
$10.00
$60.00
$5.00
$10.00
125 60
$0.22/load
$0.68/load
$0.30/load
0.7
$0.22/load
$0.68/load
$0.30/load
1.0
0.8 1.0
Scenario Cost Assumptions
Scenario 1 Scenario 2
1Source: General user feedback - estimate
2Source: Multi Housing Laundry Association 3Source: Estimate industrial launderers
Life Cycle
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Verbatim Qualitative Data that supports analysis (I didn’t put into quote bubble or format in case you decide you don’t like
adding another chart)
Based on the physical test data, field evaluations, and third party
experiences 4, we would expect Nomex® to demonstrate a product life cycle
at least double that of FRTC 88/12 on average Actual wear life can vary based on work environment
4 Garment life for FRTC 88% Cotton/12% Cotton under normal wear conditions is about 50-60%
more than durable FR 100% cotton, and perhaps 1/2 that of NOMEX®. Source: Bulwark Industry Update, Bulwark.com
4 “Garments made from Nomex® are also durable — lasting, on average, two to three times longer than most other standard and protective
fabrics, including 100% cotton, polyester/garment blends and FRT cotton. In fact, industrial launderers estimate that the average wear life of
protective apparel made of Nomex® is approximately five years, and that it can be washed and worn at least 125 times.” Source: Apparel Solutions website, © 2015 Apparel Solutions
Life Cycle Cost Calculator
Life Cycle Expectation
Scenario 1 Scenario 2
Total Cost of Ownership
Field Trials and Use
Durability Testing
Laundering Considerations
Appearance
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Total Cost of Ownership
Key assumptions: 200 employees, 4 garments, initial price $65 for FR treated cotton 88/12 and $105 for
Nomex® 6 oz, 6 year consideration period, launder garments after every 3 wearings
Replacement cost is the key
driver - Despite Initial
acquisition cost difference
Estimated Savings
$35,140
Life Cycle Cost Calculator Scenario 1
28
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Savings with Nomex® begin to occur at the 60th laundering, the
point of the first FR treated cotton replacement
Notes:
1. Analysis includes initial
garment purchase, weekly
laundering, garment
repairs and replacement
2. Analysis conducted on a
unit laundering basis to
allow for variability in
issue rate and number of
employees
Breakeven Point
2.75 years
Total Cost of Ownership
Life Cycle Cost Calculator Scenario 1
FRTC 88/12 Reorder Point
Nomex® IIIA Reorder Point
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Total Cost of Ownership
Key assumptions: 2000 employees, 4 garments per year, initial price $65 for FR treated cotton and
$105 for Nomex® 6 oz, 3 year consideration period, launder garments after each use
Estimated Savings
$528,505
Life Cycle Cost Calculator
Scenario 2
Replacement cost is the key
driver - Despite Initial
acquisition cost difference
30
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Savings with Nomex® begin to occur at the 60th laundering, the
point of the first FR treated cotton replacement
Notes:
1. Analysis includes initial
garment purchase,
weekly laundering,
garment repairs and
replacement
2. Analysis conducted on
a unit laundering basis
to allow for variability in
issue rate and number
of employees
Breakeven Point
11 months
Total Cost of Ownership
Life Cycle Cost Calculator
Scenario 2
FRTC 88/12 Reorder Point
Nomex® IIIA Reorder Point
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What opportunities would your company have to
forego as a result of these additional costs? 31
Revenue Generation Needed to Cover Total Program
Cost Differences
Opportunity Cost:
A benefit, profit, or value of something that must be given up to acquire or
achieve something else. Since every resource (land, money, time, etc.) can be put
to alternative uses, every action, choice, or decision has an associated
opportunity cost. Source: www.businessdictionary.com
Suppose additional costs are paid in the amount of $528,505 to administer a FR
PPE program with a lower initial cost of purchase.
Assume the company averages a net profit of 10%.
The company would need to generate $5,285,050 dollars worth of
additional revenues to fully cover the additional costs realized
Regardless of their ability to generate additional revenue, they will have realized an
Opportunity Cost of $528,505
Total Cost of Ownership
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33
Conclusions and Summary
Garment and FR PPE procurement costs are not the only consideration
Relative life cycle assessments can be estimated using durability testing
Launderability is a key consideration for garment life cycle assessments
Replacement costs are a key driver of the total cost of a FR PPE Program
Improperly maintained FR garments can expose the wearer to increased risk of injury
Total Life Cycle Cost Is a Better Indicator of Value Than
Initial Purchase Price Alone
Total Cost of Ownership
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