DuPont Product/Presentation · PDF fileBlend dependent, may produce gas to ... ASTM F 1449 Guide for Industrial Laundering of Flame, ... Residual oil amount and decontamination efficiency

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

[email protected]

FR Apparel Sales Technical Leader – North America

mailto:[email protected]

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


3



Pressure to save money on the front end

decision for short term gains

The cheaper alternative is not always the

least expensive to own.


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


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


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

$



Durability Launderability

Appearance Repair

Replacement


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


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?


Flame Resistant Protection Durability


Durability Flame Resistance


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




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


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



Durability Wear

Stronger and More Durable Fabric or Garment Can

Provide a Longer Service Life, and Reduce

Replacement Costs.


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.



Durability Wear



Replacement Costs.


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.



Durability Wear



Replacement Costs.


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

13


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



Launderability

Special laundering Procedures

Bleach

Hard Water

Launder Similar Fabrics Together

Contaminate Removal vs. Redistribution


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


15


Appearance


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


16


Repair

Replacement When Should FR PPE Garments be Repaired

or Replaced?


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.


17


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.


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.


18



Nomex® IIIA 6.0oz

FRTC 88/12 (cotton/nylon) 7.0oz 19


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


20


Durability

Greater Durability Should

Provide Better Wear Life


Potential for Lower

Life Cycle Costs


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.


Durability


∆ = 4.4%

∆ = 39.4%

∆ = 58.7%

∆ = 18.7%

Launderability


22

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.


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.



Nomex® Coveralls after

10 washes FRT Cotton Coveralls

after 10 washes


Appearance


Nomex®

Coveralls after

100 washes

FRT Cotton

Coveralls after

100 washes


24


Scenario 1 Scenario 2


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


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


1Source: General user feedback - estimate

2Source: Multi Housing Laundry Association 3Source: Estimate industrial launderers

Life Cycle


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 Expectation



Field Trials and Use

Durability Testing

Laundering Considerations

Appearance



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

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” 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”

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


Life Cycle Cost Calculator Scenario 1

FRTC 88/12 Reorder Point

Nomex® IIIA Reorder Point



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


Scenario 2

Replacement cost is the key

driver - Despite Initial

acquisition cost difference

30

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” 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”

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



Scenario 2

FRTC 88/12 Reorder Point

Nomex® IIIA Reorder Point


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




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



Documents

DuPont Product/Presentation · PDF fileBlend dependent, may produce gas to ... ASTM F 1449 Guide for Industrial Laundering of Flame, ... Residual oil amount and decontamination efficiency