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Health and Safety on our Health and Safety on our RotomouldingRotomoulding MachinesMachines

Rotomachinery Group

Walter BONAZZI

POLIVINIL ROTOMACHINERY S.p.A. has been active in the rotational molding industry formore than 40 years producing all kind of rotomolding machines, accessories and ancillaryequipments.We have two production sites: the original headquarter in Cerano, in northern Italy, nearMilan Malpensa AirportMilan Malpensa Airport

and the factory in Sherbrooke, QuébecCanada, founded in 2005.

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SHUTTLE

INDEPENDENT ARMS

CARROUSEL

360°PRODUCT

LINELAB-MACHINE

BOX-OVENS

ROCKING OVENS

DOSING UNITS

Problems of the safety existsin all the areas of the process.

CUSTOMISED MACHINES

SHUTTLE 3 ARMS

IS ROTATIONAL MOULDING DANGEROUS?IS ROTATIONAL MOULDING DANGEROUS?

Generally on rotomoulding machines we have to consider:

- Low speed rotations and carts or turret movements;

- Absence of high pressure mechanism;

- Burner flame inside a closed chamber;

- No dangerous raw materials with low flammability.

y g

IT'S REALLY LIKE THIS?

We may think that a correct burner installation is all we need to

ensure the safety of the site and of the people

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- The weight of the moulds;

- Temperature of the oven walls and of the tools;

JUST LOOKING AT:JUST LOOKING AT:

- Need for manual intervention;

- High variability of demoulding from part to part;

- Loading of the raw material, addictives and use of release agents;

- Particular operations (pre-heating, inserts, cleaning and manteinance)

IT'S CLEAR THAT WE HAVE HEALTH AND SAFETY ISSUES IN

- Manual operation risks.

OUR INDUSTRY

- Machine-related risks;

WHAT CAN WE DO TO MINIMIZE AND TRY TO OBTAIN ZERO RISKS?

ASAS MACHINEMACHINE MANUFACTURERMANUFACTURER WEWE AREARE

SORRYSORRY TOTO SAYSAY THATTHAT OFTENOFTEN SAFETYSAFETY ISIS

PERCIEVEDPERCIEVED ASAS ANAN OPTIONOPTION.. FEWFEW

CUSTOMERSCUSTOMERS INVESTINVEST TIMETIME ANDAND MONEYMONEY ONON

ITIT:: IFIF APPROACHEDAPPROACHED SERIOUSLYSERIOUSLY SAFETYSAFETY ISIS

AA BIGBIG ISSUEISSUE..AA BIGBIG ISSUEISSUE..

First mistake is the poor attention given to the safety features of the machines (PASSIVE

SAFETY) and how the operators will interact with the interface, the moulds and the raw

material.

- What should I do by-law?- Do I have the installation report for the burner. That's it!- Do I simply rely on manufacturer experience?

Main concerns:

COMMON QUESTIONS CAN B

GOOD SOLUTIONS ARE NOT EXPENSIVE, EASY AND VERY EFFICIENT

- Main concerns:

- The cost of safety it's too high!- Output slows down!- Everything becomes too complicated!- This is not my case!

SAFETY COST MUST BE INTENDED

AS A GOOD INVESTMENT- Do I really need all this?

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There's no vertical harmonized rule EC

standard for rotomoulding machines: the

manufacuter has to match all the technical

requirements according to the solution

chosen in each case and related to the

specific machine. The goal of the design is

a completly safe machine.

Barriers, fences and safety ladders

ACTIVE SAFETY ACTIVE SAFETY -- 1:1:

On the top of the oven and of the cooling chamber to allow a safe mainteinance.

Photocells inter-acting with machine's

movementTo stop the machine in case of interference

of man or objects in dangerous areas for the arms movements, opening/closing of the

oven doors).

ACTIVE SAFETY ACTIVE SAFETY -- 2:2:

Integrated software to manage dangerous operations

The management software forces the operators to follow specific steps using double check button. Easy to understand and to check effectiveness. Movements are blocked if operations are out of safe-protocols.

U f i dl i t fUser friendly interface

Clear informations, real-time instructions and efficient alarm management. Looking at the datas on the screen will help the operator to follow the protocols. Changing settings is protected by password.

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Sudden and unforeseen arm rotation can lead to serious injures. A good balancing (mechanical or via software)

Arm Balancing

ACTIVE SAFETY ACTIVE SAFETY -- 3:3:

balancing (mechanical or via software) can minimize the impact and the risk.

Allow to avoid injuries of the operators touching the walls and most of all to reduce the gas consumption and to keep the working ambient cool.

Good and efficient thermal insulation of the structure of the oven,

ACTIVE SAFETY:ACTIVE SAFETY:

A SUBJECT IN CONSTANT EVOLUTIONA SUBJECT IN CONSTANT EVOLUTIONRegulations changes, machines and devices evolves. Active safety must move accordingly.

A good solution for a carrousel machine can be a bad solution for a shuttle or a rock and roll machinemachine.

Basically, a good cooperation with the customer is required to understand needs and opportunity.

You see safety devices we put on all our rotomoulding machines.

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The mechanical structures and the safety torque

FOLLOWING MANUFACTURER'S INSTRUCTIONS FOLLOWING MANUFACTURER'S INSTRUCTIONS -- 11Respect max load capacity of the arm

Read the user manual prescriptionswhich are the result of the risk analysisand where the residual unresolveddangerous situations are welldescribed!

of the braking systems are calculated to avoid dangerous breakages or falls. Periodically check of the alignment of the sprockets and of the primary and secondary rotation is important.

Follow the mainteinance schedule

Regularly check of screws, bearings, gears and chains it is quite important. Keep clean air inlets, ducts, fans and carts rail to avoid problems during the production process.

OPERATOR'S SAFETYOPERATOR'S SAFETY

To avoid being trapped in the oven, we have put on our machines a system that is composed of a steel wire connected to handles placed inside the cooking chamber.

A worker that remained trapped in the oven can pull the handle placed inside the cooking chamber that will immediatly stop the machine.

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It is very important to do a regularly maintanance of the burner to check the combustion efficiency

A good combustion is safe healthy and convenient

FOLLOWING MANUFACTURER'S INSTRUCTIONS FOLLOWING MANUFACTURER'S INSTRUCTIONS -- 22

A good combustion is safe, healthy and convenient. Cleaning the combustion chamber is an operation to consider to do it periodically.

Always make sure the arm-mounting flangesAlways make sure the arm-mounting flanges

are working and fixed properly

- Threads

- Screw length

- Tightening torque

TO AVOID PROBLEMS!

The active safety of a machine is the result of the risk analysis and structure calculation.

The accurate choice of safety devices are not enough. Most of the problems comes from

misuse or avoidable errors

COMMON MISTAKES IN DAILY OPERATIONSCOMMON MISTAKES IN DAILY OPERATIONS

misuse or avoidable errors.

Having more than 40 years of experience in machines installations, test and training

operators of different countries and sectors, with different skills, we can document some

common mistakes that impact on safety.

On the other side we can even illustrate the best practices seen in more than 1000

installations currently in operation around the world.

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THE MOST CRITICAL OPERATION: LOADING / UNLOADINGTHE MOST CRITICAL OPERATION: LOADING / UNLOADING

Risks are related to human intervention.

OPENING AND CLOSING OF THE MOULDSOPENING AND CLOSING OF THE MOULDS

We have personally seen many operators during their free climbinghanging on moulds or even acrobats going on unstable stairs.

The risk of serious injuries caused by falls can be easily

avoided using mobile platforms.

To avoid those risks we suggest our clients to use

platforms. When the arm is in position the platform

approaches and the operator can work safely, standing on

a stable frame.

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RISK IN REMOVING PARTSRISK IN REMOVING PARTS

We saw operators manually rotate the arm todrop the piece from the mold although itweighs more then 100 kg.

The risk of crushing can be avoided using

removable hooks.

The upper part of the mould is held

by the hoist. Then the lower part

remains on the arm and the operator

let down the piece and removes the

inserts in safe.

OTHER SOLUTIONS:

Customised platforms

RISK IN REMOVING PARTSRISK IN REMOVING PARTS

Special equipments and custom

configurations can solve particular

problems: support frames, automatic

opening / closing of the moulds, slides,

positioning of the cranes, etc.

We suggest you check with theWe suggest you check with the

manufacturer to find out the best

solution on a case by case basis.

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It's a common practice to load the powder in the

RISK WITH RAW MATERIAL RISK WITH RAW MATERIAL

HANDLINGHANDLING

mould manually. For heavy weights too!

Acrobats may lean out into the mould to

better distribute the powder.

Manual operations of handling the powder

(opening bags, racking between containers,

RISK IN RAW MATERIAL HANDLINGRISK IN RAW MATERIAL HANDLING

weighing) that often remain on the floor can

create slippery surfaces.

THESE RISKS CAN GENERALLY BE

AVOIDED USING MATERIAL HANDLINGS

AND DOSING SYSTEMS FOR A BETTER

WORKING OF THE OPERATORS.

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We produce a system to work in safe where the

material is stored in a silo and is conveyed into

a hopper with a suitable transport system: this

RISK IN RAW MATERIAL HANDLINGRISK IN RAW MATERIAL HANDLING

a hopper with a suitable transport system: this

allow us to eliminate the risk of leakage of the

material and of the handling of the bags.

The system allow an automatic reading of the

labels for the right quantity and weight. The

operator simply directs the pipe into the mould and

presses the button for the right distribution of the

material: no risk of falling into the mold, right

weight dosage and the absence of dust around are

the advantages.

PREPRE--HEATING RISKHEATING RISK

In some cases (complicate shapes with hidden cavities

or to obtain different thicknesses) it is required to pre-

heat the mould.

Systems are available today for automatic pre-

heating:

The use of direct flames on the mould is the current

procedure, even with the mould in rotation!

The high risk of burns or shocks with the moving and

rotating moulds is evident.

- Positioning of the mold directly in front of the

heating source;

- Adjustable deflectors that automatically direct

the air in the desired direction;

- Innovative air circuit in the head of the arm for

the Venturi effect.

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For Example:- Why do we use solvent-base release agents?

W t b d l t d 't i

STAY TUNED FOR THE LATEST TECHNOLOGICAL SOLUTION!STAY TUNED FOR THE LATEST TECHNOLOGICAL SOLUTION!

CONCLUSIONSCONCLUSIONS

- Water-based release agents doesn't require protections and masks.

- QUALITY MOULDS AND QUALITY MACHINES;

- LATEST GENERATION OF MOULD CLAMPS;

- MACHINES DESIGNED WITH SAFETY;

ALWAYS KEEP SAFETY IN MIND!ALWAYS KEEP SAFETY IN MIND!

- KEEP IN TOUCH WITH THE MANUFACTURER FOR ANY

UPDATE/UPGRADE/MODIFICATION ON THE MACHINE.

OBVIOUS: PAY ATTENTION!OBVIOUS: PAY ATTENTION!

Forgetting to close a clamp will cause powder leakage from the mould. The powder is taken

by the fan and the risk of fire can happen. PE has a low fire index but when the fire is

triggered, to put it out can be extremely hard, above all when the structure of the oven is

covered with dirty melted polyethilene.

THANK YOU FOR YOUR ATTENTION!