Our Quality team wants to introduce an induction heat sealer for our range of AdBlue bottles. 

I am to review the task but my initial concern on reading the instruction manual is that it states: 

“do not operate this equipment in a hazardous environment. Operating this equipment near flammable vapours, fuels or combustibles; including atmospheric product dust or particulates, may result in explosion or fire, causing serious injury or death.”

The proposed location of this device will be approximately 4 metres away from where Aerosols are manufactured, and as such it leaves me concerned at the risk of static production and explosion. 

We also have employees who work in the proposed area who are fitted with electronic medical devices, so in my present opinion, the proposed activity should be relocated to eliminate the risk.

Does anyone have any understanding of safe distances away from production which gives rise to airborne vapours, where electronic devices will be safe to use?

Hi Hendlem

In an earlier post your describe yourself as an "Apprentice H&S Officer" and perhaps you have been given a task which should be a team effort.

If the aerosol production near this proposed heat sealer has the potential for an explosive atmosphere then teh company needs to have a "DSEAR" assessment in place and you or I are probably not competent to do this without specialist support.

In very simple* terms if a DSEAR assessment is needed then that should identify what is Zone 0 (probably very small and in the immediate vicinity of the aerosol production), what is Zone 1, typically on oval shape around the point of potential creation of an explosive atmosphere (IF a single point), and then Zone 2.

It is impossible to know (on the basis of the information you give) whether a new process some 4m away would be in any of these Zones.

I suggest it is time for a chat with those owning the process that gives rise to the issue of concern.

*I could describe this in much more complex terms! (including other Zone numbers)

"Caution - contents may be hot!" Beware reading too much in to the content of a manufacturers instruction manual as they often contain statements in an attempt to absolve liability in the event of use by idiot.

I suspect the seal is electromagnetic induction rather than actual "hot plate" meaning as Peter indicates the risks are with the components in the box not being rated for ATEX purposes.

Do have to ask what happened to the previous bottle sealing kit given foil seals are common in motor factor supplies (screen wash, AdBlue, oil, brake fluid etc.) and typically integrated within the packing line.

Alternativley ultrasonic welding is an option (although again the box of tricks may not be ATEX rated).

Originally Posted by: Holliday42333

I agree that the main question you need to resolve is where are the Zones areas from the aerolsol manufacturing.

Is your organisation art of BAMA (the British Aerosol Manufacturers Association)?  If you are they certaily used to have excellent guidance around this and many other topics.

Even if you are not, then its worth contacting them for advice.  I know the Technical Manager at BAMA and he would likely be able to answer your query in his sleep with his hands tied behind his back.

Sorry for the apalling spelling and grammar in the above.  I typed it quickly and since I stopped paying IOSH subs they have taken my editing rights away.  Its the only thing I've noticed missing out on so far from dropping my membership!