BCF Guide To The Safe Operation of Dispersion Equipment

The BCF Guide
To the Safe Operation

of
Dispersion Equipment
British Coatings Federation · Riverbridge House · Guildford Road · Leatherhead · Surrey · KT22 9AD
Tel: 01372 365989 · email: enquiry@coatings.org.uk · www.coatings.org.uk
Ref: HS 033 rev 3.1, Nov 2016 replaces version 3.0 Oct 2016
Changes from version 2.0
Paragraph
2 Added basket mills to scope
8 Added CE Marking requirements
8.1 Added second-hand equipment
12 Added ‘mechanical’ as hazards of triple roll mills covered
Added graphic of triple roll mill
14.1 – 18.2 More guidance and photographs for triple roll mills
15 Updated standard
15.1 Added ‘jewellery’
19 Ball mills continued use
31 Added reference to basket mills
34 Added ‘jewellery’
40 Replace BS EN 292 with BS EN ISO 13857
45 Updated standard reference to BS EN ISO 12100-2
46 Inserted “captive” key
55 Made gender neutral
61 Updated safety distances for square apertures (to BS EN ISO 13857)
69 Updated standard
71 Updated standard
77 Updated standard
81 Ventilation change
96 Added link to HSE Safe Maintenance website
Photographs Good and bad practices highlighted

Photographs All photos renumbered as figures
Photographs New photos inserted in Roll mills section
Figures 3a &3b Replaced photos to show guard in place
Figures 9a-d Updated images of cage enclosure and interlocking
Replaced ‘castle key’ with ‘captive key’
Appendix 1 Reference made to DSEAR

Appendix 2 Add basket mills
Added ‘Not exhaustive’
Added ‘remove jewellery’
Added ‘Check that the pan is securely fixed’
Added ‘and eye protection
Appendix 4 Updated references and links
Appendix 5 Updated Cleaning section to align with Red Book chapter.
The British Coatings Federation is grateful to the members of the Safety Advisory Panel for assistance in the preparation of this
booklet.
2
The illustrations and photographs in this booklet are reproduced by kind permission of Akzo Nobel Decorative Coatings, BASF,
Becker Industrial Coatings, HMG Paints, Millroom Mixing Machines, Sun Chemical, SITA Limited and Tetrosyl.
" The information and guidance contained in this publication is believed at the time of publication to be true and accurate. It is
based on general principles and is intended for general guidance and information only. Its applicability to individual circumstances
must be considered having full regard to the specific prevailing conditions. All recommendations contained in this publication are
made without guarantee and the British Coatings Federation cannot accept any liability in respect of consequences arising
(whether directly or indirectly) from the use of such advice." © BCF 2016
3
SAFE OPERATION OF DISPERSION EQUIPMENT
CONTENTS
PAGE
5. Introduction
5. Legal Background
7. Roll Mills
11. Ball Mills
12. Bead and Shot Mills
13. Vertical Shaft Mixers and Dispersers
29. General Safety Features
31. Maintenance
32. Training
33. Appendix 1 - Specific Legal Requirements
35. Appendix 2 - Operators Checklist
37. Appendix 3 - Risk Assessment - Mechanical Hazards
38. Appendix 4 - References and Further Reading
40. Appendix 5 - BCF Guidance on Cleaning of Plant and Equipment with

Flammable Liquids
4
INTRODUCTION
1 This document is intended to provide advice on the safe operation of dispersion machinery
and equipment used in the manufacture of paint, printing ink and allied products. It focuses
primarily on the risks associated with the use of dispersion equipment and does not attempt to
include all risks associated with ink and paint manufacture. Other guidance is available on e.g.
manual handling, COSHH, handling and storage of flammable liquids, noise (see List of
References and Further Reading - Appendix 4)
2 Specific dispersion equipment covered includes :
 Roll Mills
 Bead, shot, basket and ball mills
 Mixers and dispersers
but the general principles described also apply to all other types of dispersion
equipment.
3 The document is aimed mainly at employers since they have the principal statutory duties,
but is also intended to be useful to machinery operators, supervisors and maintenance staff.
LEGAL BACKGROUND
4 The requirement on employers to provide and maintain plant and systems of work that are, so
far as is reasonably practicable, safe and without risks to health is contained in the Health and
Safety at Work Act. This general duty is expanded and made more explicit in the Management of
Health and Safety at Work (MHSW) Regulations and Provision and Use of Work Equipment
Regulations.
5 The key to identifying the preventive and protective measures needed for machinery safety is
risk assessment. Risk assessment is required under the MHSW Regulations. Appendix 1 gives an
example of how an assessment of mechanical hazards might be made. Similar assessments should
be made of other potential hazards to ensure machine safety e.g. electricity, heat, dust, fumes,
noise etc. Consideration needs also to be given to the working environment, the person etc.
6 Risk assessment means looking critically at the operation of a machine together with the
method of work and operating procedures associated with it to determine if there is the possibility
that someone could be injured, and in what way, so that appropriate preventive precautions can
be taken.
7 Risk assessment can be broken down into five stages :
 identify what can harm people in the workplace

 identify who might be hurt and how
 evaluate the risks and decide how to reduce or control them
 record the finding
 review and update as necessary
It is a good idea to involve employees and safety representatives in the assessment as they will
have experience of what happens in practice and will be required to operate safety procedures.
8. The Supply of Machinery (Safety) Regulations 1992 require manufacturers and suppliers to
ensure that machinery is safe when supplied. It must also be CE Marked. The principles for
5
addressing the hazards from new machinery generally are set out in BS EN ISO 121001. There are
no BS or EN standards specifically covering high speed or rotor/stator mixers. New equipment
must carry the CE mark and be provided with instructions for safe use and a Declaration of
Conformity. The latter must declare in what way conformity with the requirements of the
regulations have been fulfilled, or a Declaration of Incorporation, declaring that partly completed
machinery is intended for incorporation into other machinery or equipment.
8.1 For second-hand machinery, the supplier has an obligation to make sure that it is safe for use and
to provide instructions. It may not be CE Marked (unless it has been totally refurbished). There is
a duty on the buyer to ensure that it is safe, suitable for the work and maintained in a safe
condition.
9. Every dangerous part of machinery should be securely guarded.
10. The Provision and Use of Work Equipment Regulations require that access to dangerous
machinery is prevented by the fitting of fixed guards. Where this is not practicable then removable
guards must be used. If this is not practicable, then other relevant controls may be acceptable.
These could include providing a safe system of work backed up by a permit-to-work.
This must offer the same degree of protection as guarding and should be thoroughly enforced. It
should be supported by adequate instruction, information and training. The risk assessment, with
its reasonings, should be fully documented.
These alternatives may also be appropriate where fitting guards could lead to an increase in the
risk to health and safety.
11. The risk assessment should be used to determine, from a machinery safety and guarding
standpoint,:
• whether there is evidence that significant injury could occur from contact with the
equipment?
• whether it is possible to gain access to the dangerous parts of the equipment? If the
answer is yes, then some control measures will be needed.
Specific legal requirements are listed in Appendix 1.
1
BS EN ISO 12100:2010, Safety of machinery. General principles for design. Risk assessment and risk reduction
6
ROLL MILLS
12. The main mechanical hazards associated with any multi-roll mill are the in-running nip and the
take-off blade, known as the doctor blade or knife. The most common type of roll mill used in
the coatings industry is the triple roll mill.
Fig. 1: Triple roll mill showing position of doctor blade
13. Another hazard associated with roll mills is 'Ink Fly' or ‘Fly’ of other coatings. This can be
minimised through correct product formulation and the use of full covers or ‘fly strips'.
14. On a triple roll mill an in-running nip occurs between the feed roll and the middle roll. This must
be guarded while the machine is in motion. Many operators have lost a finger in unguarded
nips.
14.1 The full width of the nip (including the roll edges outside the hopper/hopper plates) should be
protected by a guard, which is fully interlocked to the motor driving the rolls. Alternatively, the
full width of the nip should be protected by an interlocked hopper assembly. Entry into the
hopper should be prevented by size, position or interlocked protective bars or covers.
Figs. 2a & b: Large triple roll mill showing interlocked “T-Bar” nip guard in place
14.2 The correct operation of all guards and interlocks should be checked regularly.
Should a foreign object be trapped in the in-running nip of a mill, no attempt to retrieve it should
be made while the machine is running (see figure 1). The object must only be removed after the
mill has been brought to rest. An in-running nip also occurs at the bottom of the middle and
apron roll but this is usually safe by position.
7
Figs. 3a & b: Do not retrieve dropped objects from nip, use stop button
15. There are several methods of guarding the in-running nip between the feed roll and middle
roll. The industry standard method is the “T-Bar” that fits in the in running nip. The nip guard
must be mechanically or electrically interlocked to the standards given in BS EN ISO 12100-
2 and BS EN 60204-1. An example is given in figure 2.
Figs. 4a & b: Interlocked nip guards
Fig. 5: A captive key system is used to interlock the power

supply to the mill.
8
15.1 Operators hair and clothing should be tucked in or tied back to avoid being drawn into the nip.
Loose jewellery should be removed
Figs. 6a & b: Avoid loose clothing
Figs. 7a & b: Tie back long hair
16. The knife or doctor blade is mounted on to an apron, which allows the ink being milled to be
discharged into containers (see figure 3). The knife blade is razor sharp and has to be replaced
when worn. Whenever the blade is exposed, for example during cleaning or changing, it must
be protected by a doctor blade cover as it still will be extremely sharp. There should be a
written safe system of work for this procedure which should only be carried out by operators
who have been adequately trained in it. Doctor blades should be stored and disposed of safely.
16.1 One or more accessible, obvious (e.g. by size, shape or colour) emergency stop button should
be fitted (see paragraph 63) as required by the risk assessment. All emergency stop buttons
should be kept clean and tested regularly.
Fig. 8: Emergency stop button on a Fig. 9: Emergency stop with grab line across the
laboratory mill. width of the roll.
9
16.2 The rotational movement of a mill should not be stopped or slowed down by applying friction,
even after the motor has stopped. Rolls should not be able to rotate in the opposite direction.
16.3 The mill should not be allowed to run dry with the rollers in contact.
16.4 The mill should not be left unattended when it is running, unless controls are in place to
prevent unauthorized access.
16.5 Operators should be trained to recognize the hazards and risks involved in operation of the
mill and are supervised as necessary.
17 When cleaning the mill, the apron roll is opened and the scraper tray and the doctor blade
are removed. Care is required as the doctor blade will be extremely sharp. Eye protection and
chain mail gloves (or other gloves with sufficiently high cut resistance) should be worn when
handling blades.
17.1 The apron should be held securely when removed from the mill to prevent it falling or slipping
and causing injury.
18 Safe systems of work should be used when cleaning rollers e.g. clean with cloth at 90° to roller
so that any pressure on the cloth/hand takes it up and away. Where a mill has the facility
cleaning, this should be done at the slowest or “inching” speed. Tools such as scrapers or pallet
knives should only be used when the rolls are stationary. Gloves resistant to the cleaning
materials should be worn. Low flashpoint materials should not be used for cleaning.
Figs. 10 a & b: Cleaning triple roll mill
18.2 A preventative maintenance schedule, specifying all safety critical requirements and inspection,
testing and maintenance schedules should be provided. Engineering and other staff who need
access to mills should have adequate training.
10
BALL MILLS
19 It is understood that ball mills are still used for a small number of operations in the industry. The
principle hazard associated with ball mill operations is contact with the revolving drum
especially when the running-out cock is in position.
20 Access to the mill is necessary for charging, discharging, sampling, pressure relieving and
cleaning activities and precautions should be taken to ensure that the mill cannot turn while any
of these operations is being carried out. Interlock guarding to achieve this should be provided.
If access to the mill is by a manhole in a mezzanine floor the manhole cover should also be
interlocked with the mill.
One way of guarding a ball mill is to enclose it in a permanent guard cage which
prevents access to the revolving drum. Hatches and gates into the caged area should
be protected with interlock guards which prevent entry until the mill is completely at
rest. The mill controls should be positioned outside the cage.
21 Entry into ball mills should be strictly controlled. A written procedure for entry into
confined spaces should be produced in accordance with statutory requirements e.g. minimum
manhole dimensions. The operation should be subject to a written permit-to-work detailing
the precautions to be taken. As a minimum these should include : ensuring that the mill has
been degassed and that a gas free certificate has been issued. If the mill cannot be certified as
safe to enter, full life-support equipment must be worn. In addition the mill should be isolated
from electrical and any other energy source controlling the braking of the mill
22 When there is a risk of a dangerous pressure build up during the running of the mill
arrangements should be made for the mill to be relieved in a safe manner at regular intervals, the
timing depending on the mill size, ball/product charge, viscosity etc. Under some circumstances a
ball mill may become a "pressure vessel" . BCF guidance is available (see Appendix 4).
21 When discharging a mill by pumping care should be taken to ensure that the vent hole is clear or
that the small end is open to avoid the formation of a vacuum which could damage the lining.
22 The discharging of ball mills by use of pressure is not recommended.
23 A significant number of fires has been caused during the charging, discharging and cleaning of
ball mills by static electricity discharges. In addition to the provision of suitable earthing and
bonding arrangements (see paragraph 78). It is recommended that a relaxation period of 15
minutes, to allow accumulated electrostatic charges to dissipate, is allowed between the mill
coming to rest and any further activity. Because of their insulating properties brick lined mills
and porcelain/steatite balls have a higher static risk than steel.
11
BEAD AND SHOT MILLS
24 Bead and shot mills may be of the horizontal or vertical type. The power transmission machinery
must always be securely enclosed when the machine is in operation (see figure 4).
Fig. 11 Horizontal bead mill
25 Care should be taken to monitor the flow to ensure no undue pressure builds-up. Pressure
relief should be provided. Attention should also be paid to temperatures, in particular with
horizontal machines where spitting of product from the outlet pipe may occur. The set-up should
be designed to avoid this e.g. by the use of closed receiving tanks, coupled discharge pipes
26 Care should be taken to prevent the build-up of product in equipment, with particular attention
paid to pipes, junctions, constrictions and outlets. Regular cleaning and maintenance is required.
27 Vessels should be adequately earthed and bonded to the mill to prevent static build-up on
discharging product.
12
VERTICAL SHAFT MIXERS AND DISPERSERS
28 There are a number of types of mixers and dispersers , including basket mills, but the common
hazards for all of them are the rotating shaft and the blade (impeller) either of which may be
exposed during loading, cleaning, sampling and maintenance (see figures 5 and 6). If shafts are
exposed they may cause serious injury if people or clothing or objects that people are handling
become wrapped around the shafts. Photographic examples of poorly guarded machines are
shown in figure 12a & b.
X X
Figs. 12a & b: Inadequate guarding
Accident Experiences
29 Serious a cc id en ts co nt in u e to o cc ur w it h such equipment. Many accidents
have occurred when adding powder from paper or plastic bags into open vessels.
30 It is not sufficient to rely on people acting sensibly, it is important to physically

prevent them coming to harm.
Accident Experience
An operator was emptying powder from bags into a vertical bead mill. Some of the wrapping
caught on the vertical rotating shaft and pulled his arm towards it. He managed to pull his
arm free. The operator suffered a broken forearm, which required a hospital operation to
reset it.
Types of Vertical Shaft Mixers

31 The mixers and dispersers which have vertical shafts can be divided into a number of
types
Type 1: Lifting or Swinging Head Dispersers for use with Mobile Open Vessels (portable pans);
these are usually variable high-speed (1000 to 1500 r.p.m.) dispersers with permanently mounted
shafts and blades. The complete motor, stirrer and drive mechanism is raised and lowered to
place the dispersion blade in the vessel.
Type 2: Lifting or Swinging Head Mixers for use with Mobile Open Vessels;
these are usually fixed speed slow (<500 r.p.m.) speed mixers, often with a coupling allowing
the stirrer blade to be detached in order to move the vessel.
Type 3: Fixed Head Dispersers mounted in Fixed Closed Vessels;
13
these are variable high-speed machines.
Type 4: Fixed Head Mixers mounted in Fixed Closed Vessels (tanks);

these are usually fixed slow speed mixers.
Type 5: Rotor/Stator Mixers;

these consist of a mixing head assembly comprising a high speed rotating blade (rotor)
within a stationary perforated ring and bottom plate (stator). They are variable high- speed
machines. These include basket mills where a basket containing beads surrounds the rotating blade.
These can be supplied with dedicated mixing vessels (see Figs. 2 a & 2 b.
There are machines which have characteristics of more than one type.
Figs. 13a & 2 b: Vertical shaft mixers with dedicated moveable vessels
31a Smaller (almost portable) mixers (see figure 1 4 ) also have an accident history and need similar
guarding standards to Types 1 and 2. Where the fitting of fixed or removable guards is not practicable
then other relevant control measures may be acceptable. These controls must be very effective and
could include control by virtue of location, physical warning barriers such as plastic chains or stopping
arrangements e.g. adjacent emergency stop button / pull cord/ isolation switch, supported by suitable
training, instruction and supervision. A risk assessment, which will need to be sufficiently robust to
satisfy HSE inspectors, will dictate requirements. An example of a shaft guard and lid is shown in figure
15.
X 
Fig. 14: Small mixer, unguarded Fig. 15: Small mixer, guarded
14
32 From a machinery safety and guarding standpoint three questions have to be asked:
 Are the moving parts accessible? If so, there is likely to be a need for control measures.
 Would contact with the moving parts result in significant injury? If so, control measures will
need to be applied.
 Is the disperser/mixer head used with mobile open vessels or permanently mounted in a
fixed closed vessel? Because different methods of guarding are used for fixed and mobile
vessel.
Change pan mixers are a greater hazard because of the increased risk of exposure to
the impeller and shaft
Guarding of Dispersers for use with Mobile Open Vessels Types 1 and 2
33 The most dangerous part of the machine is the rotating shaft and blade.
These have to be enclosed to prevent contact with them.
34 Contact with the shaft and subsequent entanglement by hair, jewellery, clothing or, as
has happened in several accidents, powder bags, should be prevented as recommended below.
Lids
35 The only certain way to prevent contact with the shaft is to fit the disperser with a
permanently attached lid with a permanent or interlocked grille (or mesh) for addition of
powders and liquids (figure 1 6 ). Removable lids (figure 1 7 ) are not recommended; they rely
on operators to put them on.
 X
Fig. 16: Permanently fitted lid Fig. 17: Removable lids are not recommended
Vertical Movement of Lids

36 Permanently attached lids must be free to move vertically so that they remain in place on the
top of the mobile vessel when the blade is raised from its lowest position to its highest working
position. (The highest working position will normally be about half way up the mobile vessel, two
thirds at the most.) The travel distance allowed by the sleeve enclosing the upper part of the shaft
and the pneumatic or hydraulic retraction cylinders must be equivalent to this working height
adjustment (figure 3 7). (See also comments in paragraphs 43 - 47 concerning interlocking).
15
Accident Experience
An operator was charging powder from plastic bags into a mobile vessel. A bag caught on
the vertical stirrer shaft. The bag became entangled with his arm, which was broken in two
places.
Guarding of Shafts above Lids

37 The shaft above the lid must be totally enclosed. This is preferably achieved by an outer sleeve or
a telescopic sleeve or bellows. All have been used successfully in the past (figure 1 8) Where such
sleeves or tubes are open to the pot they will become contaminated with powder and resin. They
should be cleaned regularly because friction between the shaft and accumulated resin has caused
at least one fire.
 
Fig. 18: Bellows sleeves shaft to its Fig. 19: Solid sleeve protects maximum
working height shaft to its maximum working height
38 A simple, cheap method of guarding mixer shafts is to attach a vertically-moveable rod that
holds a flexible concertina tube (similar to that used on tumble dryer vents) (see figure 7).
Fig. 20: Simple method of guarding rotating shaft
16
Grilles/Bars
39. All reasonably practicable steps should be taken to provide guarding which minimises the chance of bag entry
and entanglement during discharge. A lid with an open hole or a single bar across the opening is not enough.
A grille or bars running from front to back i.e. at right angles to the mouth of a b ag, should be used (figure
2 1 ). Bars may be used instead of a grille to minimise the build up of residues due to accumulation
of resin and pigment. Bars must be thick enough so that they do not bend but should be of the
minimum diameter possible consistent with strength to minimise resin/pigment “hold up”. A less
than ideal example is shown (photograph 10).
 X
Fig. 21: Bars across opening Fig. 22: Bars spaced too widely
40 The width between the grilles will depend on the safety distance between the opening and
the dangerous parts, and whether they are square or slotted. The safe distances for given apertures are
given in BS EN ISO 13857.
Slotted grille/bars
Grille/bar aperture width Safety distance
< 120mm > 850mm
< 20mm > 120mm
But if aperture < 30 x 65mm > 200mm
Square grille
Grille aperture width Safety distance
< 120mm > 850mm
< 40mm > 200mm
< 30mm > 120mm
Distances for smaller slotted apertures are given in paragraph 61. Other distances for
square and round apertures are given in the standard.
41 If the grille/bar aperture widths are impractical due to contamination caused by material build-
up, safety distances can be increased by the use of permanent or interlocked charging
chutes/funnels or raised tables.
Accident Experience
An operator was charging powder from a large bag with a plastic inner liner into a
mobile vessel under a high speed stirrer. The inner bag touched and wrapped around
the vertical shaft dragging his arm into it. Both bones of the forearm were broken and one
was exposed. The operator’s arm was reset surgically and he was kept in hospital for some
days.
17
42 The distances given in paragraph 40 above are those recommended by the European standard,
however, these may not in all cases be appropriate to the coatings industry and different standards
may be required. These will be highlighted by the risk assessment.
The recommended safety distance does not take into account the probability of a raw material
bag entering through the grille/bars with an aperture width of, say, 120mm, wrapping around the
rotating shaft and pulling in an operator’s arm subjecting it to a sideways force, causing injury
against the bars or the lid.
To avoid this three possible actions are suggested:
a) ensuring that the slots are at right angles to the orientation of the bag when
loading e.g. running from front to back
b) reducing the grille/bar aperture widths e.g. from 120 to 50m
c) increasing the safety distance by installing interlocked hoppers for loading raw
materials from bags .
43 An interlocked grille, which stops the disperser when it is removed, may be used.
Liquids from drums or pails may be added with the grille removed and disperser stopped
and then mixed in provided this is technically allowable. Grilles with magnetic instead of
mechanical interlocks have been used successfully in a number of coatings factories. They must be
of a design that cannot be defeated by use of a metal object.
Cleaning
44 It can be difficult to clean the shaft and blade when interlocks are fitted. A useful device to
assist in cleaning by retracting the lid is shown in (figure 2 3 ).
Fig. 23: Device for retracting lid for cleaning Fig. 24: Vessel secured with clamp
18
Bottom Enclosure
45 The shaft and blade should also be guarded by;
• Placing the shaft/and blade inside a vessel.
• Making sure that the shaft/blade cannot be started if is not inside a vessel.
46 The vessel should be secured in place with a clamp or strap (photograph 12). The clamp or
strap should be fitted with an interlock (photograph 13) which does not allow the motor to be
started if a vessel is not clamped or strapped in place (see figure 8).
Fig. 25: Clamp/strap set-up
Guarding may be achieved by enclosing the whole machine in a cage with an interlocked
access gate (see Figs. 26-27). Those where the change pan needs to revolve as part of
the mixing process should be guarded in this way (see BS EN ISO 12100-2 and BS EN
60204-1). This system can also be used for ball mills.
Figs. 26a & b: Interlocked enclosure for whole machine
19
Figs. 27a & 9b: Detailed view of the interlocking
A captive key is removed from its station, which isolates the machine electrically. The key is then
used to open the guard door (which has a secondary interlock).
47 A strap should be used instead of a chain; it gives a better grip. A chain/hook

adjustment at the end of the strap (figure 2 9 ) may be preferable to a strap tensioner as
it is easier to adjust and is less likely to slip.
Fig. 28: Strap interlocking device Fig. 29: Chain/hook adjustment
48 As well as ensuring that a vessel is locked in place to prevent contact with the shaft and blade
the clamp/strap also keeps the vessel in position to ensure that it does not move during
dispersion and that the dispersion blade does not hit the vessel.
49 The clamp/strap should be capable of working with any small vessels used e.g. 205 litre drums.
An adjustable spacing bar may be used for supporting a small vessel or drum in a central position.
50 The disperser should also be prevented from starting when the blade is above the top of the
vessel by a height sensor interlocked to the motor. This is usually done by a sensor on the
20
pedestal which supports the machine (figures 3 0 & 31). The height at which the sensor cuts out
the motor or prevents it starting should be at or before the point when the lid starts to lift
off the vessel and such that the blade is well below the top of the vessel. This height adjustment
is important. The bottom of all vessels used should be below the minimum height of the
dispersion blade; holes have been made in the bottom of pans in the past.
Fig. 30: Height sensor interlock on upright Fig. 31: Height sensor interlock
51 When a vessel does not guard the disperser blade - even though it cannot start – any sharp
edged blade can be guarded with a temporary blade enclosure such as a small drum or by
removing the blade, or by covering it with a split hose.
52 Shaft guards should be secured with fastenings that require a tool for removal (figure
3 3 ) or should be interlocked (figures 3 2 a & b )
Figs. 32 a & b: Interlocked guards
21
Fig. 33: Shaft guard requires
tool to remove
52a Operators must not be able to reach into mixing containers whilst the mixer is in motion and
must not sample the mix until the mixer is at rest. Whilst the machine is in motion no attempt
should be made to retrieve any object which may have fallen into the mix (see figure 10). See
further examples of inadequate guarding in figures 11 a and b.
Fig. 34 Do not reach into vessel whilst mixer is in motion
Guarding Fixed Head Dispersers in Fixed Closed Vessel Types 3 and 4

53 Guarding of these vessels is essentially the guarding of the charging hatch and any exposed
portion of shaft / drive coupling.
Drive Mechanisms / exposed drive couplings & shaft

54 Drive mechanisms should be fully enclosed (figure 3 5 ). Any exposed portion of shaft / drive
coupling (figure 36) must also be enclosed (figure 3 7 )
Accident Experience
Having switched off the power a temporary operator tried to stop the still rotating mixer
shaft using his hand. He was wearing rubber gloves. He broke his arm severely.
22
 X
Fig. 35: Drive mechanism fully enclosed Fig. 36: Drive coupling exposed
 X
Fig. 37: Drive coupling fully enclosed Fig. 38: Risk from falling into low level hatch
Person Entry
55 If the hatchway is large enough to permit the entry of a person for maintenance then it is
large enough for them to fall in accidentally particularly when the hatch is at or near ground
level (figure 3 8 ). This must be prevented by making the opening smaller. The simplest way is
to fit bars across the opening (figure 3 9 ). Bars should be secured at each end either with a
locknut or a split pin; it should not be possible to remove the bar(s) without tools (figure 4 0 ).
23
Fig. 39: Bars to prevent falling into vessel Fig. 40: Grille can only be removed with a tool
Entanglement; High Speed Shaft/Blade through the hatchway

56 The distance between the opening and the high-speed shaft/blade is normally large; so big that
bags/clothing at the opening cannot reach them. In this case the shaft is “safe by distance” and
there is no need for a grille (although one may be used to prevent a bag being dropped into
the mixer for quality reasons). This can also be improved by relatively simple measures (figures
4 1 - 42). A simple device to assist adding liquids can be used (figure 4 2 ).
Figs. 41a & b: Simple methods to prevent reaching shaft
Fig. 42: Simple device to assist adding liquids
24
57 In some instances the opening lid may extend almost the full width of the
vessel (figure 4 3 ). This is unnecessary and consideration should be given to
modifying the lid so that there is only a small hatch for normal use.
Entanglement; Scraper Blade Drives

58 Many closed vessel dispersers are fitted with slow speed scraper blades that clean the
inside surface of the vessel. Often these, or the arms that drive them can be reached
through the charging hatch (figure 4 4 ). They can provide a trapping hazard as
they pass the bar(s) protecting the opening. Resin and powder may accumulate
on these arms and there is a need to clean them after powder addition. This is usually
achieved by an operator leaning into the vessel and brushing the tops of the arms.
 X
Fig. 43: Full width lid opening Fig. 44: Hazard from scrapper blades
59 To ensure that this procedure is safe the arms must be stopped. To achieve this the hatch
must be fitted with a grille which is interlocked to the scraper drive or the hatch itself can be
interlocked.
Accident Experience
A temporary worker had his arm broken when he became entangled with the rotating shaft of a
stirrer running at slow speed. He was removing a plastic sheet covering the mixing vessel which
became wrapped around the shaft drawing him in. He also fainted and his head and trunk (part)
became immersed in the dispersion paste. Fortunately a co-worker heard the mixer making
unusual noise and rescued him. A similar incident occurred in France and the operator was killed.
25
Rotor/Stator Mixers Type 5
60 Open bars–type guarding, as usually supplied with this type of equipment is not considered
satisfactory. It is recommended that the shaft is fully protected by the use of further enclosures
such as bellows or cages (figure 4 6 - 49). Care should be exercised in choice of materials as some
rubbers and plastics may be susceptible to attack by the solvents used. The condition of these
should be monitored.
Small mixers may also need guarding to similar standards in order to prevent injury (figure 4 5 ).
The risk assessment will indicate this. Where the fitting of fixed or removable guards is not
practicable then other effective control measures may be acceptable (see paragraph 31a).
Fig. 45: Small rotor/stator mixer – poorly guarded
Fig. 46: Bellows to protect shaft of Fig. 47: Cage to protect shaft of rotor/stator mixer
rotor/stator mixer
26
61 The safety distances for small apertures, to prevent fingers or hands from coming into contact
with the moving parts, are given in BS EN ISO 13857 (see also paragraph 40).
Safety distance between protective bars and moving parts
Aperture width Slotted aperture Square aperture
< 20mm < 120mm < 120mm

< 12mm < 100mm < 80mm
< 10mm < 80mm < 25mm
< 8mm < 20mm < 15mm
< 6mm < 10mm < 5mm
< 4mm < 2mm < 2mm
Fig. 48: Cage of mixer opened for cleaning Fig. 49: Close up of cage protecting shaft of
rotor/stator
All Types
62 The cleaning of mixers should always be carried out when the machine is at rest and isolated.
Long-handled brushes would be appropriate for cleaning. Use brushes with natural bristles
as synthetic ones may become electrostatically charged.
27
In normal operation variable speed mixers should be started at and brought to rest from
the slowest speed.
63 Other issues that need to be considered in vertical shaft guard design are:
 Interlocks should be robust and reliable and difficult to defeat. They should be of the
positive type, which means that they cannot be simply taped over, or if magnetic of a
type that cannot be defeated by placing metal against the switch.
 An emergency stop button should be fitted to the disperser/mixer close to the operator’s
normal loading position. Release of the emergency stop should not cause the machine
to restart.
 Maintenance should be carried out with the equipment physically and electrically isolated. It
is highly recommended that, for maintenance, a permit system should be used.
 All guards should be regularly inspected and interlocks should be regularly tested (at least
weekly). Trained operators may do this – a checklist is useful. (Checklists can now be easily
prepared which include photographs of the actual equipment illustrating the relevant
safeguards which must be checked –digital cameras and desktop PC’s make this easy.
 All controls should be clearly visible and identifiable to the operator and labeled where
appropriate. Start buttons should be shrouded to prevent accidental operation and should
be kept clean.
 Operators need to be trained in the potential hazards of the equipment and the reasons why
the guards and interlocks are present.
The risk of crushing e.g. head, arm, body when lowering a lid onto a vessel should be
taken into consideration in the risk assessment.
28
GENERAL SAFETY FEATURES
64 New equipment must carry the ‘CE’ mark, but in addition it should be checked to ensure that the
supplier has met his legal duties regarding supplying a machine in a safe condition and that the
necessary information for its safe installation, operation and maintenance has been provided.
65 Where existing machinery needs to be upgraded to comply with statutory changes etc. the
original supplier or manufacturer may be approached to supply the necessary guards or advise
on any other protection necessary.
66 The results of the assessment will show what guarding is required. Fixed guards should be provided
wherever practicable e.g. regulation 11 of the Provision and Use of Work Equipment Regulations
requires that fixed guards of adequate construction and strength must be provided for all
dangerous parts e.g. gears, chains belts etc.
67 Where it is not practicable to provide fixed guards, or where it is necessary to remove guards
frequently, they should be interlocked by mechanical or electrical means to ensure that the
machine cannot operate without the guards in position.
68 The main methods of interlocking are electrical limit switches, electrical interlock and captive key
systems. Whichever system is used it should be sufficiently robust to operate in the environment
for which it is intended. Interlocks should operate in the positive mode and fail to safety.
69 The relevant standards for guarding are given in BS EN ISO 12100-2 & BS EN 60204 -1. In general
what is required is that access to dangerous parts should be prevented while the machine is
operating including any run down period.
70 Machinery should be provided with appropriate controls to ensure its safe operation e.g. it
should only be possible to start or restart a machine by using a control. The requirement for two-
handed start up controls, to ensure operator is clear of danger area should be considered.
71 Where the assessment shows it to be appropriate, machines should be provided with one or
more easily accessible emergency stop buttons as indicated by the risk assessment. Common types
of emergency stop controls are mushroom-headed buttons (coloured red with a yellow
background), bars, levers or kick-plates. Guidance on specific features of emergency stops is given
in the following standards, BS EN ISO 12100-2 & BS EN 60204 -1) . Release of the emergency
stop button should not cause the machine to restart. Emergency stop controls should not be
used routinely during operation and should not be considered a substitute for necessary
safeguarding. They should be kept clean. Consideration should be given to the needs of left-
handed operatives when siting emergency stop controls.
72 Means of isolating the machine from electricity and other sources of energy should be provided
for maintenance activities and in case of emergencies.
73 All controls should be clearly visible and identifiable to the operator and labelled where
appropriate. Start buttons should be shrouded to avoid accidental activation.
74 Where vulnerable workers e.g. lone or handicapped personnel are involved, consideration
should be given to linking the emergency controls to an audible warning system.
75 Any personal protective equipment (PPE) e.g. overalls, dust mask footwear, including any respiratory
protective equipment (RPE), which is specified as a result of the assessment must be used by
operators. Loose clothing and soft shoes should not be allowed. Long hair should be contained e.g.
by a snood and jewellery which might become entangled should not be worn.
29
76 PPE must comply with the PPE at Work Regulations and carry the CE mark. PPE should be used
and maintained in accordance with the suppliers instructions.
77 Where there is a risk of a flammable mixture of vapours being present electrical equipment
should be constructed and installed to a suitable explosion-protected equipment standard.
Advice on the selection and installation of such equipment is given in BS EN 60079-10 Explosive
atmospheres. Classification of areas. Explosive gas atmospheres. Part 102.
78 Precautions should be taken to prevent vapours being ignited by the discharge of static
electricity. Static electricity can build up from the movement of all materials, powders as well as
liquids. To protect against static build, up all fixed equipment should be earthed and bonded
together to ensure equal electrical potential between the equipment components. Mobile
equipment should be earthed and bonded by the use of earthing clips and connectors. Earthing
clips should be robust enough to withstand the handling and use that they will meet. They should
be regularly cleaned to remove accumulated paint and ink deposits so that electrical continuity is
maintained. Earthing points should be kept clean. BCF guidance on the safe handling and use of
flammable liquids is available (see Appendix 4).
79 People can also become electrostatically charged and be the source of a static discharge.
Operators should wear conductive overalls, gloves and anti-static footwear which should be kept
clean and free from build-up of deposits.
80 An adequate level of lighting should be provided in all working areas.
81 Sufficient ventilation should be provided to achieve six air changes an hour. Where general
ventilation is not sufficient to reduce vapour concentrations to below their flammable limit or the
relevant occupational exposure limit mechanical and/or local exhaust ventilation will be needed.
82 Occupational noise levels should be checked and remedial action taken if they are found to
exceed statutory standards.
83 High standards of housekeeping are essential to the maintenance of a safe and healthy working
environment. Spillages should be cleared when they occur and not allowed to build up. Waste
should be removed from the workplace to a safe place, preferably in the open air, at the end of
each shift. Cleaning cloths which are soiled with flammable solvent or resin/paint/ink are liable to
spontaneously ignite and so should be placed in a metal, lidded container and removed from the
workplace at the end of the shift to a safe place. Special care is required where there is a risk of
spontaneous combustion.
84 The use of flammable liquids for cleaning purposes presents special risks and suitable
precautions should be taken. BCF guidance on the safe handling and use of flammable liquids is
available (see Appendix 5).
85 Further guidance is given in the BCF publication "Guide to Good Housekeeping and Spillage
Handling" see Appendix 4).
86 All personnel should be encouraged to report hazards and defects.
2 Explosive atmospheres. Classification of areas. Explosive gas atmospheres. Part 10;, BS EN 60079-10: 2015, BSI
30
MAINTENANCE
87 30% of all accidents that occur in the chemical industry happen during maintenance activities,
thereby showing the extra care necessary when such work is being carried out.
88 There is a statutory duty to ensure that work equipment is maintained in an efficient state, in
efficient working order and in good repair. Due note should be taken of the supplier’s
recommendations on servicing and maintenance.
89 Maintenance work should only be done by those who have received adequate information,
instruction and training. Contractors should be given adequate information to allow them to carry
out the job safely. Plans should be drawn up with contractors taking account of the effect of the
work on site staff and of site work on the contractors. Local rules e.g. no smoking, and any
special safety requirements should be communicated.
90 Although limited maintenance may be undertaken by an appropriately trained operator, more

extensive work will be carried out by maintenance engineers. Responsibility must be carefully
defined as to which maintenance procedures are to be carried out by which persons and be clearly
understood by all those involved.
91 A programme for the regular inspection, testing and maintenance of all guards and other
protective devices should be established including :
- inspection and testing of guards, including interlock guards;

- checking drive belts for tightness and wear;
- the alignment of shafts and impellers;
- checking the integrity of electrical equipment and wiring;
- inspection and testing of earthing and bonding systems
92 Equipment must always be isolated from electricity and other sources of energy before guards
and power transmission cladding is removed.
93 All guarding must be reinstated before equipment is handed back to the operators.
94 A written permit-to-work system should be considered for maintenance work both by employees
and outside contractors.
95 It is possible that the maintenance operation could become subject to the Confined Spaces
Regulations. The definition of confined space is a place which is substantially (though not always
entirely) enclosed, and in which there is a risk of hazardous substances or conditions. Examples
include the inside of a mixing vessel or machine in which flammable vapour or one hazardous to
health could be present. In such cases, entry should be prevented. If this is absolutely necessary
and all other methods have been exhausted, a safe system of work should be employed.
96 Further information and advice is contained on the HSE Safe Maintenance website
www.hse.gov.uk/safemaintenance/index.htm.
31
TRAINING
97 There should be a Safety Training programme for all employees from directors to shopfloor
workers. Records should be kept of all training given so that each employee's development can
be checked and further training needs recognised.
98 In addition to general safety training, employees working with machinery will need specific safety
training to understand the principles of machine guarding, the need to maintain guards in good
condition and the need for safe systems of work for particular operations where the potential for
hazard is high, e.g., cleaning procedures, locking off procedures.
99 Under no circumstances should an employee be asked to do a job for which he/she has not
been trained
100 It is recommended that retraining is carried at appropriate intervals or when procedures,

processes or personnel change.
32
Appendix 1
Specific Legal Requirements
Suppliers, employers and employees all have legal responsibilities for the safe provision and use of
machinery:
Suppliers
- suppliers of machinery and equipment must ensure that they comply with legal requirements and
in particular that the equipment meets the "essential health and safety requirements” of the The
Provision and Use of Work Equipment Regulations 1998.
- suppliers must provide sufficient information, including drawings, to make possible the correct
installation, the safe use and maintenance of machinery
Employers
- every part of transmission machinery and every dangerous part of all other machinery shall be
securely guarded
- the guards shall be properly constructed and maintained and shall remain in position whilst the
machine is in motion or in use
- the risks arising from lifting, carrying and handling tasks should be assessed and appropriate
safeguards implemented. Particular attention is drawn to the manual handling of change pans,
mixing bowls and mobile tanks
- workplaces sho uld be provided with adequate ventilation and lighting, kept at a reasonable
temperature and kept clean
- exposure to hazardous substances and processes should be assessed and controlled
- where assessments show It to be necessary appropriate and approved PPE should be provided
- written procedures and systems of work should be prepared for high risk activities e.g. entry into
confined spaces
- a written permit-to-work system should be used when jobs are carried out In the absence of normal
safeguards or when they introduce abnormal hazards
- noise levels should be assessed and action taken to control or reduce excessive exposure
- ball mills may become pressure vessels under certain circumstances and the Pressure Systems
Regulations would apply (see BCF note PUB/83 for further guidance)
- adequate information, instruction, training and supervision should be provided for all levels of staff
to enable them to use equipment correctly and to work safely
Employees
- should take reasonable care of their own health and safety and that of others who may be affected
by what they do or do not do
- should co-operate with their employer on health and safety matters and report any health and safety
problems
33
- should not interfere with or misuse anything provided for their health, safety and welfare
- should use correctly any work item provided in accordance with the training and instruction
they receive in its safe use.
34
Appendix 2
OPERATORS CHECKLIST
General (not exhaustive)
Before Starting
Ensure that guards are in place and are in good condition

Ensure that earthing leads and clips are in place and are free from insulating deposits
Ensure that general and any local exhaust ventilation is switched on
Ensure that you are using the correct personnel protective equipment for the job
During Operation
All personal protective equipment supplied should be worn

Spillages should be cleaned up immediately
Waste should not be allowed to build up
Soiled cleaning cloths should be put into metal lidded containers and removed from the
workplace daily
Any potential hazards or failures in safety equipment should be reported immediately
.. .
Three Roll Mills
Before starting
Remove or secure loose clothing (ties, cuffs, etc) and jewellery

Tie back long hair
Familiarise yourself with the location of emergency stop buttons and check that they work
Check that the nip guard is securely in place
Check that the hopper is securely in place
Check that the pan is securely fixed
Carry out any routine safety checks as instructed
Report any faults immediately to your supervisor/manager
Do not use a machine that you think is unsafe
During Operation
Do not allow untrained persons to run, or help to run, the mill

Use a guard at all times – never attempt to use the mill without one
Do not lean over to the apron from the back of the mill
Always work away from the back (in-running) nip with knives, etc
Do not try to scrape down the guard when the mill is running
Do not allow the mill rolls to run dry
Do not leave the mill unattended when it is running
Stop the machine before attempting to remove a foreign object in the nip
During Cleaning
Do not allow untrained persons to clean any part of the mill

Ensure that you have suitable gloves and eye protection
35
Clean rotating mill rolls with your fingers pointing away from in-running nips
Use well soaked wipers for cleaning rotating rolls
Always clean rotating mill rolls with the guard in place – do not remove the guard even if it
is possible
Do not scrape rotating rolls with knives, etc to remove ink or coating
When cleaning do not place knife or cloth near nip
Do not scrape the guard to remove ink/coating when the rolls are rotating
Use the tools provided to remove the doctor blade from the apron
Work over a bench to avoid dropping the blade/mill apron on your
feet
Take care when handling sharp blade; wear chain mail gloves
Use plenty of wipers between your hands and the blade
Take great care when reassembling the doctor blade/apron and use the tools provided
Always use interlock when removing guard
Ball Mills
Always use interlock when entering or accessing ball mill area

A full permit-to-work system must be used if the ball mill is to be entered
Receptacles should be earthed and bonded to the mill to avoid static build-up on charging and
discharging
Pressure should not be allowed to build-up in the mill
If discharging by pump, ensure vent is clear
Bead and Shot Mills
The temperature and flow through the mill should be monitored to prevent pressure build-up
Receptacles should be earthed and bonded to the mill to avoid static build-up on discharging
Mixers and Dispersers
Exposed shafts should be guarded

Do not attempt to take a sample or reach into the vessel until the mixer has completely stopped
Do not attempt to clean a machine unless it is completely at rest
36
Appendix 3
Risk Assessment - Mechanical Hazards
Stage 1 identify the hazards
1 What are the moving parts ?

They may include:
- transmission parts e.g. pulleys, belts, gears, rack and pinion shafts
- operational parts e.g. rollers, blades, impellers etc.
Does their movement present a hazard taking Into account any existing safeguards ?
What kind of harm or injury might they cause e.g. entanglement, impact, drawing-in
(nips), abrasion etc.
Are there any static parts that may cause harm e.g. take-off blades ?
Will the product create additional hazards e.g. flammable or harmful fumes, “ink fly”, heat ?
Stage 2 who might be harmed and how
2 Consider not only machinery operatives but also maintenance staff, cleaners, contractors, visitors
etc. Pay particular attention to especially vulnerable individuals e.g. lone workers, young and
inexperienced staff and those with disabilities
3 Identify those situations and activities which might result in the hazard causing injury :
- consider all the activities involved in the dispersion process e.g. setting-up, charging,
sampling, cleaning etc.
- look at what is actually done rather than how it should be done or how you think it is done
- look particularly at situations where normal safeguards cannot be relied on e.g. removal
of guards during maintenance
Stage 3 evaluate and prevent/control the risks
4 Once the risks have been identified all reasonably practicable steps should be taken to prevent or
control them to prevent injury. The precautions that are taken should be proportional to the risk
- the greater the risk the more will need to be done to control It.
5 A hierarchy of controls of four levels is recommended by HSE
- fixed enclosing guards

- other guards or protection devices
- protection appliances e.g. jigs or holders
- the provision of information, instruction, training and supervision.
Stage 4 record the findings
A written record of the assessment should be made and maintained
Stage 5 revise and review the assessment
6 The assessment should be reviewed when there are reasons for thinking that it is no longer valid
e.g. if there has been a change in the product or in the method of work. It should be revised
as necessary.
37
Appendix 4
References and Further Reading
Acts
The Health and Safety at Work etc. Act 1974
Regulations
Control of Substances Hazardous to Health Regulations 2002 (SI2002:2677) and amendments

The Management of Health and Safety at Work Regulations 1999 (SI1999:3242) and amendments
The Manual Handling Operations Regulations 1992 (SI 1992: 2793) and amendment (SI2002:2174)
The Personal Protective Equipment at Work Regulations 1992 (SI 1992: 2966) and
amendment (SI2002:2174)
The Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 1995 (SI 1995:
3163) and amendments SI2012:199 SI1471:2013
The Electricity at Work Regulations 1989 (SI1989:635)
The Provision and Use of Work Equipment Regulations 1998 (SI1998:2306) and amendment
(SI2002:2174)
The Workplace (Health, Safety and Welfare) Regulations 1992 (SI 1992: 3004) and amendment
(SI2002:2174)
The Dangerous Substances and Explosive Atmospheres Regulations 2002, SI2002:2776
The EU Regulation on Classification, Labelling and Packaging of Substances and Mixtures
(1272/2008/EU)
HSE Guidance
HSE Work Equipment and Machinery webpages

Managing Contractors - A guide for employers
Managing Contractors, HSE webpages
Permit-to-work systems in the chemical industry
Confined spaces, HSE webpages
Controlling risk in the workplace, HSE webpages
COSHH Essentials, easy steps to control chemicals
Personal Protective Equipment at Work, HSE webpages
Manual Handling, Guidance, HSE webpages
Chemical warehousing: The storage of packaged dangerous substances, HS(G)71
The Storage of Flammable Liquids in Containers, HS(G)51
The Storage of Flammable Liquids in Tanks, HS(G)176
The Safe Use and Handling of Flammable Liquids, HS(G)140
Noise at Work, HSE webpages
Electricity at Work: safe working practices, HS(G)85
Vehicles at Work, HSE webpages
The Management of Health and Safety at Work, HSE webpages
Dangerous substances and explosive atmospheres. Dangerous Substances and Explosive
Atmospheres Regulations 2002. Approved Code of Practice and guidance L138.
British and European Standards

BS EN ISO 12100:2010, Safety of machinery. General principles for design. Risk assessment and
risk reduction
38
BS EN ISO 13857:2008 Safety of machinery. Safety distances to prevent hazard zones being
reached by upper and lower limbs
BS EN 60204-1:2006+A1:2009. Safety of machinery. Electrical equipment of machines. General
requirements
BS EN 60079-10-1:2015, Explosive atmospheres. Classification of areas. Explosive gas atmospheres
PD CLC/TR 60079-32-1:2015, Explosive atmospheres. Electrostatic hazards, guidance
BCF Guidance
Safe Handling and Use of Flammable Liquids in the Surface Coatings Industry, HS008
COSHH: Hazard rating of raw materials, HS020
Guidelines to the COSHH Regulations, HS015
Guide to Work in Confined Spaces, HS006
Guide to Good Housekeeping and Spillage Handling, HS018
Ball Mills as Pressure Vessels, PUB/83 (available from the BCF)
39
Appendix 5
The Cleaning of Plant and Equipment with Flammable Liquids
Introduction
Like any other work activity, cleaning operations should be assessed to identify the hazards that exist
in carrying them out and the nature and degree of the risks that might arise. Appropriate and
adequate measures should then be put in place to prevent or control the risks. The risk assessment
should also identify how much training and information is required for staff.
Control Measures
What needs to be done in any particular situation will depend on the result of the assessment but the
following will be relevant in all manual cleaning activities involving flammable liquids :
 Ventilation
Good ventilation will ensure the dispersal of flammable vapours.
All areas where cleaning with flammable liquids takes place should be adequately ventilated to
dilute any released vapours to a safe level, below the lower explosive limit. A risk assessment will
determine the level of ventilation required. Whatever its capacity, the ventilation should ensure
that the amount of vapour in any work areas is not only diluted to well below its flammable limit,
but also reduced to a level below the relevant occupational exposure limit. (Guidance note EH 403
gives advice on occupational exposure limits.)
Ventilation systems should exhaust to a safe place in the open air away from building eaves and
other obstructions. The height above ground level and from building openings, boundaries and
sources of ignition should be rationalised between health and safety and environmental
requirements. Additional requirements for positioning exhausts from ventilation systems may be
found in Process Guidance Notes issued under the Local Air Pollution Prevention and Control
(LAPPC) regime 4. Vent ducts should be arranged so that vapours cannot condense and collect at
low points within the ducts.
Electric motors used in ventilation ducting should not be situated in the path of the vapour being
extracted. Centrifugal or bifurcated fans can be used, or a motor situated in a safe area can be
connected to a fan by a belt drive. Fans made from non-sparking materials provide an additional
precaution against friction sparks. The ductwork itself should be fire-resisting.
Where the failure of an extraction system would entail a flammable concentration of vapour in
the plant or an escape of toxic vapour, fit an airflow detector in the ducting (such as differential
pressure switch) linked to an alarm. Where it is reasonably practicable, the detector should also
be interlocked with the vapour-producing process.
 Ignition sources
Ignition sources should be excluded from hazardous areas.
The main objective when handling flammable liquids is always to avoid the unwanted creation of
flammable concentrations of vapours by containment and ventilation. However in certain areas,
flammable atmospheres may occur either during normal operation or due to accident spills or
leakage. Measures to control the introduction of sources of ignition are required in these areas.
3 Guidance note EH 40, HSE Books

4 Secretary of state’s Guidance for the Manufacture of Coating Materials, PG6/44
36
Hazardous area classification is the method used to identify areas where flammable
concentrations of gases or vapours are likely to be present. The aim is to reduce to a minimum
acceptable level the probability of a flammable atmosphere coinciding with an electrical or other
ignition source. It is normally used to select fixed electrical equipment, but it can also be used in
the control of other potential ignition sources such as portable electrical equipment, hot surfaces
and vehicles.
Potential ignition sources include;

- Electrostatic discharge
- Electrical equipment
- Friction sparks
- Protection of vehicles
- Space heating
- Hot work
- Cold cutting*
- Smoking
*Cold cutting - Safety is ensured through the omission of sparks and flames which guarantees
there will be no ignition of combustible gasses left in the pipe etc.
Where there is a risk of a flammable concentration of vapours arising electrical equipment should
be constructed and installed to a suitable explosion protected standard such as a British Standard
BS EN 60079-10: Explosive atmospheres. Classification of areas. Explosive gas atmospheres. Part
10; Classification of hazardous areas5.Electrostatic charging
Precautions should be taken to prevent vapours being ignited by the discharge of static electricity.
The movement of flammable liquids during cleaning operations, for example by pumping, pouring
or spraying, can cause electrostatic build-up.
Flammable liquids should not be splash-filled into vessels; they should be added at a controlled
rate avoiding free fall by, for example, running them down the side of the vessel.
Static electricity generated by flammable liquids should be reduced by avoiding the free fall of
liquids and restricting pumping speeds. For liquids with conductivity up to and including 50 pSm-
1 (pico Siemens/metre) the flow velocity in a pipe where a second phase may be present (a second
phase could be a gas or a solid, or an immiscible liquid such as water) should not exceed 1 m/s.
Water may be present even if it has not been deliberately introduced (for example, condensate)
and so a flow velocity above 1 m/s should only be considered if this is not a possibility. PD CLC/TR
60079-32-16 offers further advice for higher velocities. Anti-static additives can be used to increase
the conductivity of flammable liquids with a conductivity less than 50 pSm-1. Where used,
however, the effectiveness should be monitored.
When some types of equipment, such as ball mills and batch mills, are cleaned by running with a
charge of cleaning solvent high levels of static electricity will be generated and will accumulate on
the balls and heads. The charge will remain even after the mill is drained. Any further addition to
the mill before the charge has dissipated creates the risk of a static discharge. In addition to the
provision of adequate earthing and bonding it is recommended that a relaxation period of 15
minutes is allowed between the mill coming to rest and the next operation.
5 Explosive atmospheres. Classification of areas. Explosive gas atmospheres, BS EN 60079-10: 2015, BSI
6 PD CLC/TR 60079-32-1:2015, Explosive atmospheres. Electrostatic hazards, guidance
37
Where solvents are added by inserting a rigid or flexible pipe into a tank or mill there is a risk, if
the contents have accumulated an electrostatic charge, that as the gap between the pipe and the
contents lessens an incendive spark could jump across the narrowing gap. Suitable precautions
(see above) should be taken to prevent the build-up of an electrostatic charge.
Clothing made of synthetic fibres can cause incendive electrostatic sparks, especially if they are
worn in areas with non-conducting floors. It is recommended that clothing should contain a
minimum of 60% natural material e.g. cotton.
Clothing contaminated with flammable liquids should be changed promptly in an area away from
any sources of ignition.
Conducting footwear and floors should be utilised to prevent the generation of electrostatic
charges. PD CLC/TR 60079-32-17 gives general advice on the control of static electricity and the
determination of electrostatic properties.
Floors should be conducting for the purpose of static charge. It is recommended that a resistance
of between 106 to 1010 ohms be maintained. Checks should ensure that these properties are
maintained, especially if the floor is painted. Conductive floor paints are available and should be
specified if flammable liquids are to be handled. Most epoxy paints will form an insulating layer if
applied too thickly. Quick check meters for measuring surface resistance are available.
 Containment
Dispensing and decanting of liquids for cleaning purposes should be carried out in a way which
reduces the possibility of spills and releases of flammable vapour. The need for these operations
should be assessed and, where possible, minimised.
Containers of flammable cleaning materials should be kept closed except when actually being used.
Vessels should be kept covered and tanks closed as far as is practicable during cleaning operations.
Tanks and vessels containing work-in-progress in the vicinity of cleaning processes should be
covered. In the case of fixed tanks, covers should be metal and hatches and other openings should
be kept closed except for operational activities. Where possible, mobile tanks should also be
provided with rigid metal covers. However, in many situations this will not be practicable and in
such cases conductive plastic covers, secured with a band may be used. It should be recognised,
however, that such covers will not provide protection in the event of a fire and the provision of
additional safeguards e.g. increased separation distances, sprinklers, may be required to mitigate
the consequences of a fire, should it occur. In all cases the amount of work-in-progress in the
vicinity should be kept to a minimum.
The manual handing and decanting of flammable cleaning solvents should be restricted. Where
possible these should be transferred through fixed enclosed systems or by the use of portable
pumps and flexible pipes. Where manual handling is necessary safety containers and safe barrel
pourers should be utilised. These should be protected from the build-up of electrostatic charge as
above.
Dirty flammable liquids, which have been used for cleaning purposes, should be placed in a suitable
closed container and removed to a safe place as soon as the operation is complete.
7
PD CLC/TR 60079-32-1:2015, Explosive atmospheres. Electrostatic hazards, guidance
38
Rags or cleaning cloths contaminated with highly flammable liquids should be deposited after use
in a suitably marked metal bin with a close fitting lid provided solely for such a purpose. These bins
should be removed and emptied in a safe place at the end of each shift. The depositing of
contaminated rags in rubbish skips is a dangerous practice.
Where it is necessary to clean areas by applying solvent with a cloth, brush or cleaning pad the
solvent should be dispensed from a proprietary safety container and not from an open bucket.
Insulating items e.g. synthetic bristles which might generate static should not be used. Used
cleaning cloths should be placed in a metal bin with a self closing lid which should be removed to
a safe place at the end of each shift.
 Floor cleaning
Care should be taken when using flammable solvents to clean floors. The area worked on at any
one time should be minimised and other steps taken to avoid the generation of a flammable
atmosphere.
These residues may need to be softened with a solvent before removal. The area to be cleaned at
any one time should be kept to a minimum and fenced off while the residues are softening. The
softened residues should be deposited as soon as possible into suitable containers which should
be promptly removed from the workroom. Wherever possible, solvents which are not highly
flammable liquids should be used for this work. The areas should be adequately ventilated to
remove vapours given off by the solvents, paying particular attention to any health risk, and to
prevent the formation of a dangerous concentration of vapours. Where the residues cannot be
removed without the use of a flammable liquid, arrangements must be made to ensure that the
choice of solvent, the method of application, and the quantities used, are strictly controlled and
are in accordance with the requirements of regulations.
 Exchange
Where possible a non-flammable cleaning agent should be used. Where the use of flammable
solvents cannot be avoided one with the highest flash point suitable for the job should be selected.
Heating solvents above their flashpoints should be avoided.
The minimum practicable quantity of flammable liquids necessary for the cleaning operation
should be used. New and waste solvents should be stored in designated areas away from process
areas, in suitable, closed containers.
 Separation
Other sources of flammable vapour (such as pots containing work-in-progress, other cleaning
operations) should be segregated from the cleaning operation. This can be by the use of covers or
physical separation.
 Pressurised solvent spray cleaning systems

Guidance on the use of Pressurised Solvent Spray Cleaning Systems is available from BCF8.
8
Guidance on the Safe Use of Pressurised Solvent Spray Cleaning Systems, BCF
39
General control measures when using flammable liquids
1 Exclude ignition sources.(Friction, Spark. Hot surfaces, etc)

2 Use high flash point materials, where possible
3 Introduce additive to aid conductivity
4 Avoid heating solvents above their flash point
5 Store materials not in direct use out of the manufacturing area
6 Provide ventilation to keep atmospheric concentrations below the Lower Explosion
Limit
7 Protect electrical equipment to appropriate standard
8 Tanks in the vicinity of the cleaning operation should be covered
9 Metal covers provide protection from fire spread
10 Only antistatic polythene to be used,(ensure surface resistivity is below 10-11 ohms) care
should be taken to ensure no steam, or high pressure air leaks adjacent to the film can charge
up the surface that may give rise to static discharge).
11 Antistatic footwear to be used in Zone 1, and Zone 2 areas
12 Consider Nomex fire protective overalls
13 Bond all electrical items to earth
14 Bond all metal items to earth
15 Bond all pipe joints
16 Ensure all hoses are conductive, and earthed
17 Bond any item that may become electrostatically charged
18 Regularly inspect all earth clips, and earthing points
19 Avoid aluminium when it may come into contact with rusty metal
20 Keep all tank covers closed
21 Never splash fill with flammable liquids.(add at controlled rate by running down side)
22 Use pumps to transfer flammable liquids
23 In pipelines ensure flow rate does not exceed one metre per sec
24 Allow static relax time of 15 minutes in e.g. ball mills after discharge
25 Avoid dip sticks, and other conductive devices. they may charge during cleaning
operation
26 All staff should receive suitable, and sufficient training in the hazards present
27 Provide bunding / drip trays / vermiculite or other suitable absorbent
28 Do not use synthetic brushes, use only natural fibre bristle brushes
29 Keep all cleaning cloths in a metal bin with a closed metal lid
30 Use approved solvent storage cans with spark arresters to dispense cleaning solvent
31 Commission an area classification drawing, and electrical schedule for in each work room
32 Investigate if the addition of a fire wall would significantly lower the risk
37

BCF Guide To The Safe Operation of Dispersion Equipment

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

BCF Guide To The Safe Operation of Dispersion Equipment

Uploaded by

Copyright:

Available Formats

The BCF Guide

To the Safe Operation

Photographs Good and bad practices highlighted

Appendix 1 Reference made to DSEAR

11. Ball Mills

12. Bead and Shot Mills

13. Vertical Shaft Mixers and Dispersers

29. General Safety Features

33. Appendix 1 - Specific Legal Requirements

35. Appendix 2 - Operators Checklist

37. Appendix 3 - Risk Assessment - Mechanical Hazards

38. Appendix 4 - References and Further Reading

40. Appendix 5 - BCF Guidance on Cleaning of Plant and Equipment with

2 Specific dispersion equipment covered includes :

7 Risk assessment can be broken down into five stages :

 identify what can harm people in the workplace

9. Every dangerous part of machinery should be securely guarded.

Specific legal requirements are listed in Appendix 1.

Fig. 1: Triple roll mill showing position of doctor blade

Figs. 4a & b: Interlocked nip guards

Fig. 5: A captive key system is used to interlock the power

Figs. 6a & b: Avoid loose clothing

Figs. 7a & b: Tie back long hair

Figs. 10 a & b: Cleaning triple roll mill

22 The discharging of ball mills by use of pressure is not recommended.

Fig. 11 Horizontal bead mill

30 It is not sufficient to rely on people acting sensibly, it is important to physically

Types of Vertical Shaft Mixers

Type 3: Fixed Head Dispersers mounted in Fixed Closed Vessels;

Type 4: Fixed Head Mixers mounted in Fixed Closed Vessels (tanks);

Type 5: Rotor/Stator Mixers;

Vertical Movement of Lids

Guarding of Shafts above Lids

Fig. 20: Simple method of guarding rotating shaft

Fig. 25: Clamp/strap set-up

Figs. 26a & b: Interlocked enclosure for whole machine

47 A strap should be used instead of a chain; it gives a better grip. A chain/hook

Fig. 28: Strap interlocking device Fig. 29: Chain/hook adjustment

Figs. 32 a & b: Interlocked guards

Fig. 34 Do not reach into vessel whilst mixer is in motion

Guarding Fixed Head Dispersers in Fixed Closed Vessel Types 3 and 4

Drive Mechanisms / exposed drive couplings & shaft

Entanglement; High Speed Shaft/Blade through the hatchway

Figs. 41a & b: Simple methods to prevent reaching shaft

Fig. 42: Simple device to assist adding liquids

Entanglement; Scraper Blade Drives

Fig. 45: Small rotor/stator mixer – poorly guarded

Safety distance between protective bars and moving parts

Aperture width Slotted aperture Square aperture

< 20mm < 120mm < 120mm

80 An adequate level of lighting should be provided in all working areas.

86 All personnel should be encouraged to report hazards and defects.

90 Although limited maintenance may be undertaken by an appropriately trained operator, more

- inspection and testing of guards, including interlock guards;

100 It is recommended that retraining is carried at appropriate intervals or when procedures,

- exposure to hazardous substances and processes should be assessed and controlled

General (not exhaustive)

Ensure that guards are in place and are in good condition

All personal protective equipment supplied should be worn

Three Roll Mills

Remove or secure loose clothing (ties, cuffs, etc) and jewellery

Do not allow untrained persons to run, or help to run, the mill

Do not allow untrained persons to clean any part of the mill