The U.K NO1 DSEAR Risk Assessment Specialists

Case Studies » Smurfit Kappa

The Challenge

The Smurfit Kapa site at Mold allow for large scale production of cardboard and paper-based packaging materials for sale to a wide client base. The majority of processes are not hazardous in normal operation however while most product is stable, dust from combustible paper-based materials may present some hazard potential and the risk of formation of explosive mixtures in air – both inside or outside of processing equipment.

Starch powder and flammable gases are other hazardous substances in widespread use at the plant. There is an inherent flammable hazard associated with these materials and specific control measures are adopted to limit risk from loss of containment or ignition.

The solution

Facilities at the Mold site allow for large scale production of cardboard and paper-based packaging materials for sale to a wide client base. The majority of processes are not hazardous in normal operation despite extensive use of mechanized systems and automatic material transfer activities. Activities are largely carried out in open plant areas though process equipment provides containment of most hazardous materials.

It was identified that while most product is stable, dust from combustible paper-based materials may present some hazard potential and the risk of formation of explosive mixtures in air – both inside or outside of processing equipment. Starch powder and flammable gases are other hazardous substances in widespread use at the plant. There is an inherent flammable hazard associated with these materials and specific control measures are adopted to limit risk from loss of containment or ignition.

A detailed review of the control systems applied on-site was undertaken and areas where improvements could be achieved were clearly identified. By providing a simple to understand action plan; management were able to quickly introduce the recommendations and ensure the safety of the operations.

What Smurfit Kappa said:

A very thorough report that has pointed out to us a number of issues we were not fully aware of; many thanks for your professional support.

Kirsty Rae
Smurfit Kappa
2012-01-10