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Case Studies » Trouw Nutrition GB

The challenge

A visit was made to Trouw Nutrition GB premises at Ashbourne, Derbyshire in September 2014 to consider compliance of their milk replacement plant in respect of the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR).

Facilities include product mixing, conveying and automatic bag filling equipment and with milk-related whey powders and powder additives fed from external silos or internal bulk bags. Processes carried out thus involve combustible powders with a potential for release of fines generated during plant operation.

The solution provided

The milk replacement plant represents a small part of the extensive layout at the premises. It is evident that most components in milk replacement formulations are combustible while in powdered form. Given that there is significant overlap in terms of charging and conveying of materials within the confines of equipment, it is prudent to adopt a worst-case scenario when considering fire and explosion hazards.

Documentary evidence was provided pertaining to existing material inventory, site procedures and maintenance - plus an overview of site safety systems at the time of survey. Additional background information was provided by management.

An assessment of the site was carried out in compliance with the DSEAR regulations 2002 and a number of points of significance were noted.

Hazardous area classification applies to those areas where a flammable atmosphere may persist either briefly or for longer periods of time as outlined in the regulations – specifically within confines of equipment or around material handling or storage locations.

Combustible replacement milk product properties require strict procedures and maintenance of key equipment to minimise life safety risk. Adequate statutory checks are a critical requirement for relevant extraction, pressure systems and / or relief vents installed on-site.

Combustible dust is a significant hazard associated with protein and whey ingredients used in milk replacement plant operations on-site. Fine dust may ignite – and give rise to potential fire and explosion hazards if present at sufficient concentration in air.

The significance of earthing and continuity checks was also emphasised at the time of survey

All of these issued were considered and a detailed DSEAR report, hazardous zoning plan and series of recommendations was issued to management to ensure sufficient control of DSEAR risks is maintained.

What Trouw Nutrition GB said:

Very knowledgeable consultant who quickly understood our business and provided easy to understand advice.

Kevin Swift
Trouw Nutrition GB