OSHA Inspection: COLORS FOR PLASTICS, INC.

Issued

Nov 24, 2014

Abate by

Jun 30, 2015

Penalty

Initial $4,500 · Current $4,500

Hazardous substances M110

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970:  The employer did not furnish employment and a place of employment which were free from recognized hazards that were causing or likely to cause death or serious physical harm to employees in that employees were exposed to combustible plastic resin and pigment dust explosion, deflagration or other fire hazards while working at or near media-type dust collectors (baghouses) and associated upstream equipment:    a) The outdoor Donaldson Torit Downflo DFT2-12 Dust Collector used to collect combustible plastic resin and pigment dust from the manual feed hoppers on the extruder lines lacked means of 1) explosion protection and 2) deflagration propagation protection (isolation) for the upstream processes and the unit's collection drum. In addition, the collector was not electrically bonded to equipment upstream (hopper exhaust housing) and downstream (dust collection drum), as non-conductive flexible plastic hose was installed to make connections.    b) The indoor DCE Vokes Unimaster UMA152G5 Dust Collector (S/N 85-1574-2) used to collect combustible plastic resin and pigment dust from the pigment batching station, concentrate batching stations, micropulverizing stations, and drum lid removal area for the tumbler operations lacked means of 1) explosion protection and 2) deflagration propagation protection (isolation) for the upstream processes and the unit's collection drum.  In addition, the dust collector discharged exhaust air directly into the building. Also, the collector was not electronically bonded to upstream equipment, as non-conductive flexible plastic hose was installed at the ends of ridged metal ducting in multiple areas.     c) The indoor DCE Vokes Unimaster UMA152-G5 Dust Collector (S/N 83-1242-2) used to collect combustible pigment dust from the high intensity mixers lacked means of 1) explosion protection and 2) deflagration propagation protection (isolation) for the upstream processes and the unit's collection drum.  In addition, the dust collector discharged exhaust air directly into the building. Also, the collector was not electronically bonded to upstream equipment, as non-conductive flexible plastic hose was installed at the ends of ridged metal ducting in multiple areas.    Among other methods, a feasible method to correct these hazards would be to follow the National Fire Protection Association (NFPA) Standard 654, "Standard for the Prevention of Fire and Dust Explosions fro the Manufacturing, Processing, and Handling of Combustible Particulate Solids, 2013 ed.", Sections 7.1.4, 7.1.6, 7.1.7, 7.6.3, 7.6.4, 7.13.1.1, 7.13.1.2.1, 7.13.1.6.2 and 9.3.2.1.    Specifically, for the outdoor dust collector: 1) provide a method of explosion protection such as, but not limited to, explosion venting to a safe location in accordance with NFPA 68, "Standard on Explosion Protection by Deflagration Venting", 2) provide a method of deflagration propagation protection (active or passive system) in accordance with NFPA 69, "Standard on Explosion Prevention Systems" for both the upstream "dirty air" ducting and the drum located beneath the unit's discharge hopper.     Specifically, for the indoor dust collectors: 1) relocate the indoor dust collectors to an outdoor location, 2) provide a method of explosion protection such as, but not limited to, explosion venting to a safe location in accordance with NFPA 68, 3) provide a method of deflagration propagation protection (active or passive system) in accordance with NFPA 69 for both the upstream "dirty air" ducting and the drum located beneath the unit's discharge hopper, and 4) prohibit the return of exhaust air into the building.  Alternatively, provide the indoor dust collectors with 1) a method of explosion protection and deflagration propagation (isolation) protection, such as chemical deflagration suppression and 2) a method of exhausting filtered air to a safe, outdoor location away from air intakes.    Specifically, for ensuring bonding and grounding conditions where flexible connections are necessary: utilize conductive or static-dissipative hoses and ensure that they are adequately connected to conductive end fittings and properly grounded.

Issued

Sep 11, 2014

Abate by

Sep 30, 2014

Penalty

Initial $2,700 · Current $2,700

Hazardous substances 073026169135F104

General-duty citation text

29 CFR 1910.134(c)(1): In any workplace where respirators are necessary to protect the health of the employees or whenever respirators are required by the employer, the employer did not establish and implement a written respiratory protection program with required worksite-specific procedures:    a) 2239 and 2245 Pratt Boulevard Buildings - Colors for Plastics, Inc. did not ensure that a written respiratory protection program was established and implemented for those employees required to wear respiratory protection, including Precision Safety N95 Particulate Respirators and Precision Safety Comfort Masks.  Employees performing the tasks of Pigment Batcher, Concentrate Batcher, Micropulverizer, Mixer, and Hopper Filler were required to wear respiratory protection to protect themselves from dust(s) generated from the process of manufacturing dry color concentrate compounds.    The respiratory protection program shall include, at a minimum, procedures for selecting respirators; medical evaluations; fit testing; procedures for proper use in routine and reasonably foreseeable emergency situations; procedures for cleaning, storing, inspecting, repairing and discarding respirators; employee training regarding respiratory hazards they are exposed to, proper uses and limitations of respirators; and procedures for regularly evaluating the effectiveness of the respirator program.

Issued

Sep 11, 2014

Abate by

Sep 30, 2014

Penalty

Initial $2,700 · Current $0 Reduced

Hazardous substances 073026169135F104

General-duty citation text

29 CFR 1910.134(d)(1)(ii): The employer did not select and use a NIOSH-certified respirator in compliance with the conditions of its certification:    a) 2239 and 2245 Pratt Boulevard Buildings - Colors for Plastics, Inc. did not ensure employees required to wear respiratory protection, including a Precision Safety Comfort Mask, were provided a NIOSH-certified respirator.  Employees performing the tasks of Pigment Batcher, Concentrate Batcher, Micropulverizer, Mixer, and Hopper Filler were required to wear respiratory protection to protect themselves from dust(s) generated from the process of manufacturing dry color concentrate compounds.

Issued

Sep 11, 2014

Abate by

Sep 30, 2014

Penalty

Initial $2,700 · Current $0 Reduced

Hazardous substances 073026169135F104

General-duty citation text

29 CFR 1910.134(e)(1): The employer did not provide a medical evaluation to determine the employee's ability to use a respirator, before the employee was fit tested or required to use the respirator in the workplace:    a) 2239 and 2245 Pratt Boulevard Buildings - Colors for Plastics, Inc. did not ensure that employees required to wear respiratory protection, including Precision Safety N95 Particulate Respirators and Precision Safety Comfort Masks, were provided with a medical evaluation to determine their ability to use a respirator.  Employees performing the tasks of Pigment Batcher, Concentrate Batcher, Micropulverizer, Mixer, and Hopper Filler were required to wear respiratory protection to protect themselves from dust(s) generated from the process of manufacturing dry color concentrate compounds.

Issued

Sep 11, 2014

Abate by

Sep 30, 2014

Penalty

Initial $2,700 · Current $0 Reduced

Hazardous substances 073026169135F104

General-duty citation text

29 CFR 1910.134(f)(2): Employee(s) using tight-fitting facepiece respirators were not fit tested prior to initial use of the respirator:    a) 2239 and 2245 Pratt Boulevard Buildings - Colors for Plastics, Inc. did not ensure that employees required to wear respiratory protection, including Precision Safety N95 Particulate Respirators and Precision Safety Comfort Masks, were fit tested prior to the initial use of the respirator.  Employees performing the tasks of Pigment Batcher, Concentrate Batcher, Micropulverizer, Mixer, and Hopper Filler were required to wear respiratory protection to protect themselves from dust(s) generated from the process of manufacturing dry color concentrate compounds.

Issued

Sep 11, 2014

Abate by

Sep 30, 2014

Penalty

Initial $2,700 · Current $0 Reduced

Hazardous substances 073026169135F104

General-duty citation text

29 CFR 1910.134(k)(1): The employer did not provide respirator training that would ensure each employee could demonstrate knowledge of items in section (i)-(vii):    a) 2239 and 2245 Pratt Boulevard Buildings - Colors for Plastics, Inc. did not ensure that employees required to wear respiratory protection, including Precision Safety N95 Particulate Respirators and Precision Safety Comfort Masks, were provided appropriate respirator training.  Employees performing the tasks of Pigment Batcher, Concentrate Batcher, Micropulverizer, Mixer, and Hopper Filler were required to wear respiratory protection to protect themselves from dust(s) generated from the process of manufacturing dry color concentrate compounds.

Issued

Sep 11, 2014

Abate by

Oct 7, 2014

Penalty

Initial $3,600 · Current $3,600

General-duty citation text

29 CFR 1910.178(l)(4)(iii): An evaluation of each powered industrial truck operator's performance was not being conducted at least once every three years:  a) 2239 and 2245 Pratt Boulevard Buildings - Colors for Plastics, Inc. did not ensure that an evaluation of each powered industrial truck operator's performance was conducted at least every 3 years.

Issued

Sep 11, 2014

Abate by

Oct 7, 2014

Penalty

Initial $3,600 · Current $3,600

Hazardous substances M110

General-duty citation text

29 CFR 1910.1200(h)(1): Employees were not provided effective information and training on hazardous chemicals in their work area at the time of their initial assignment and whenever a new hazard that the employees had not been previously trained about was introduced into their work area:  a) Colors for Plastics, Inc. did not provide information and training to employees exposed to hazardous chemicals, which included the hazards from dust(s) generated during the process of manufacturing dry color concentrate compounds.  Dust(s) collected by the outdoor dust collector (Donaldson Torit Downflo II DFT 2-12) and the two indoor dust collectors (DCE Vokes UMA152G5) were tested and determined to be combustible dust with Kst values of 20.18 bar*m/s, 34.17 bar*m/s, and 28.07 bar*m/s, respectively.

Issued

Sep 11, 2014

Abate by

Oct 15, 2014

Penalty

Initial $900 · Current $900

General-duty citation text

29 CFR 1910.178(a)(6): The employer did not ensure that all nameplates and markings were in place  a) 2245 Pratt Boulevard Building - Colors for Plastics, Inc. did not ensure that the nameplates on the Toyota forklift were maintained in a legible condition.

Issued

Sep 11, 2014

Abate by

Sep 23, 2014

Penalty

Initial $0 · Current $0

Hazardous substances 9760

General-duty citation text

29 CFR 1910.1200(f)(5)(i): The employer did not ensure that each container of hazardous chemicals in the workplace was labeled, tagged or marked with the identity of the hazardous chemical(s) contained therein:  a) 2239 Pratt Boulevard Building - On or about May 10 and June 2, 2014, Colors for Plastics, Inc. did not ensure that a spray bottle containing mineral spirits was labeled, tagged, or marked with the identity of the hazardous chemical it contained.

Issued

Sep 11, 2014

Abate by

Sep 23, 2014

Penalty

Initial $0 · Current $0

Hazardous substances 9760

General-duty citation text

29 CFR 1910.1200(f)(5)(ii): The employer did not ensure that each container of hazardous chemicals in the workplace was labeled, tagged or marked with the appropriate hazard warnings:  a) 2239 Pratt Boulevard Building - On or about May 10 and June 2, 2014, Colors for Plastics, Inc. did not ensure that a spray bottle containing mineral spirits was labeled, tagged, or marked with the appropriate hazard warning(s).