Chemical Management Procedure Useful For Textile Industry

Chemical management procedure

The textile industry has been under scrutiny for its environmental impact due to the hazardous chemicals used in the production process. To address this, chemical management procedures have been implemented to reduce the environmental impact and improve sustainability. Thus, the purpose of this chemical management procedure is to ensure that all the chemicals that are procured, handled, stored, identified, and authorized for use in a will-documented, prescribed to ensure a controlled & safe use of the chemicals for Eco-label and Conventional production.  This type of procedure will be the most effective management system for the textile industry. This article will discuss the responsibilities, procedures, benefits, and challenges associated with using chemical management for eco-level or conventional production in the textile industry.

Responsibilities:

Manager (Store):

To ensure receiving of the right Eco-label chemical with the help of quality report from the Head of the Lab. Ensure separation of Eco-label chemicals from conventional chemicals. Ensure the use of PPE in the chemical handling area.

Dyeing Manager

To ensure the use of the right Eco-label chemicals as approved by the Head of the Lab. Ensure separation of Eco-label chemicals from conventional chemicals. Ensure the use of PPE chemical handling production area.  

Manager ETP

To ensure the use of the approved chemicals in the operation of ETP.  

Chemical Responsible

Is responsible for segregating chemicals as per category and issuing chemicals for production per the approved recipe?

Head of Lab

To authorize the use of chemicals and alternative chemicals.

Forms  

The recipe is developed according to the floor requirement.

Store inventory The store officer keeps the inventory separately for the Eco-label chemicals.

Chemical Management Procedure:

Evaluation:

Any new dyes, chemicals including non-textile chemicals proposed for use in any department are evaluated initially by the Dyeing Manager and/or the Laboratory Manager. No dyes or chemicals including non-textile chemicals are allowed to bring on-site without proper evaluation and authorization. The criteria for any new dyes or chemicals are set by certain parameters of Replacement of existing products due to availability, price advantage, improved performance, and environmental / safety improvement, and New product not used before.

Initial samples of the new dyes/chemicals are obtained from the supplier along with the MSDS. A technical development sheet is produced to formally track the trial product through the various stages of processing for an informed assessment of performance.

The product is the first trial in the Laboratory if it is decided a meaningful result will be achieved, or a bulk production sample is produced if it is felt it is more practical to do so. This is agreed upon by the Dyeing Manager and/or the Laboratory Manager, once the trial product has been produced and fully tested in the Laboratory, the results are evaluated by the Dyeing Manager and/or the Laboratory Manager.

For other non-textile processing chemicals, the relevant head of the department should submit the product information and MSDS for the intended product to be used to the Dyeing Manager and/or Laboratory manager for evaluation in terms of suitability of use by the Health and Safety and environmental point of view. If the new product meets the set criteria agreed upon initially then the results and all other relevant information are forwarded to the Managing Director with recommendations for approval and purchase.

Ordering and Replenishment  

Once the Managing Director has given his approval the order for the product will be raised by the Laboratory Manager for non-textile chemicals by the relevant department head and sent to the purchasing manager. He will open an L.C. against the product.   At the end of each calendar month, the dye and chemical store man carries out a stock count of all dyes and chemical products held in the store.

The stock reflects an opening stock at the beginning of the month, a closing stock at the end of the month, and a total used stock figure. This report is given to the Laboratory manager. The Laboratory manager calculates how much stock he requires for the next month based on usage from the previous month and the forecast for the month ahead. A requisition is raised for all the requirements and the process follows the same route as for the new product ordering procedure.  

When the product arrives at the factory, the store person checks the Challan against the copy of the L.C. If the goods are correct in terms of product type and quantity and there is no visible damage to the good then goods are taken to the relevant chemical stores and placed in the designated area.

If the goods are found to be faulty, the Dyeing Manager and/or the Laboratory Manager are consulted and the goods are either returned to the supplier, put into quarantine clearly marked, or a decision is made if the product are fit for purpose and released from quarantine. A random small sample of the stored dye or chemical goods (where testing is possible) is taken and tested for suitability in terms of the strength of the product against the given strength expected to vie the technical specification.

A test report is produced and kept on file. If the goods are within tolerance the product is released for use. If the product fails the test another sample is taken from another drum within the consignment and tested, if this passes a decision is made by the Dyeing Manager and/or laboratory manager to release the product for use or inform the supplier and ask that all products within the consignment are tested.

If the product fails again the product is held in quarantine until the supplier can arrange collection. When the passed goods are required an issue note is raised and given to the store person, and the product is transported to the processing floor.  

Auxiliaries  

All auxiliary chemicals will be delivered to the machine in the same way as other chemicals. These will be mixed in dilution with water to the correct recipe in the storage tank and transferred to the side at the correct rate for the recipe. Any spillage is contained and cleaned up in accordance with the safety data sheet.  

Handling & Storage of Chemicals  

All dyes and chemicals are handled by trained personnel in terms of the use of PPE and manual handling throughout the process from transporting from the stores to use within the processing department. The chemical store areas are designed to ensure no risk of contamination and cross-contamination of hazardous / non-hazardous chemicals is possible into watercourses or ground. Secondary containment and segregation of hazardous chemicals are incorporated into the design of the storage area. Adequate lighting and ventilation are available and all chemicals are clearly identified with the product name and all MSDS is available in a strategic position to allow access in an emergency.  

In the process area, all open and partially used drums of chemicals are clearly marked with the product name, and MSDS for all products are available in strategic positions for use in an emergency. Chemicals are only stored in areas with adequate drainage to the ETP in the event of spillage. No chemicals are stored in undesignated areas. All empty drums of chemicals are thoroughly cleaned before returning to the chemical store and are awaiting disposal by an approved waste handling company.  

Identification & Segregation

When new dyes and/or chemicals arrive in the store’s area, the storeman checks the drums whether for Eco-label or Conventional production. Based on the category, dyes/chemicals are given an Identification mark. Eco-label dyes/chemicals are marked with a green sticker. Storemen also look for hazard identification; if no identification on the drum the MSDS must be consulted. Once the level of category and hazard has been established the appropriate sticker is placed on the drum before location in the designated area for that particular chemical.  Eco-label chemicals are stored in the designated area for Eco-label only. Eco-label chemical storage is totally segregated from Conventional chemicals.                                                                               

Transportation of Eco-label dyes and chemicals is done by a designated person of the chemical store only. No more dyes and chemicals are stored in the process area than are needed for this period unless they are part drums. All drums must be checked for the Eco-label sticker attached before they are transported to designated areas. If the sticker has become detached, a new one must be attached before moving. Eco-label chemicals are transported to the designated areas in the three side enclosed cages painted Green for ease of identification.

The cage is brought to the chemical store by the forklift truck and loaded in accordance with correct handling procedures and PPE where applicable. The cage is then transported to the designated sub-store areas where all dyes and chemicals are held in a contained area displaying relevant MSDS for each product held there. From the chemical sub-store dyes and chemicals are taken as needed to the relevant mixing areas by trained operatives using the required PPE necessary for the particular chemical.

Auxiliaries

All auxiliary chemicals will be delivered to the machine in the same way as other chemicals. These will be mixed in dilution with water to the correct recipe in the storage tank and transferred to the side at the correct rate for the recipe. Any spillage is contained and cleaned up in accordance with the safety data sheet.  

Defective Chemical  

During the production process from time to time, chemical products can become defective. This can be due to shelf life exceeding, open drum contamination or temperature degradation, or product manufacturing failure. If during processing a chemical product does become defective, that product will be quarantined by clearly labeling the drum or container QUARANTINED in the instance of a product exceeding its shelf life, a check will be made of any similar stock held to ensure the expiry date for the same product has not been exceeded.

If the defective product is felt to be a product manufacturing failure the relevant chemical company will be contacted and the product replaced. Any other defective product will be disposed of through the ETP in a controlled manner ie with dilution factor dependent on the chemical and its relative strength and impact on the ETP. The instance will be recorded for stock replacement purposes and cost evaluation on a Defective Product From.  

Rotation of Chemical  

To ensure dyes and chemicals are used on a first-in-first-out basis all new stock deliveries will be placed behind current stock in the chemical storage areas. Prior to a known delivery schedule for incoming stock, the stock controller will instruct that all current stock be moved forward in the stock holding area. When new delivery arrives all new stock will be placed to the rear of all current to ensure old stock is used first.  All issued stock will be checked by the stock controller against the stock received inventory to ensure the oldest stock is issued first.    

Approval of Usage

The dyeing Manager is full authority for use of the right dyes and chemicals. All recipes must be confirmed by Technical Manager before use. In his absence, Lab Manager will perform the same responsibility. But as soon as Dyeing Manager is available, that recipe must be confirmed and countersigned by him.

Conclusion:

The standard chemical management procedure is mandatory for an industry. This is highly potential to get a good buyer and effective production.

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