Responsible Foam Production and Risk Management
Responsible production is at the forefront of every manufacturing company, whatever the sector. As foam is made using organic chemical compounds, the industry has many safety practices in place to protect employees' health and wellbeing. With processes and standards ranging from engineered ventilation systems to employee training and medical checks, polyurethane manufacturing is in fact praised for providing one of the safest plant-controlled jobs.
The chemical risks: isocyanates
Modern foam manufacture means working closely with isocyanates, the group name for a number of highly reactive chemicals. Mostly used to produce flexible and rigid foams, they're also powerful irritants, particularly to the respiratory and gastrointestinal tracts. Direct contact with skin and eyes can cause considerable inflammation, so protection from isocyanates matters for several reasons. There have also been reported deaths among people exposed to isocyanates, where the chemicals triggered severe asthma.
Engineering controls and ventilation
There are many ways manufacturers mitigate the risks. In the UK, following standard health and safety procedures almost guarantees that workers won't be intentionally exposed to harmful chemicals along a production line. Given the high-risk nature of foam manufacture, factories are often well equipped with highly engineered ventilation, production and off-loading emergency shut-off controls, and stack engineering and scrubber technologies.
Good ventilation is key to reducing the effects of isocyanate fumes. Using very strong exhaust systems, harmful vapours are captured and removed so that no more than 1.6 ounces of isocyanate per ton of polyurethane foam is emitted. With stack engineering systems, excess isocyanate emissions are managed by reacting with humidity in the stack, leaving chemically inactive fumes.
PPE and training
Safety extends beyond the process itself. Employees are issued PPE such as respirators to reduce inhaled fumes, plus goggles, earmuffs and gloves in case of accidental contact with isocyanates. All staff are trained and briefed on both the benefits and limitations of PPE, so they understand it isn't effective protection on its own.
Training goes hand in hand with PPE, and manufacturers ensure all employees receive high-standard training regularly to mitigate risks. From handling hazardous materials to recording information on Safety Data Sheets (SDS) and the Global Harmonisation System (GHS), training in this sector is comprehensive, and largely proactive: staff are required to brief delivery personnel on safety procedures, which keeps everyone's health and safety knowledge current.
For more information on eFoam's manufacturing and safety procedures, please contact us.
Frequently asked questions
What are the main chemical risks in foam manufacturing?
Modern foam is made working closely with isocyanates, a group of highly reactive chemicals used to produce flexible and rigid foams. They are powerful irritants to the respiratory and gastrointestinal tracts, can inflame skin and eyes, and have triggered severe asthma in some exposed individuals.
How do foam manufacturers control these risks?
UK factories follow standard health and safety procedures and are typically equipped with highly engineered ventilation, emergency shut-off controls, and stack engineering and scrubber technologies. Strong exhaust systems capture harmful vapours, and stack systems react excess isocyanate with humidity to render the fumes chemically inactive.
What protection do foam factory workers have?
Workers are issued PPE such as respirators, goggles, earmuffs and gloves, and are trained that PPE alone is not effective protection. Regular, comprehensive training covers handling hazardous materials and recording information on Safety Data Sheets and the Global Harmonisation System.
