Workplace Safety and Health Practices Award:

Workplace Safety & Health Awards 2007

Nalco Pacific Pte Ltd

Semi Automatic Liquid Product Filling System

Presenter: Saifuddin Jailani Riduan Sariman

Chemical / Ergonomics / Safety

• Nalco company is a leading company which provides water

treatment, energy, process solution and improvement services. We serve a wide range of customers from the oil and gas industries, pulp and paper industries and industrial water systems.

• We manufacture specialty chemicals and provide process

improvement equipment and services. We help our customers to reduce the consumption energy, water and other natural resources. At the same time, we boost the performance, save operation cost and reduce pollution and environmental impact.

• In Singapore, we are located at 21 Gul Lane and the manufacturing plant has been in operation since 1984.

• Our 3D TRASAR® Technology utilised in the cooling tower system is able to detect system parameter changes, determine the corrective response and deliver the right dosage of chemical inhibitors to keep the system in perfect balance.

Semi Automatic Liquid Product Filling System Before

Liquid products were manually filled from reactors into

containers. Technicians monitors amount being filled and

stops the pump and shuts off filling lance’s valve when

set point is attained.

After

An operator will enter the filling weight set point and select the type

of container to be filled on the touch screen control panel. Once

setup is ready, he uses the control handle to guide the filling lance to

the container bung hole. System automatically transfers the required

amount of liquid product into the container and stops once the

weight set point has been reached.

Risk/ Exposure Level before control

o Tripping due to presence of flexible hoses.

o Back ache and strain for workers while filling.

o Fatigue due to close monitoring required when filling.

o Chemical spills due to over-filling.

o Chemical drips when transferring filling lance from one

container to another.

o Noise generated from the air operated diaphragm

pump during filling operation.

Benefits

Improve setup time by 30%; filling operation time improved by

24.5% (25L jerry cans), 23.41% (200L metal and plastic drums)

and 7.04% (1000L tote tank and porta feed).

More accurate weighing scale leads to overall savings of

approximately $8,000 per month (for 2 installed units)

Improved morale, working atmosphere and working ergonomics

for workers.

More organized, neat and reduces tripping hazards at work area.

No chemical spills or drips

Risk/ Exposure Level after control

o The risk of chemical exposure to operator is still

available but lower as compared to the manual filling

method. To improve the system further, we are

planning to modify and install a transparent shield to

protect against splashes and foams coming in contact

with the operator.

Equipment Design and Working Concept

The elements of LEAN manufacturing is taken into consideration

when designing the filling system.

Everything an operator needs for the filling operation inclusive of

the closing tools should be within reach. Just like a workstation.

The filling system was fabricated by Fillpack Technologies Pte Ltd

and Winston Engineering Corporation Pte Ltd based on the

guidelines and process design requirement provided by Nalco.

Semi Automatic Liquid Product Filling System Comprehensive Protection

1. The setup and layout is compact and organized making sure that hazards such as tripping and knocking can be prevented.

2. To assist in flushing and cleaning of filling system, drain pipes from various locations are routed underground to the nearest

main drainage point. This minimizes chemical contact, spills and keeps the floor area dry, eliminating falling hazards.

3. Interlock features are present in the control program such as (i) no filling if there is no container or if wrong container placed on

weighing scale, and (ii) having a 3 speed filling sequence that ensures that the system does not overfill.

Ease of Set-up and Use

The steps to carry out for operation of the system are:

1. Connect the flexible hose from vessel to pump skid.

2. Install filter bag and check pump skid valve line up for filling operation.

3. Set filling program at the filling system touch screen interface.

4. Place the packing container on weighing scale.

5. Prime the pump skid and the filling operation can be started.

Expandability

1. This system can be used for “batching” or “liquid blending” where 2 or more types of liquid are required to be mixed according

to product specifications.

2. Also applicable when “repacking” liquids from bulk storage containers such as IBC (1000L) to smaller containers such as jerry

cans (25L).

Life Cycle Cost

1. Equipment installed aimed to improve safety and as a key initiative for “LEAN” manufacturing project.

2. Savings is derived from shorter packaging time which means an increase to the production capacity. Soft factors includes high

morale and working atmosphere.

3. Expected payback period is 2 years and quarterly preventive maintenance, servicing and scale calibration cost could be

covered from savings gained.

4. The filling system is strategically positioned to cater for 3 vessels and utilization can be maximized with proper planning.

Innovation

1. This filling system is able to fill up 7 different types of product packaging containers. (1000 L Intermediate Bulk

Containers, 1000L Porta Feeds, 1500L Senior Porta Feeds, 25L Jerry Cans and 200L Metal and Plastic Drums.)

Semi Automatic Liquid Product Filling System In Action

1) Pump speed selection 2) Filling program setting

3) Filling operation 4) Container cap fastening

Semi Automatic Liquid Product Filling System

Closing Tools Filling System 2 Filling System 1

Semi Automatic Liquid Product Filling System

Filling System 1 Filling System 2