Pallet and lumber industry leaders wear many hats to keep a facility running smoothly and successfully, but one of the most important hats they wear is unofficially that of safety manager. A good leader in the pallet space considers risk exposures to his team, operations and facility at every turn. These managers know the risks of doing business in this niche and take the appropriate steps to mitigate hazards.
While a number of risk exposures threaten pallet manufacturers on a daily basis, four are rising to the top as of late, as we at Pennsylvania Lumbermens Mutual Insurance Company (PLM) see insurance claims mounting in these areas.
Recognizing the Risks
1. Wood Dust
This past year set records for dust explosions in facilities across the territory I oversee. Unfortunately, a number of companies had not been abiding by their dust control protocols. Dust accumulated in facilities, which led to explosions. And while in some cases, the facility had implemented spark detection and dust suppression systems, these systems were not regularly maintained and tragically not in working order to prevent the incidents. One facility suffered $1 million in damages due to an explosion caused by wood dust and neglected maintenance and another of our policyholders fell victim to an explosion that caused even more catastrophic damage.
When it comes to risks around wood dust, it just makes good sense to instill good housekeeping habits. Dust accumulated just to the thickness of a dime can create an ideal situation for an explosion. We have seen facilities burn to the ground simply because they did not have good cleaning practices in place. That said, maintaining good housekeeping practices can not only reduce your fire risk, it also can reduce your maintenance costs because less dust and debris can get into the motors and bearings.
To mitigate the risk of a dust explosion, consider these best practices:
• Develop a formalized housekeeping program to ensure dust is properly and regularly cleaned.
• Do not allow dust to pile up around the facility. All dust piles should be cleaned within a day.
• When cutting wood, dust piles should be at least 50 feet away from the building. If not, heavy concrete blocks should be used to create a firewall that is taller than the wood dust pile.
• Train employees at hire, annually and after any dust related incident.
• Use a dust collection system that includes a spark detection and suppression system.
• Regularly maintain the dust collection system.
• Clean dust from the dust collection systems with a vacuum or wash. Do not attempt to blow the dust with an air hose as that can create fertile ground for an explosion.
• Consider purchasing wood cutting machines attached to local dust collection systems.
• Conduct inspections and check for blockages in duct work at least semi-annually, looking in the blower motors, the blower fans, and the belts.
• Utilize thermography to check key systems for overheating.
2. Wood Waste
Pallet manufacturers and other lumber facilities approach wood waste in different ways. Some facilities burn it in their boilers. Others save the waste and sell it as animal bedding or mulch. But wood waste can pose a risk to business owners in the space as well – fire risk in particular. Consider the following:
• If burning wood waste in the boiler, ensure there is a heat sensor so that the feed conveyor and auger can detect fire and dump a stream of water to flood the auger and extinguish the fire before it ignites the woodpile.
• If a third party comes in to convert the wood waste into mulch or wood chips, the business owner should make sure they have contracts in place with the third party and confirm certificates of insurance.
• If the business owner is involved in the distribution of the wood waste as mulch or chips, they should ensure they have good maintenance programs for their equipment, well-trained employees, consider telematics for their vehicles and more.
3. Grinders
The grinder is often inside a building and takes the wood waste and cuts it down to size to be piled up outside the building or stored in a silo. To mitigate risk exposures related to the grinder, we suggest business owners:
• Conduct regular grinder maintenance and cleaning according to manufacturers’ recommendations.
• Regularly check the grinder belts.
• Ensure the bearings are properly lubricated.
• With tub grinders, consider one with a suppression system mounted to the unit.
• Ensure the hydraulic hoses are free and clear of debris and that they do not have any leaks.
• Consider keeping a bulldozer on site to push away a potential burning portion of a wood waste pile, so you can separate it. Then, turn it repeatedly until the fire is out.
• Consider using a drone to test the heat on your mulch pile to reduce risk of spontaneous combustion.
4. Heat Treatments
In the pallet business, heat treatments are conducted in the production of food grade or medical grade pallets. Heat treatment procedures help to ensure there are no bugs or pathogens in the wood. Sometimes propane, or heat provided by the boiler is used for heat treatment. In other cases, manufacturers will use a dehumidifier to dry out the moisture. When using heat treatment, consider the following:
• Ensure there is a safety shut off valve on the boiler.
• Have it inspected according to the manufacturer’s recommendations.
• Ensure the propane tank is protected from damage like nearby traffic.
Wrapping It Up
In the end, pallet safety usually comes down to good housekeeping and monitoring hot works programs. But having a good partner to help you properly assess your facility’s unique risks and determine a plan to mitigate those risks can go a long way. An insurer who knows the wood niche can be a valuable resource here.
Facilities get busy. Let’s not allow safety to take a back seat. Consider your risk exposures and take steps now to ensure your lumber facility or pallet operation is prepared for whatever the future may bring.
Editor’s Note: Mike Seiwert is a senior loss control representative with Pennsylvania Lumbermens Mutual Insurance Company (PLM), the oldest and largest mutual insurance company dedicated to the wood products and materials industry. He can be reached at mseiwert@plmins.com. To learn more about Pennsylvania Lumbermens Mutual Insurance Company, visit www.plmins.com.
