United States
Environmental Protection
Agency
Office of
Toxic Substances
Washington, D.C. 20460
April 1990
&EPA
Toxic Substances
TEXTILE DYE WEIGHING
MONITORING STUDY
Site Visit Reports
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TEXTILE DYE NEIGHING MONITORING STUDY
SITE VISIT REPORTS
Exposure Evaluation Division
Economics and Technology Division
Office of Toxic Substances
U.S. Environmental Protection Agency
401 M Street, S.W.
Washington, D.C. 20460
Printed on Recycled Paper
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EXECUTIVE SUMMARY
A survey was conducted jointly by the U.S. Environmental
Protection Agency (EPA), the American Textile Manufacturers
Institute, Inc. (ATMI), and the Ecological and Toxicological
Association of the Dyestuffs Manufacturing Industry (ETAD) to
estimate airborne concentrations of dye dust in the dye weighing
rooms (drug rooms) of plants that use powder dyes in the dyeing
and printing of textiles. The purpose of the project was to
conduct a well-designed study of representative textile dye
weighing rooms, in order to improve the assessment of workplace
exposure associated with the use of powder dyes in the American
textile industry.
This document contains copies of the individual site visit
reports which were prepared by two industrial hygienists, one
supported by EPA and the other by ATMI/ETAD. No site
identification information is contained in this document. The
individual site reports are published here to complete the record
for this study. The site reports have not undergone any formal
peer review since they contain descriptive material only.
The data resulting from this study have been published in a
separate EPA report, "Textile Dye Weighing Monitoring Study," EPA
560/5-90-009, April 1990.
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This report was prepared under contract to an agency of the
United States Government. Neither the United States Government nor
any of its employees, contractors, subcontractors, or their
employees makes any warranty, expressed or implied, or assumes any
legal liability or responsibility for any third party use of or the
resulst of such use of any information, apparatus, product, or
process disclosed in this report, or represents that its use by such
third party would not infringe on privately owned rights.
ii
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CONTENTS
SITE NUMBER 1/0 1
SITE NUMBER 1/6 11
SITE NUMBER 2/1 23
SITE NUMBER 2/4 29
SITE NUMBER 2/7 45
SITE NUMBER 3/0 57
SITE NUMBER 3/3 69
SITE NUMBER 3/8 81
SITE NUMBER 4/1 93
SITE NUMBER 4/3 105
SITE NUMBER 4/6 117
SITE NUMBER 4/9 129
SITE NUMBER 5/2 141
SITE NUMBER 5/4 153
SITE NUMBER 5/9 165
SITE NUMBER 6/2 177
SITE NUMBER 6/5 189
SITE NUMBER 6/6 201
SITE NUMBER 7/7 213
SITE NUMBER 7/9 225
SITE NUMBER 8/0 237
SITE NUMBER 8/6 249
SITE NUMBER 8/8 261
SITE NUMBER 9/1 273
iii
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TEXTILE DRUG ROOM MONITORING STUDY
SITE VISIT REPORT
Site Number 1/0
William L. Dyson,^>ft.D., ^:i.H.
Health and Hygiene, Inc.
e/d/ Unger.
/Associates, Inc.
Prepared for:
U.S. ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF TOXIC SUBSTANCES
401 M STREET, S.W.
WASHINGTON, DC 20460
-------
INTRODUCTION
This survey was conducted as part of an exposure study being performed
as a cooperative effort between the U.S. Environmental Protection Agency
(EPA), the American Textile Manufacturers Institute, Inc. (ATMI), and the
Ecological and Toxicologlcal Association of the Dyestuffs Manufacturing
Industry (ETAD). The study's objective was to determine the extent of
textile workers' exposure to dye dust when weighing and mixing powder dyes.
The sites to be visited were selected to obtain a random sampling of eligible
sites. Contact with the site representative to schedule the site visit was
made by William L. Dyson, Ph.D., C.I.H. of Health and Hygiene, Inc.,
representing ATMI and ETAD. In attendance at the site on the day of the
survey were Dr. Dyson and Robert D. Willson, C.I.H., Beta Associates, Inc.,
subcontractor for PEI Associates, Inc., representing EPA. The pre-survey
meeting was held with company officials on December 3, 1986. The industrial
hygiene monitoring and recording of data were performed during the third
shift (11:00 p.m. to 7:00 a.m.) of the preceding night. Company
representatives were very cooperative 1n assisting with this survey.
-------
SITE CHARACTERIZATION
GENERAL
The drug room at site 1/0 is part of a captive dyehouse operating on an
integrated basis. Approximately 18 million pounds per year of synthetic and
snythetic-natural blend fabrics for men's and women's outerwear are dyed in
batch operations at this privately owned facility. Seventy-five dyeing
machines (jet and beck) were available, all of which were in operation during
the monitoring period. Fibers dyed are acrylic/modacrylic, rayon, wool,
polyester, and cotton. Site operations Include storage, preparation, dyeing,
and finishing.
DRUG ROOM
The drug room is a rectangular room approximately 60 feet long and 30
feet wide, with a 15-foot ceiling. The room is accessed by one door at the
north end of the room which leads to the mixing area, one door at the west
side of the room which leads to the utility and cleaning area, and two
outside doors at the south end of the room. Dye weighing and storage areas
are located in the drug room; the mixing area 1s a separate area outside the
north end of the drug room. Figure 1 presents a sketch of the drug room.
Dyes are stored In drums utilizing the floor space along the walls of
the drug room. Small candy jar-like containers of 60 dyes are also stored on
each of two tables which are situated behind the two weighing stations. The
dye drums vary in size from 200- to 250-pound barrels to smaller, 50- to
-------
PASS THROUGH
m WINDOWS
f-
UTILITY AND
CLEANING AREA
60 ft
1-
_- x^ ^V
i ' i if
-
^
i
2
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I
i/i t/i /
»•» a
>.o Bi IBI
a vo !•] !•!
5u. H A
LJ ^ V flB
_-x TABLE
V
s
\
\
\
AIR SUPPLYJL
*4^
*
RAISED
PLATFORM
* ' t 4/1
ABOVE FLOOR §
3 STFPS
=] •
1
1
a
I
e
[•] LARGE
1 ' SCALE
DOOR
•
i
AIR SUPPLY
-6-
]— *AIR "
DOOR
i i >
'
AIR
< it n 1 11
30 ft
s>»
^••••^H
in t/\
>• O
UO
•
1
k
*
\
\
x
DOOR
1
AIR
u rir\w«
DOOR
L
v
— —
DRUMS
AIR*~C
15 ft CEILING
AIR SUPPLY-
TYPICAL OF
FOUR PLACES
AIR FLOW APPEARS
TO BE OUT OF ROOM
NO VISIBLE EXHAUST
FROM THE ROOM. ONLY
SUPPLY VENTS.
TWO WEIGHERS AT
WEIGH TABLES AT
ALL SHIFTS
DYE MACHINE
AREA
LEGEND
• WEIGHING STATION
• AREA SAMPLER AT DRUM STORAGE
A AREA SAMPLER AT WEIGHING STATION
'DENOTES FLOW OF DYES FROM STORAGE
~^ THROUGH WEIGHING TO MIXING
Figure 1. Sketch of drug room area.
-------
100-pound containers. The "candy jars" each contain approximately 8-10
pounds of dye.
One weighing station housing two small scales is located at the end of
the drug room near the pass-through windows used to transport the weighed dye
batch to the mixing area. A larger scale is located near the drum storage
area.
The general appearance of the drug room was fairly clean. The walls
appeared slightly stained from dye materials. Very little spillage of dye
material was observed. Reportedly, the floors are wet mopped between each
shift. No floor drains are located in the drug room.
The drug room has no local exhaust ventilation installed for removing
airborne dye material. There are air conditioning units and four air-supply
vents. The air flow was out of the room at the south entrances.
Environmental conditions of the drug room (i.e., temperature, humidity,
and barometric pressure) were recorded hourly during the survey and are
summarized In Table 1.
TABLE 1. ENVIRONMENTAL CONDITIONS RECORDED DURING THE SURVEY3
Parameter
Temperature, °F
Relative humidity, %
Barometric pressure, In. Hg.
Mean,
8-hour value
70
77
29.9
Minimum
69
73
29.5
Range
Maximum
71
80
29.9
a Readings of each parameter were -ecorded hourly over the 8-hour work shift.
DYE WEIGHER ACTIVITIES
The company employs two full-time dye weighers on each of three shifts.
Their duties include:
0 Relocating drums within the storage area.
0 Weighing dyes and recording weights on batch tickets.
-------
0 Transferring dyes to the mixing area by passing the batch through a
window.
0 Cleaning dye storage and weighing areas.
The dye weighers employed at this facility are involved in the handling,
transferring, and weighing of dyes.
The monitored dye weigher was a 44-year old male. He has been employed
at the company for 18 years; 17 of those years have been spent handling dyes.
He had no previous dye handling experience.
Training
Specific dye weigher training regarding the safe handling of dyes is
provided by the company in the form of respiratory protection instructions
for working with powder dyes.
Personal Protective Equipment
Personal protective equipment utilized by the monitored dye weigher dur-
ing dye weighing activities included a 3M 8710 respirator and rubber gloves.
There was no dermal contact with dyestuffs due to the consistent wearing of
rubber gloves.
Personal Habits
The monitored dye weigher was not observed drinking or eating in the
drug room during the survey. He did smoke inside the weighing area. The
monitored dye weigher also performed the following two activities which
created additional dye dust in the area:
1) Wiping the scale pan with cheesecloth following the dye weighings.
2) Banging the scale pan on the edge of the table to loosen the dye
particles.
Work Activities
The dye weigher's activities in filling each batch ticket order were as
follows: dyes were obtained by walking to a drum in the storage area contain-
ing the appropriate dye, using a hand scoop to remove an approximate quantity
-------
of the dye, transferring the scoop of dye to the weigh station, pouring the
required amount onto the scale dish, returning the unused portion of the dye
to the drum, and-transferring the weighed portion of the dye to a stainless
steel bucket. This operation was repeated until all of the dye weighings
specified on the batch ticket had been completed. The batch was then manual-
ly transferred to the mixing area through the pass-through window.
SPECIFIC MEASUREMENTS AND OBSERVATIONS
The monitored employee was in the drug room for approximately 376
minutes over the 8-hour period (480 minutes). His duties required him to
enter the drug room 11 times. He was monitored for exposure to particulates
over a 449-minute period from 11:02 p.m. to 6:31 a.m. The data collected and
observations made during the survey are summarized in Table 2. Table 3 pre-
sents a list of the dye materials handled during the survey, including the
dye color index number, the number of weighings of each dye, and the total
weight of each dye.
ANALYTICAL RESULTS
Solids filtered from the air in this facility were analyzed by EPA for
total dye content. Total weight of all solids and analytical results from
the four filtering devices, corrected for recovery, follow (in milligrams dye
per cubic meter air):
Active Total
Colorants Commercial Dyes Weight
Average of 2 monitoring 0.22 0.46 0.73
devices in worker's breathing
zone
Drug room area sampler at 0.09 0.20 0.31
weighing station
Drug room area sampler at drum 0.05 0.10 0.19
storage, remote from weighing
area
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TABLE 2. SUMMARY OF DATA AND INFORMATION RECORDED DURING SURVEY
A.
Time in work area
Percent of
monitoring
Time, minutes period
Total time monitored
Total time in drug room
Lunch and breaks
B.
C.
D.
E.
F.
Work capacity
Maximum work load
Units in operation at
Powder dyes weighed
Total
Disperse
Basic
Direct
Dyes
Total
Disperse
Basic
Direct
Dry chemicals weighed
Astro Sperse PEL 50
All chemicals weighed
Total
Dyes
Dry chemicals
time of survey
449
376
NA
Number
process
75
75
a
of
units
Number of dyes
Number of
weighings
97
20
21
56
Number of
weighings
1
Number of
weighings
98
97
1
30
8
11
11
Weight of dyes
Percent pounds
100
21
22
57
Percent
100
Percent
100
99
1
268.455
84.085
25.061
159.309
Weight of
chemicals,
pounds
2.751
Weight of
dry chemicals
pounds
271.206
268.455
2.751
100
84
NA
Percent
100
100
Percent
100
27
37
37
*
Percent
100
31
9
59
Percent
100
>
Percent
100
99
1
(continued)
8
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TABLE 2 (continued)
G.
H.
Dyes weighed most
frequently
Direct Brown 115
"Direct Blue M-2"
Direct Red 227
Direct Red 89
Direct Black 80
Disperse Blue 60
Largest quantity
of dyes weighed
Direct Black 80
"Disperse Black M-2"
Disperse Blue 281
Disperse Blue 60
Direct Blue 191
Direct Brown 115
"Direct Orange M-2"
Number of
weighings
10
8
8
7
6
6
Number of
weighings
6
2
3
6
4
10
5
Percent
10
8
8
7
6
6
Percent
6
2
3
6
4
10
5
Weight of
dyes, pounds
17.667
8.447
5.648
6.656
64.852
21.454
Weight of
dyes, pounds
64.852
26. 2C1
25.615
21.454
20.655
17.677
15.950
Percent
7
3
2
2
24
8
Percent
24
10
10
8
8
7
6
NA - Not available.
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TABLE 3. DYE MATERIALS HANDLED DURING THE SURVEY
Dye color index number
Number of
weighings
Total weight
of weighings,
pounds
Disperse Dyes:
Disperse Yellow 54
Disperse Orange 41
Disperse Red 73
Disperse Blue 73
"Disperse Blue U-4"
Disperse Blue 60
Disperse Blue 281
"Disperse Black M-2"
Basic Dyes:
Basic Yellow 13
Basic Yellow 51
Basic Yellow 28
Basic Orange 21
Basic Red 46
"Basic Red U-2"
Basic Red 15
Basic Blue 54
Basic Blue 3
Basic Blue 141
Basic Green 4
Direct Dyes:
Direct
"Direct
Direct
"Direct
Direct
Direct
"Direct
Direct
Direct
Direct
Direct
Yellow 106
Orange M-2"
Red 89
Red U-l"
Red 80
Red 227
Blue M-2"
Blue 191
Blue 251
Brown 115
Black 80
2
2
1
1
3
6
3
2
1
1
2
1
1
5
2
1
4
1
2
4
5
7
1
1
8
8
4
2
10
6
1.676
3,
4,
0,
.665
.839
.398
0.235
21.454
25.615
26.203
0.040
0.925
2.520
3.571
1.342
0.211
9.296
2.684
0.180
0.150
4.142
3.723
15.950
6.656
2.363
0.300
5.648
8.447
20.655
13.048
17.667
64.852
10
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TEXTILE DRUG ROOM MONITORING STUDY
SITE VISIT REPORT
Site Number 1/6
^ ^
jx. ''-*'<_i
, Ph.D., C.ITH.
WTmam L. Dyson,
Health and Hygiene, Inc.
Prepared for:
U.S. ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF TOXIC SUBSTANCES
401 M STREET. S.W.
WASHINGTON, DC 20460
11
-------
INTRODUCTION
This survey was conducted as part of an exposure study being performed
as a cooperative effort between the U.S. Environmental Protection Agency
(EPA), the American Textile Manufacturers Institute, Inc. (ATMI), and the
Ecological and Toxicological Association of the Dyestuffs Manufacturing
Industry (ETAD). The study's objective was to determine the extent of
textile workers' exposure to dye dust when weighing and mixing powder dyes.
The sites to be visited were selected to obtain a random sampling of eligible
sites. Contact with the site representative to schedule the site visit was
made by William L. Dyson, Ph.D., C.I.H. of Health and Hygiene, Inc.,
representing ATMI and ETAD. In attendance at the site were Dr. Dyson and
Robert D. Willson, C.I.H., of Beta Associates, Inc. subcontractor for PEI
Associates, Inc., representing EPA. The pre-survey meeting was held with
company officials on the morning of December 4, 1986. The Industrial hygiene
monitoring and recording of data were performed during the second shift (3:00
p.m. to 11:00 p.m.) on the same day. Company representatives were very
helpful in assisting with this survey.
12
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SITE CHARACTERIZATION
GENERAL
The drug room at site 1/6 is part of a dyehouse operating on a commis-
sion basis. Approximately 5 million pounds per year of fabrics for the manu-
facture of outerwear garments, life jackets, and hot-air balloons are dyed
with powder dyes at this publicly owned facility. Sixteen batch dyeing
machines and one continuous dyeing machine were available for use at this
facility; three of the batch machines were not in operation during the moni-
toring period. The types of dyeing machines at this site include a thermosol
continuous machine, and jigg and pressure beam batch machines. Fibers of
acetate, rayon, nylon, and polyester are dyed. Site operations include
storage, preparation, dyeing, and finishing.
DRUG ROOM
The drug room is a rectangular room approximately 90 feet long and 30
feet wide, with an 18-foot ceiling. The room Is accessed by two doors at one
end of the room which lead to the adjacent dyehouse and a door at the oppo-
site end which leads to the auxiliary storage area. Dye weighing and primary
storage areas are located In the drug room. Figure 1 presents a sketch of
the drug room.
Dyes are stored in drums along the walls of the drug room and in a
larger area at the back of the room. Most of the dyes are stored In 110-
pound drums.
13
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DYE MACHINE
AREA
i
18 f
i
i
45 f
i
t
27 1
\
t
't
r
i
't
i
i .
•
't
•
'1
AUXILIARY DRUM
STORAGE AREA
DRUMS
^ TO **. ^1 1 — - , , -ir ft *_
\
\ WEIGHING AND —^
X"N 4 MIXING STATION ( )
81— {Sx 0
os ~ \ o
\ o
^0
V} **~S
10
i . 0
,' n
L / ^-^
O
OOO O
DRUMS /"""N
0
»
•
. OUTSIDE WALL
i
CEILING
HEIGHT
18 ft
LEGEND
• WEIGHING STATION
• AREA SAMPLER AT DRUM ^TORAGE
A AAEA SAMPLER AT WEIGHING STATION
'DENOTES TLOW OF DYES FROM STORAGE
- THROUGH MIXING TO DYEING
Figure 1. Sketch of druo room area.
14
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One weighing station housing one scale is located in the center of the
drug room for weighing powder dyes.
The general appearance of the weighing and storage areas was dirty. The
walls, equipment, and stored drums all showed signs of accumulated dye mate-
rial. Very few dyestuff spills were observed during the survey.
There was no local exhaust ventilation installed for the purpose of
removing airborne dye material from the drug room. There appeared to be no
visible exhaust from the room. There were steam exhaust vents on the dye
machines in the dyehouse. There was no makeup air.
There are no floor drains in the drug room.
Environmental conditions of the drug room (i.e., temperature, humidity,
and barometric pressure) were recorded hourly during the survey and are
summarized in Table 1.
TABLE 1. ENVIRONMENTAL CONDITIONS RECORDED DURING THE SURVEY*
Parameter
Temperature, °F
Relative humidity, %
Barometric pressure, 1n. Hg.
Mean,
8-hour value
68
82
30.16
Minimum
68
77
30.07
Range
Maximum
69
88
30.20
*
Readings of each parameter were recorded hourly over the 8-hour work shift.
DYE WEIGHER ACTIVITIES
The company employs one full-time weigher on each of three shifts. His
duties include:
0 Weighing dyes and dry chemicals and recording weights on batch
tickets.
0 Transferring weighed dyes from the scale pan to buckets.
15
-------
0 Mixing weighed dye material with water to liquefy mixture.
0 Straining of dye solutions/dispersions.
0 Cleaning dye storage and weighing areas.
The dye weighers employed at this facility are involved in the handling, and
weighing of dyes and dry chemical; however, very few chemical additions were
performed by the monitored dye weigher on the day of the survey.
The dye weigher monitored during this survey was a 50-year old male. He
has been employed at the company for 17 months. He is a utility man who
fills in as the dye weigher when needed. He had no previous dye handling
experience.
Training
Specific dye weigher training regarding the safe handling of dyes is
provided as part of the company's Hazard Communication Program and Respira-
tory Protection Program and consists of review of dye material safety data
sheets and instructions on respirator usage and maintenance.
Personal Protective Equipment
Personal protective equipment utilized by the monitored dye weigher
included a Wilson Model AR700 half-mask respirator with a RIO dust filter and
an R22 chlorine/organic vapor cartridge. As the worker did not wear gloves,
there was dermal contact of the hands with the dyes while obtaining dye
materials from their storage containers.
Personal Habits
The monitored dye weigher was observed drinking and eating in the drug
room during his breaks and lunch period. He did not smoke inside or outside
of the weighing area. However, because he was chewing tobacco, ingestion of
the dye material is possible. The monitored dye weigher washed his hands
frequently to remove accumulated dye material.
16
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Work Activities
The dye weigher's activities in filling each batch ticket order were as
follows: dyes were obtained by walking to a drum in the storage area con-
taining the appropriate dye, using a hand scoop to remove an approximate
quantity of the dye, transferring the scoop of dye to the weigh station,
pouring the required amount into the scale dish, returning the unused portion
of the dye to the drum, and transferring the weighed portion of the dye to a
bucket. This operation was repeated until all of the dye weighings specified
on the batch ticket had been completed. Next, a small amount of water was
added to the bucket and stirred to liquefy the mixture. On the day of the
survey, only one batch was strained following mixing. Then, the bucket was
transferred by other operators into the dye machine.
SPECIFIC MEASUREMENTS AND OBSERVATIONS
The monitored dye weigher was 1n the drug room for a total of 407 min-
utes over the 8-hour period (480 minutes). During that time, his duties
required him to enter the drug room 10 times. He was monitored for exposure
to particualtes over a 464 minute period from 3:00 p.m. to 10:44 p.m. The
data collected and observations made during the survey are presented in Table
2. Table 3 presents a list of dyes handled during the survey, including the
dye color index number, the number of weighings of each dye, and the total
weight of all weighings of each dye.
17
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ANALYTICAL RESULTS
Solids filtered from the air In this facility were analyzed by EPA for
total dye content. Total weight of all solids and analytical results from
the four filtering devices, corrected for recovery, follow (1n milligrams dye
per cubic meter air):
Active Total
Colorants Commercial Dyes Weight
Average of 2 monitoring 0.09 0.16 0.25
devices in worker's breathing
zone
Drug room area sampler at 0.07 0.12 0.15
weighing station
Drug room area sampler at drum <0.01 <0.01 0.04
storage, remote from weighing
area
18
-------
TABLE 2. SUMMARY OF DATA AND INFORMATION RECORDED DURING SURVEY
A.
Time in work area
Percent of
monitoring
Time, minutes period
Total time monitored
Total time in drug room
Lunch and breaks
B.
C.
D.
E.
F.
Work capacity
Maximum work load
Units in operation at
- Continuous
- Batch
Powder dyes weighed
Total weighed
Acid
Disperse
Dyes
Total
Acid
Disperse
Dry chemicals weighed
Sodium bichromate
(Na2Cr20?)
All chemicals weighed
Total
Dyes
Dry chemicals
time of survey
Number of
weighings
54
53
1
Number of
weighings
2
Number of
weighings
56
54
2
464
407
NA
Number of
process units
17
14
1
13
Number of dyes
11
10
1
Weight of dyes
Percent grams
100 56,410
98 56,310
2 100
Weight of
chemicals,
Percent grams
100 324
Weight of
all chemicals
Percent grams
100 56,734
96 56,410
4 324
100
88
NA
Percent
100
82
100
81
Percent
100
91
9
,
Percent
100
>99
<1
Percent
100
*
Percent
100
>99
<1
(continued)
19
-------
TABLE 2 (continued)
G.
H.
Dyes weighed most
frequently
Acid Blue 25
Acid Yellow 135
Acid Yellow 99
Acid Red 266
Largest quantity
of dyes weighed
Acid Yellow 99
Acid Blue 113
Acid Blue 25
Acid Yellow 49
Acid Green 25
Add Red 266
Number of
weighings
12
10
8
8
Number of
weighings
8
5
12
5
2
8
Percent
23
19
15
15
Percent
15
9
23
9
4
15
Weight of dyes,
grams
7,482
2,258
15,856
5,155
Weight of dyes,
grams
15,856
8,269
7,482
7,256
5,673
5,155
Percent
13
4
28
9
Percent
28
15
13
13
10
9
NA - Not available.
20
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TABLE 3. DYE MATERIALS HANDLED DURING THE SURVEY
Dye color index number
Number of
weighings
Total weight
of weighings,
grams
Acid Dyes:
Acid Yellow 135
Acid Yellow 49
Acid Yellow 99
Acid Orange 149
"Acid Orange U-l"
Acid Red 266
Acid Red 52
Acid Blue 25
Acid Blue 113
Acid Green 25
Disperse Dyes:
Disperse Yellow 184:1
10
5
8
1
1
8
1
12
5
2
2,258
7,256
15,856
4,192
69
5,155
100
7.482
8,269
5,673
100
21
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TEXTILE DRUG ROOM MONITORING STUDY
SITE VISIT REPORT
Site Number 2/1
William 1. Dyion, Ph.D., C.I.H. Les{i///Unger$i
Health and Hygiene, Inc. PEI"Ai|pcutei, Inc.
U.S. ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF TOXIC SUBSTANCES
401 M STREET, S.W.
WASHINGTON, D.C. 20460
23
-------
INTRODUCTION
This survey was conducted as part of an exposure study being performed
as a cooperative effort between the U.S. Environmental Protection Agency
(EPA), the American Textile Manufacturers Institute, Inc. (ATMI), and the
Ecological and Toxicological Association of the Dyestuffs Manufacturing
Industry (ETAD). The study's objective was to determine the extent of
textile workers' exposure to dye dust when weighing and mixing powder dyes.
The sites to be visited were selected to obtain a random sampling of eligible
sites. Contact with the site representative to schedule the site visit was
made by William L. Dyson, Ph.D., C.I.H. of Health and Hygiene, Inc.,
representing ATMI and ETAD. In attendance at the site were Dr. .Dyson and
Leslie J. Ungers, C.I.H, Senior Industrial Hygienist for PEI Associates,
Inc., representing EPA. The pre-survey meeting was held with company
officials on the afternoon of October 7, 1986. The industrial hygiene
monitoring and recording of data was performed during the second shift (3:00
p.m. - 11:00 p.m.) on the same day. Company representatives were very
cooperative in assisting with this survey.
24
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SITE CHARACTERIZATION
GENERAL
The drug room at site 2/1 is part of a captive dyehouse operating on an
integrated basis. Approximately 3.5 million pounds per year of knitted
apparel fabrics are dyed in batch operations at this publicly owned facility.
There are eleven atmospheric beck dyeing machines available, all of which
were operating at the time of this survey. Fibers dyed are acrylic/mod-
acrylic, polyester, cotton, or combinations of these fibers. Site operations
include storage, preparation, dyeing, and finishing.
DRUG ROOM
The drug room 1s a rectangular area located in the basement of the
facility measuring approximately 15 feet long and 5 feet wide with a 12-foot
ceiling. The room 1s accessed by personnel by one of two doors at either end
of the room. The south entrance leads directly from the drum storage area.
The drug room includes shelving and dye and dry chemical scales. Separated
from the drug room by an interior wooden wall, the drum storage area measures
15 feet by 60 feet. All drums are stored on the basement floor of this area.
Drums vary in size from 200-250 pound barrels to smaller, 50-100 pound con-
tainers. The mixing area is completely separate from this area of the facil-
ity. Figure 1 presents a sketch of the drug room area.
The general appearance of the weighing and storage areas was fairly
clean. Although powder dye spills were not cleaned up Immediately, the
25
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MIXING AREA
20 ft
EXTERIOR —
BRICK
WALL \
WINDOW —
TO OUTSIDE
60 ft
m
»
SCALE
ELECTRONIC ^
READOUT ^^
\ A ^XsNTRAN
1
J> 14 "SCALE
•
TABLE * »*
/ \XXF
/ \
/ \ wo
/ \ §
-, / \ S
/ \L-
/ \
SHELVES \
\
\ ^\|NTRAi
N INTERIOR ^» \
WOODEN
WALL
RAMP
t *
\ _.
1
|
CE
•* INTERIOR
WOODEN
WALL
LOCATION OF
HYDROTHERMOGRAPH
ICE
\
(ALL DRUMS IN THIS AREA)
BASEMENT FLOOR
15 ft
1
(NON-DYE STORAGE)
15 ft
• ME1CHIK STATION
• AREA SAWUR AT MUM STOKAGt
* AREA SAHTICR AT MCICMIKC STATION
- ocNorcs rim or orrt FHN STORACC
- TMIOWK MICMIN6 TO MIIING .
Figure 1. Sketch of drug room area.
26
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walls, floors, and general area were maintained in fair condition. Cleanli-
ness of equipment, however, was poor, with evidence of dye dust accumulation.
Environmental conditions of the drug room (i.e., temperature, humidity,
and barometric pressure) were recorded hourly during the survey and are
summarized in Table 1.
TABLE 1. ENVIRONMENTAL CONDITIONS RECORDED DURING THE SURVEY*
Parameter
Temperature, °F
Relative humidity, %
Barometric pressure, in. Hg
Mean,
8-hour value
73
49
30.12
Range
Minimum Maximum
68 75
44 55
30.11 30.14
Readings of each parameter were recorded hourly over the 8-hour work shift.
The drug room has no active local exhaust ventilation system installed
for the purpose of removing airborne dye particles. Floor drains are present
for drainage purposes in the drug room. The drum storage area is exposed
along one side to the remainder of the basement area.
DYE WEIGHER ACTIVITIES
The company employs one full-time dye/chemical weigher on each of three
shifts. His duties Include:
0 Weighing dyes and recording weights on dye batch tickets.
0 Transferring weighed dyes from the scale pan to stainless steel
buckets.
0 Adding liquid agents to buckets.
0 Carrying buckets of batched chemicals to the mixing area.
0 Cleaning dye storage and weighing areas.
27
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TEXTILE DRUG ROOM MONITORING STUDY
SITE VISIT REPORT
Site Number 2/4
William L. Dyson, Ph.D., C.f.H. f Le$i1tf J. Ungers, C.I.H,
Health and Hygiene, Inc. \./ yPE/Associates, Inc.
Prepared for:
U.S. ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF TOXIC SUBSTANCES
401 M STREET. S.W.
WASHINGTON. DC 20460
29
-------
INTRODUCTION
This survey was conducted as part of an exposure study being performed
as a cooperative effort between the U.S. Environmental Protection Agency
(EPA), the American Textile Manufacturers Institute, Inc. (ATMI), and the
Ecological and Toxicological Association of the Dyestuffs Manufacturing
Industry (ETAD). The study's objective was to determine the extent of
textile workers' exposure to dye dust when weighing and mixing powder dyes.
The sites to be visited were selected to obtain a random sampling of eligible
sites. Contact with the site representative to schedule the site visit was
made by William L. Dyson, Ph.D., C.I.H. of Health and Hygiene, Inc.,
representing ATMI and ETAD. In attendance at the site were Dr. Dyson and
Kenneth Troutman, C.I.H., subcontractor for PEI Associates, Inc.,
representing EPA. The pre-survey meeting was held with company officials on
December 9, 1986. The Industrial hygiene monitoring and recording of data
were performed during the first shift (7:00 a.m. to 3:00 p.m.) on the next
day. Company representatives were very cooperative in assisting with this
survey.
30
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PIPE BASEMENT
STAIRS
DRUG ROOM
i
40 ft
j
00
00
00
OO
00
00
OO
OO
00
00
00
OO
OO
00
/OO
OO
00
OO
OO
OO
00
OO
OO
OO
OO
°°«
OO*
OO
o
o
o
o
o
o
o
o
o
o
o
o
o
o
STAIRS TO.
STORAGE
MIXER
DYE
STORAGE
M
A
J
X
>\,
^^^^
f
1
»
^M
UJ
5
\n
k*
^•H
X
/
*
m
k^
CO
UJ
o
z
5
in
i£
u
5
DRUG ROOM AREA
IS APPROXIMATELY
25 ft x 40 ft
OPEN AREA BY STOCK
KETTLES AND VATS
SOUTH END OF PLANT
SOUTH END OF
FIRST FLOOR
LEGEND
• WEIGHING STATION
• MCA SAMPLER AT DRUM STOMGE
* AREA SAMPLER AT WEIGHING STATION
OWOTK tlM V OTIS nON STOUtt
_-* nOOUCI NCHHtK AND NIIIK TO OTE
MCVIM IK*
Figure 1. Sketch of drug room area.
32
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SITE CHARACTERIZATION
GENERAL
The drug room at site 2/4 is part of a captive dyehouse operating on an
integrated basis. Approximately 2.5 million pounds per year of wool raw
stock are dyed in batch operations at this publicly owned facility. Thirty-
three stock dye machines were available, 20 of which were in operation during
the monitoring period. Fibers of wool and nylon are dyed for the carpet
industry. Site operations include storage, dyeing, and drying.
DRUG ROOM
The drug room, located on the first floor of the plant building, is a
rectangular room approximately 40 feet long and 25 feet wide, with a 20-foot
ceiling. The drug room is open to the adjacent mixing area. The drum stor-
age area for the dyes is located in the pipe basement which is accessed from
the stairwell in the drug room. Dyes are also stored in bins on racks in the
drug room. The dye drums In the basement contain approximately 300 pounds of
dye material while the bins In the drug room contain approximately 2 to 3
pounds of dye. Dry chemicals are not stored 1n the drug room area. Figure 1
presents a sketch of the drug room.
A weighing station housing one scale for weighing the powder dyes is
located In the drug room near the racks which support the dye bins. A small
hand mixer is located near the dye scale for mixing dye batches.
31
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0 Mixing the dyes In the bucket using a hand mixer.
0 Hand carrying the buckets to the dye machines.
0 Cleaning dye storage, weighing, and mixing areas.
The monitored dye weigher was a 47-year old male. He has been employed
at the company for 21 years; fifteen of those years have been spent handling
dyes. He had no previous dye handling experience.
Training
Specific dye weigher training regarding the safe handling of dyes was
limited to instruction concerning use of chemical-resistant gloves and dust
mask respiratory protection.
Personal Protective Equipment
The monitored dye weigher In the drug room did not utilize any personal
protective equipment. However, the monitored dye weigher did demonstrate
good technique during all weighing and mixing activities.
Personal Habits
The monitored dye weigher was not observed drinking or eating in the
drug room. He did not smoke Inside the weighing area, but he did smoke
outside of that area.
Work Activities
The dye weigher's activities in filling each batch ticket order were as
follows: dyes were obtained by walking to a drum in the storage area con-
taining the appropriate dye and using a hand scoop to remove an approximate
quantity of the dye, transferring the scoop of dye to the weigh station and
pouring the required amount into the scale dish, returning the unused portion
of the dye to the drum, and transferring the weighed portion of the dye to a
bucket. This operation was repeated until all of the dye weighings specified
34
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The general appearance of the weighing and storage areas was good. The
walls, equipment, drums, and floors appeared to be free of accumulated dye
material. It was reported that when spillage of the dye occurs, the floor is
swept up immediately, although no spillage was observed at the time of this
survey.
The drug room was not equipped with local exhaust ventilation systems
for the purpose of removing airborne dye particles. The building was
equipped with a general ventilation system; the drug room had two ceiling
exhaust fans and one dryer exhaust.
No floor drains are located in the drug room.
Environmental conditions of the drug room (i.e., temperature, humidity,
and barometric pressure) were recorded hourly during the survey and are
summarized in Table 1.
TABLE 1. ENVIRONMENTAL CONDITIONS RECORDED DURING THE SURVEY*
Range
Mean,
Parameter 8-hour value Minimum Maximum
Temperature, °F 72 70 74
Relative humidity, % 79 64 95
Barometric pressure, torr 755 755 755
Readings of each parameter were recorded hourly over the 8-hour work shift.
DYE WEIGHER ACTIVITIES
The company employs one full-time weigher/mixer on the first shift only.
The dye weigher employed at this facility is involved in the handling, weigh-
ing, and mixing of dyes. His duties include:
0 Weighing dyes and recording weights on batch tickets.
0 Transferring dyes from the scale to buckets.
33
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on the batch ticket had been completed. The dyes were then mixed near the
dye scale using a hand mixer. He then transferred the bucket containing the
mixed dyes to the dye machine area where the dye solution was poured into the
expansion tank of the stock dyeing machine. Other workers operated the
dyeing machines.
SPECIFIC MEASUREMENTS AND OBSERVATIONS
The monitored dye weigher was in the drug room for a total of 213 min-
utes over the 8-hour period (480 minutes). During that time, his duties
required him'to enter the drug room 18 times. He was monitored for exposure
to particulates over a 440-minute period from 7:12 a.m. to 2:32 p.m. Table 2
presents a summary of the data and information recorded during the survey.
Table 3 presents a list of the dyes handled during the survey, including the
dye color index number, the number of weighings of each dye, and the total
weight of the weighings of each dye.
ANALYTICAL RESULTS
Solids filtered from the air in this facility were analyzed by EPA for
total dye content. Total weight of all solIds and analytical results from
the four filtering devices, corrected for recovery, follow (in milligrams dye
per cubic meter air):
Active Total
Colorants Commercial Dyes Weight
Average of 2 monitoring 0.08 0.12 0.31
devices in worker's breathing
zone
Drug room area sampler at 0.01 0.01 0.15
weighing station
Drug room area sampler at drum <0.01 0.01 0.10
storage, remote from weighing
area
35
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TABLE 2. SUMMARY OF DATA AND INFORMATION RECORDED DURING SURVEY
A.
Time in work area
Percent of
monitoring
Time, minutes period
Total time monitored
Total time in drug room
Lunch and breaks
B.
C.
D.
E.
F.
Work capacity
Maximum work load
Units in operation at
Powder dyes weighed
Total weighed
Acid
Dyes
Total
Add
Dry chemicals weighed
Total
All chemicals weighed
Total
Dyes
Dry chemicals
440
213
NA
Number of
process units
33
time of survey 20
Number of
weighings
108
108
Number of
weighings
0
Number of
weighings
108
108
0
Number of dyes
21
21
Weight of dyes
Percent ounces
100 1,576.01
100 1,576.01
Weight of
all chemicals
Percent ounces
100 1,576.01
100 1,576.01
0 0.00
100
48
NA
Percent
100
61
Percent
100
100
Percent
100
100
Percent
100
100
0
G.
Dyes weighed most
frequently
Acid Red 156
Add Yellow 19
Add Blue 25
Number of
weighings
15
12
12
Weight of dyes,
Percent ounces
14 57.02
11 132.95
11 40.40
Percent
4
8
3
(continued)
36
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TABLE 2 (continued)
H. Largest quantity Number of Weight of dyes,
of dyes weighed weighings Percent ounces Percent
Acid Black 172 4 4 755.00 48
Acid Red 57 66 318.87 20
Acid Yellow 19 12 11 132.95 8
NA - Not available.
37
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TABLE 3. DYE MATERIALS HANDLED DURING THE SURVEY
Dye color index number
Acid Dyes:
Acid Yellow 218
Acid Yellow 49
Acid Yellow 198
Acid Yellow 19
Acid Yellow 151 (NP)*
Acid Orange 156
Acid Red 337
Acid Red 57
Acid Red 266
Acid Red 143
Acid Red 299
Acid Red 182
Acid Violet 48
Acid Blue 80
Acid Blue 324S
Acid Blue 25
Acid Blue 40
Acid Blue 290
Acid Green 25
Acid Green 28
Acid Black 172
Number of
weighings
1
2
4
12
1
15
2
6
5
6
4
1
4
7
5
12
7
4
3
3
4
Total weight
of weighings,
ounces
0.88
1.02
5.13
132.95
0.79
57.02
6.09
318.87
20.86
37.87
1.94
0.75
24.82
43.77
2.31
40.40
17.09
4.54
87.51
16.41
755.00
*NP designates a Neutral Premetallized Dye.
38
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The dye/chemical weighers at this facility are involved in dye and dry chem-
ical handling, weighing, and mixing. No dry chemicals were weighed in the
drug room during this survey. Work activities require the dye/chemical
weigher to spend time in the drug room, storage area, and mixing room.
The monitored dye/chemical weigher was a 24-year old male. He has been
employed at the company for 6.5 years; the past 4 years have been spent
handling dyes. He had no previous dye handling experience.
Training
Information regarding the safe handling of dyes is provided by the
company as part of the company's Hazard Communication program.
Personal Protective Equipment
Personal protective equipment required by the company to be worn by
dye/chemical weighers includes half-mask air-purifying cartridge respirators,
rubber aprons and gloves, safety glasses, and ear plugs. The monitored
dye/chemical weigher did not wear his gloves consistently, thereby resulting
in frequent dermal contact with the powder dyes.
Personal Habits
The monitored dye/chemical weigher did not eat, drink, or smoke in the
weighing area.
Work Activities
The dye/chemical weigher's activities 1n filling each batch ticket order
were as follows: dyes were obtained by walking to a drum containing the
appropriate dye, using a stainless steel hand scoop to remove an approximate
quantity of the dye, transporting the scoop of dye to the weighing station,
pouring the required amount onto the scale dish, returning the unused portion
of the dye to the drum, and transferring the weighed portion of the dye to a
stainless steel bucket. This operation was repeated for additional dyes
39
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until all the weighings specified on the batch ticket had been completed.
The same technique would have been used for dry chemical weighings had any
been required during the monitoring period. Buckets containing dye/chemical
mixtures were then hand carried to the mixing area and placed on the ground
next to the mixer. The mixing operation was not observed.
SPECIFIC MEASUREMENTS AND OBSERVATIONS
The monitored employee was in the drug room for a total of 84 minutes
over the 8-hour (480 minute) period. During that time, his duties required
him to enter the drug room 12 times. He was monitored for partlculates over
a 367 minute period, from 3:10 pm to 9:17 pm. Table 2 presents a summary of
the data and Information recorded during the survey. Table 3 presents a list
of the dye materials handled during the survey, Including the dye color index
number, the number of weighings of each dye, and the total weight of the
weighings of each dye.
ANALYTICAL RESULTS
Solids filtered from the air 1n this facility were analyzed by EPA for
total dye content. Total weight of all solIds and analytical results from
the four filtering devices, corrected for recovery, follow (1n milligrams dye
per cubic meter air):
Active Total
Colorants Commercial Dyes Weight
Average of 2 monitoring 0.01 0.02 0.94
devices in worker's breathing
zone
Drug room area sampler at 0.06 0.11 0.17
weighing station
Drug room area sampler at drum <0.01 <0.01 0.14
storage, remote from weighing
area
40
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TABLE 2. SUMMARY OF DATA AND INFORMATION RECORDED DURING SURVEY
A. Time in work area
Percent of
monitoring
Time, minutes period
Total time monitored
Total time in drug room
Lunch break
367 100
84 23
Not available
B.
C.
D.
E.
Work capacity
Maximum work load
Units in operation at time of survey
Powder dyes weighed
Total weighed
Disperse
Basic
Reactive
Number of
Dyes weighings
Total 20
Disperse 5
Basic 2
Reactive 13
Dry chemicals weighed
Number of
process units
11
11
Number of dyes
15
5
2
8
Weight of dyes,
Percent kilograms
100 63.961
25 22.269
10 5.131
65 36.561
Number of
weighings
Percent
100
100
Percent
100
33
13
53
Percent
100
35
8
57
Total
41
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TABLE 2 (continued)
F.
Dyes weighed most
frequently
Reactive Blue 10
Reactive Blue 7
Number of
weighings
5
2
Percent
25
10
Weight of dyes,
kilograms
5.990
10.352
Percent
9
16
Largest quantity
G. of dyes weighed
Number of
weighings
Percent
Weight of dyes,
kilograms
Percent
"Disperse Blue M-3"
Reactive Blue 137
Reactive Blue 7
Disperse Blue 73
Reactive Blue 10
1
1
2
1
5
5
5
10
5
25
13.349
11.570
10.352
6.750
5.990
21
18
16
11
9
42
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TABLE 3. DYE MATERIALS HANDLED DURING THE SURVEY
Dye Color Index Number
Number of
weighings
Total weight of
all weighings,
kilograms
Disperse Dyes:
"Disperse Red U-2"
Disperse Red 60
Disperse Blue 73
Disperse Blue 56
"Disperse Navy Blue M-3"
Basic Dyes:
Basic Yellow 40
Basic Red 14
Reactive Dyes:
Reactive Yellow 3
Reactive Orange 70
Reactive Red 43
Reactive Red 120
Reactive Red 152
Reactive Blue 7
Reactive Blue 137
Reactive Blue 10
1
1
1
1
1
1
1
1
1
1
1
1
2
1
5
1.348
0.576
6.750
0.246
13.349
3.747
1.384
0.692
1.112
.535
.708
1.602
10.352
11.570
5.990
2.
2.
43
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TEXTILE DRUG ROOM MONITORING STUDY
SITE VISIT REPORT
Site Number 2/7
William L. Dyson, Ph.D., C.I.H. Les^jj/C^yUngers, C.I.H.
Health and Hygiene, Inc. PEI Associates, Inc.
Prepared for:
U.S. ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF TOXIC SUBSTANCES
401 M STREET, S.W.
WASHINGTON, DC 20460
45
-------
INTRODUCTION
This survey was conducted as part of an exposure study being performed
as a cooperative effort between the U.S. Environmental Protection Agency
(EPA), the American Textile Manufacturers Institute, Inc. (ATMI), and the
Ecological and Tox1colog1cal Association of the Dyestuffs Manufacturing
Industry (ETAD). The study's objective was to determine the extent of
textile workers' exposure to dye dust when weighing and mixing powder dyes.
The sites to be visited were selected to obtain a random sampling of eligible
sites. Contact with the site representative to schedule the site visit was
made by W11Ham L. Dyson, Ph.D., C.I.H. of Health and Hygiene, Inc.,
representing ATMI and ETAD. In attendance at the site were Dr. Dyson and Ken
Troutman, C.I.H., subcontractor for PEI Associates, Inc., representing EPA.
The pre-survey meeting was held with company officials on the afternoon of
October 21, 1986. The Industrial hygiene monitoring and recording of data
were performed during the first eight hours of the second of two 12-hour
dally shifts (7:00 p.m. to 3:00 a.m.) on the same day. Company representa-
tives were very cooperative 1n assisting with this survey.
46
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SITE CHARACTERIZATION
GENERAL
The drug room at site 2/7 1s part of a dyehouse operating on a commis-
sion basis. Approximately 6 million pounds of knit goods for apparel use per
year are dyed 1n batch operations at this privately owned facility. Eleven
jet dyeing machines were available, all of which were 1n operation at the
time of the survey. Fibers dyed are acryllc/modacryllc, polyester, and
cotton. Site operations Include storage, preparation, dyeing, and finishing.
DRUG ROOM
The drug room 1s a rectangular room approximately 21 feet long and 18
feet wide with a celling 12 feet 1n height . The room 1s accessed by a door
which leads to the adjacent dye machine area. An additional door leading to
a separate drum storage room 1s located 1n the southeast corner of the room.
Dye weighing, storage, and mixing areas are located In the drug room. Figure
1 presents a sketch of the drug room area.
Mixing Machine Area
One mixer Is located In the west corner of the drug room near the
weighing station. There are no physical barriers that separate the mixer
from the rest of the drug room.
47
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N
v ^ SMALL
xx\^ WINDOW
— . 1 0 ft.
OBHIXER B^°
\ '^ ^^
1 ~* (- SCALE O S*\
v^ I )
DRAIN \ WEIGHING STATION f*\
\ "^ '
! ^1
WINDOW i 1
/I
, 1
/ i
> \
SLIGHT DQnD I
OUTWARD
AIR FLOW
DYE MACHINES
AREA
DC
wrv |
1
i
°o i
°o i
^^^
o o o
o o o^
v WO
\ s~\
C j
\^^^^/
^^^^
x 0
o
o
x^'o
DYE DRUMS ^ /^ -^
n
O O O O O O LJ
f*\ s~\
s^.
^
-------
Powder Dye Storage and Weighing Area
Dyes are stored in drums utilizing the floor space along the walls of
the drug room. Dye drums are also stored in a separate storage room measuring
18 feet long and 10 feet wide located at the rear of the drug room. The
drums vary in size from 200-250 pound barrels to smaller, 50-100 pound con-
tainers.
For weighing of powder dyes, a weighing station housing one scale is
located along the wall near the mixing machine. Dry chemicals are neither
stored nor weighed in the drug room.
The general appearance of the drug room was unclean. There was accumu-
lated dye material on the walls, floors, equipment, and inventory indicating
infrequent cleaning practices. No spillage of the powder dyes was observed
during the survey; therefore, cleanup procedures could not be directly eval-
uated.
The drug room has no exhaust ventilation installed for the purpose of
removing airborne dye particles. An air supply vent is located at the rear
of the room near the entrance to the additional storage room. There was a
slight outward flow of air at the drug room exit leading to the dye machine
area.
A floor drain 1s located next to the mixing machine to facilitate drain-
age during floor cleanup activities and mixer overflow.
Environmental conditions of the drug room (I.e., temperature and humid-
ity) were recorded hourly during the survey. Barometric pressure readings
for the day were obtained from the weather station at the local airport. The
environmental conditions are summarized in Table 1.
49
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TABLE 1. ENVIRONMENTAL CONDITIONS RECORDED DURING THE SURVEY
Parameter
Temperature, °F
Relative humidity, %
Barometric pressure, in. Hg.
Mean,
8-hour value
70
68
29.37
Minimum
69
64
29.31
Range
Maximum
72
75
29.40
DYE WEIGHER ACTIVITIES
The company employs one full-time dye weigher on each of two shifts.
His duties include:
0 Relocating drums within the storage areas.
0 Weighing dyes and recording weights on dye batch tickets.
0 Transferring dyes from the scale to buckets, which are mixed and
then hand carried to the staging area outside the drug room near
the dye machines.
0 Cleaning dye storage, weighing, and mixing areas.
The dye weighers employed at this facility are involved in handling and
weighing of dyes. Work activities require the dye weigher to spend time in
both the drug room and the dye machine area.
The monitored dye weigher was a 35-year old male. He has been employed
at the company for 6 years; 5 of those years have been spent handling dyes.
He had no previous dye handling experience.
Training
Training on all chemicals used in the plant was provided to the dye
weighers in conjunction with the company's Hazard Communication program.
Personal Protective Equipment
Dye weighers are provided with 3M Model 8714 Acid Gas respirators and
rubberized boots. The respirator was worn by the monitored dye weigher only
50
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when he was handling dyes that he felt were Irritating to his sinuses. He
wore rubberized boots throughout the monitoring period. It was noted that
there was slight dermal contact with the dye material; hand protection is not
required by the company.
Personal Habits
The monitored dye weigher did not drink or eat 1n the drug room. He did
smoke both inside and outside of +*>e drug room. He appeared to use good
technique when handling the dyes.
Work Activities
The dye weigher activities in filling each batch ticket order were as
follows: dyes were obtained by walking to a drum in the drug room containing
the appropriate dye and using a hand scoop to remove an approximate quantity
of the dye, transporting the scoop of dye to the weighing station and pouring
the required amount onto the scale dish, returning the unused portion of the
dye to the drum, and transferring the weighed portion of the dye to an open
bucket. This operation was repeated until all of the dye weighings specified
on the batch ticket had been completed. The bucket of weighed dye was mixed
with water in the drug room. It was then hand carried to the staging area
near the dye machines. The dyes were transferred to the dye machines as
needed.
When a dye barrel was almost empty, the dye weigher manually transferred
the remaining powder Into the new barrel by Inverting the old barrel over the
new barrel. One or more drum transfers occurred during the survey. This was
a potentially dust generating activity. The Individual transfers were not
recorded at the time of the survey, therefore, these transfers are not re-
flected 1n the summary tables 1n the total number of dye weighings.
51
-------
SPECIFIC MEASUREMENTS AND OBSERVATIONS
The monitored employee was 1n the drug room for a total of 124 minutes
over an 8-hour (480 minute) portion of his 12-hour work-shift. During that
time, his duties required him to enter the drug room 16 times. He was moni-
tored for exposure to particulates over a 475 minute period from 7:06 pm to
3:01 am. The data collected and information recorded during the survey are
presented in Table 2. Table 3 presents a list of the dye materials handled
during the survey, including the dye color index number, the number of weigh-
ings of each dye, and the total weight of the weighings of each dye.
ANALYTICAL RESULTS
Solids filtered from the air in this facility were analyzed by EPA for
total dye content. Total weight of all solids and analytical results from
the four filtering devices, corrected for recovery, follow (in milligrams dye
per cubic meter air):
Active Total
Colorants Commercial Dyes Weight
Average of 2 monitoring 0.04 0.08 0.46
devices in worker's breathing
zone
Drug room area sampler at 0.03 0.07 0.23
weighing station
Drug room area sampler at drum 0.03 0.06 0.25
storage, remote from weighing
area
52
-------
TABLE 2. SUMMARY OF DATA AND INFORMATION RECORDED DURING SURVEY
A. Time in work area
Total time monitored
Total time 1n drug room
Lunch break
Percent of
monitoring
Time, minutes period
475
124
Not available
100
26
B. Work capacity
Work load
Units in operation at time of survey
Number of
process units
11
11
Percent
100
100
C. Powder dyes weighed
Total weighed*
Disperse
Basic
Direct
Number of dyes
16
4
6
6
Percent
100
25
38
38
Number of
D. Dyes weighings Percent
Total 27 100
Disperse 4 15
Basic 17 63
Direct 6 22
Weight of dyes,
pounds
56.422
4.298
4.611
47.513
Percent
100
8
8
84
(continued)
53
-------
TABLE 2 (continued)
E. Dry chemicals weighed
Number of
weighings
Total
F. Dyes weighed
most frequently
Number of Weight of dyes,
weighings Percent pounds Percent
Basic Yellow 28
Basic Violet 16
Basic Red 46
5
5
4
19
19
15
2.747
1.629
0.020
5
3
<:
G. Largest quantity
of dyes weighed
"Direct Black M-l"
"Direct Blue U-l"
Direct Red 224
Direct Yellow 106
Number of
weighings
1
1
1
1
Percent
4
4
4
4
Weight of dyes,
pounds
19.127
15.514
5.10
3.932
Percent
34
27
9
7
54
-------
TABLE 3. DYE MATERIALS HANDLED DURING THE SURVEY
Total weight of
Number of all weighings,
Dye color index number weighings pounds
Disperse Dyes:
Disperse Yellow 54 1 0.003
Disperse Red 60 ' 1 2.102
Disperse Blue 56 1 1.593
Disperse Green 9 1 0.60
Basic Dyes:
Basic Yellow 28 5 2.747
Basic Red 14 1 0.11
Basic Red 46 4 0.020
Basic Violet 16 5 1.629
Basic Violet 37 1 0.098
Basic Blue 3 1 0.007
Direct Dyes:
Direct Yellow 44 1 3.00
Direct Yellow 106 1 3.932
Direct Red 224 1 5.10
"Direct Blue U-l" 1 15.514
Direct Blue 106 1 0.84
"Direct Black M-l" 1 19.127
55
-------
TEXTILE DRUG ROOM MONITORING STUDY
SITE VISIT REPORT
Site Number 3/0
William L. Dyson, Ph.D., C.I.H. LesVfe J.yOngers, C.I.H.
Health and Hygiene, Inc. PEI Associates, Inc.
Prepared for:
U.S. ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF TOXIC SUBSTANCES
401 M STREET, S.W.
WASHINGTON. D.C. 20460
57
-------
INTRODUCTION
This survey was conducted as part of an exposure study being performed
as a cooperative effort between the U.S. Environmental Protection Agency
(EPA), the American Textile Manufacturers Institute, Inc. (ATMI); and the
Ecological and Toxicologlcal Association of the Dyestuffs Manufacturing
Industry (ETAD). The study's objective was to determine the extent of
textile workers' exposure to dye dust when weighing and mixing powder dyes.
The sites to be visited were selected to obtain a random sampling of eligible
sites. Contact with the site representative to schedule the site visit was
made by William L. Dyson, Ph.D., C.I.H. of Health and Hygiene, Inc.,
representing ATMI and ETAD. In attendance at the site were Dr. Dyson and Ken
Troutman, C.I.H., subcontractor for PEI Associates, Inc., representing EPA.
The pre-survey meeting was held with company officials on the afternoon of
October 24, 1986. The industrial hygiene monitoring and recording of data
were performed during the first shift (8:00 a.m. to 4:00 p.m.) on the same
day. Company representatives were very cooperative 1n assisting with this
survey.
58
-------
SITE CHARACTERIZATION
GENERAL
The drug room at site 3/0 Is part of a captive dyehouse operating on an
Integrated basis. Approximately 25 million pounds per year of yarn for
furniture and automotive fabrics are dyed 1n batch operations at this
privately owned facility. Twelve COB and Gaston County package dyeing
machines were available, all of which were operating during the monitoring
period. Fibers dyed are nylon and polyester. Site operations Include stor-
age, preparation, dyeing, and drying.
DRUG ROOM
The drug room Is a rectangular room approximately 51 feet long and 15
feet wide with a celling 12 feet In height. The room 1s accessed by one of
three doors, one In the center of each of the north, south, and west walls.
The drug room Includes a weighing station with two dye scales and dye storage
areas. Dry chemicals are neither stored nor weighed 1n the drug room. Dye
machines are located 1n an area outside the drug room, adjacent to Its west
wall. Figure 1 presents a sketch of the drug room.
Dyes are stored 1n drums utilizing the floor space 1n the vicinity of
each of the four corners of the drug room. The containers vary 1n size
The Incorrect Information was recorded on the field survey form during the
Initial site visit. Corrections were made following subsequent contact with
plant representatives and are Indicated In this report.
59
-------
N
1
\
-i-
i
MACHINE AND
I XING AREA
WINDC
SLIGHT -^_
OUTWARD DO
AIR FLOW
•^ 15 it — ^-
oo ""; ooo
o o \ooo
oo )p oo
/^\ /""V^r- DYE DRUMS ' \ 0
\
oo \
oo ^ \
N \
\
V \
\ \
Nx \
)W X
— "" SCALES < (•)
AIR ^T~l
HANDLING •— '
UNIT y
/ *
/ 1
/ 1
/ i
/ 1
/ 1
o /
OO OO
(^ Cy"* — DYE DRUMS — ^"^D ^^
oo oo
1
5
EAST SIDE OF PLANT
UCtNQ
• WE I Oi UNC. STATION
A Aftt* V"*PLt' AT ^EICllISO STATION
*OCNOT£5 r^cu f O'CS TBOM STOMO
~x timniKjii wcn,H,\r, to finnr,
• >Jj»- .
1 ft
CEILING HEIGHT -
12 ft
Figure 1. Sketch of drug room area.
60
-------
from 200-250 pound barrels to smaller, 50-100 pound containers. One weighing
station housing two scales for weighing powder dyes is located at the center
of the east wall, directly opposite the west wall entrance.
The general appearance of the drug room was very clean. The walls,
floor, equipment, and stored drums were all free of accumulated dye material.
Scale pans and spatulas-were washed at the end of each shift. Reportedly,
the floors were washed down at the beginning and end of each shift. A floor
drain located in the center of the room facilitates drainage during this
activity. No spillage of dye material was observed during the survey.
The drug room had no local exhaust ventilation installed for the purpose
of removing airborne dye particles. The air supply vent was located in the
center of the room near the weighing station. A slight outward flow of air
at the drug room exit to the dye machine area was observed on the day of the
survey.
Environmental conditions of the drug room (i.e., temperature, humidity,
and barometric pressure) were recorded hourly during the survey and are
summarized In Table 1.
TABLE 1. ENVIRONMENTAL CONDITIONS RECORDED DURING THE SURVEY*
Parameter
Temperature, °F
Relative humidity, %
Barometric pressure, in. Hg.
Mean,
8-hour value
72
54
29.26
Range
Minimum Maximum
71
53
29.21
72
55
29.28
Temperature and humidity readings were recorded hourly over the 8-hour work
shift. Hourly barometic pressure readings were obtained from the local air-
port weather bureau for the monitoring period.
61
-------
DYE WEIGHER ACTIVITIES
The company employs two full-time dye weigher/mixers on each of three
shifts. His duties include:
Relocating drums within the storage area.
0 Weighing dyes and recording weights on dye batch tickets.
0 Transferring dyes from the scale to a separate container, which is
then carried to an area outside the drug room near the dye
machines.
0 Mixing dyes with water in mixing area.
0 Cleaning dye storage and weighing areas.
The dye weigher/mixers employed at this facility are involved in dye
handling, weighing, and mixing. Dry chemicals are not handled by the dye
weigher/mixer. Work activities require the dye weigher/mixer to spend time
in the drug room and in the dye machine area outside the .rug room.
The monitored dye weigher/mixer was a 22-year old male. He has been
employed at the company for one year, during which time he has spent 8 months
handling dyes. He had no previous dye handling experience.
Training
Company training for dye weigher/mixers regarding the safe handling of
dyes Involves employee familiarization with the Individual dye material
safety data sheets (MSDS's). Dye weigher/mixers are also instructed to wear
safety glasses and a respirator during dye handling activities.
Personal Protective Equipment
Personal protective equipment provided by the company and worn by the
monitored dye weigher/mixer included a 3M Model 8710 Dust and Mist respira-
tor, gloves, and rubber boots.
62
-------
Personal Habits
The monitored dye weigher/mixer was not observed drinking, eating, or
smoking in the drug room. He was observed smoking outside of the drug room.
Work Activities
The dye weigher/mixer activities in filling each batch ticket order were
as follows: dyes were obtained by walking to a drum containing the appro-
priate dye, using a hand scoop to remove the approximate quantity of the dye,
transferring the scoop of dye to the weighing station, pouring the required
amount onto the scale dish, returning the unused portion of the dye to the
drum, and transferring the weighed portion of the dye to a separate con-
tainer. This operation was repeated until all of the dye weighings specified
on the batch ticket had been completed. The container of weighed dye mate-
rial for the batch was hand carried to the mixing area outside the drug room
where water was added until a good solution/dispersion was obtained. The dye
weigher/mixer did not operate the dye machines.
When a barrel of dye was almost empty, the dye weigher/mixer manually
transferred the remaining powder into the new barrel by Inverting the old
barrel over the new barrel. One or more drum transfers occurred during the
survey. This was a potentially dust generating activity. The Individual
transfers were not recorded at the time of the survey; therefore those trans-
fers are not reflected in the summary tables 1n the total number of dye
weighings.
SPECIFIC MEASUREMENTS AND OBSERVATIONS
The monitored employee was in the drug room for a total of 263 minutes
over the 8-hour (480 minute) first work-shift. During that time, his duties
63
-------
required him to enter the drug room 18 times. He was monitored for exposure
to particulates over a 428 minute period from 8:06 am to 3:14 pm. The data
collected and information recorded during the survey are presented 1n Table
2. Table 3 presents a list of the dye materials handled during the survey,
including the dye color Index number, the number of weighings of each dye,
and the total weight of the weighings of each dye.
ANALYTICAL RESULTS
Solids filtered from the air in this facility were analyzed by EPA for
total dye content. Total weight of all solids and analytical results from
the four filtering devices, corrected for recovery, follow (in milligrams dye
per cubic meter air):
Active Total
Colorants Commercial Dyes Weight
Average of 2 monitoring 0.10 0.31 • 0.41
devices in worker's breathing
zone
Drug room area sampler at 0.09 0.30 0.30
weighing station
Drug room area sampler at drum 0.01 0.05 0.09
storage, remote from weighing
area
64
-------
TABLE 2. SUMMARY OF DATA AND INFORMATION RECORDED DURING SURVEY
A. Time in work area
Percent of
monitoring
Time, minutes period
Total time monitored
Total time in drug room
Lunch break
428 100
263 61
Not available
B.
Work capacity
Work load
Units in operation at time of survey
Number of
process units Percent
12 100
12 100
C.
Powder dyes weighed
Total weighed
Acid
Disperse
Number of dyes Percent
21 100
7 33
14 67
65
-------
TABLE 2 (continued)
D. Dyes
Total
Acid
Disperse
Number of Weight of dyes,
weighings Percent grams
72 100 97,926.51
13 18 10,813.53
59 82 87,112.98
Percent
100
11
89
E. Dry chemicals weighed
Total
Number of
weighings
0
F. Dyes weighed
most frequently
Number of Weight of dyes,
weighings Percent grams Percent
Disperse Orange 30
Disperse Blue 73
Disperse Red 159
Disperse Blue 337
12
9
6
6
17
12
8
8
36,630.96
6,767.90
15,039.00
7,479.10
37
7
15
8
66
-------
ITLargest
quantity of
dyes weighed
Number
of
weighings Percent
Weight of dyes,
grams
Percent
Disperse Orange 30
Disperse Red 159
Acid Black M-l
Disperse Blue 337
12
6
2
6
17
8
3
8
36,630.96
15,039.00
7,520.50
7.479.10
37
15
8
8
67
-------
TABLE 3. DYE MATERIALS HANDLED DURING THE SURVEY
Dye color index number
Number of
weighings
Weight of
all weighings,
grams
Acid Dyes:
Acid Yellow 159
Acid Red 360
"Acid Red U-3"
Acid Red 299
Acid Blue 113
"Acid Blue U-l"
"Acid Black M-l"
Disperse Dyes:
Disperse
Disperse
Disperse
Disperse
Disperse
Disperse
Disperse
Di sperse
Disperse
Disperse
Disperse
Disperse
Disperse
Disperse
Yellow 93
Yellow 198
Orange 30
Red 43
Red 305
Red 159
Red 263
Red 91
Red 167:1
Violet 48
Blue 337
Blue 73
Blue 60
Blue 281
4
1
2
1
1
2
2
3
3
12
5
2
6
1
2
4
2
6
9
1
3
1054.20
364.40
13.71
701.10
1156.00
3.62
7520.50
619.82
1359.70
36630.96
1369.70
2036.00
15039.00
606.80
425.60
5656.60
679.60
7479.10
6767.90
3084.00
5358.20
68
-------
TEXTILE DRUG ROOM MONITORING STUDY
SITE VISIT REPORT
Site Number 3/3
_
William L. Dyson, Ph.D., C.I.H.
Health and Hygiene, Inc.
7L/smAJ7Unge1rs, C.I.H.
iX PEi/Assoclates, Inc.
Prepared for:
U.S. ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF TOXIC SUBSTANCES
401 H STREET, S.W.
WASHINGTON, DC 20460
69
-------
INTRODUCTION
This survey was conducted as part of an exposure study being performed
as a cooperative effort between the U.S. Environmental Protection Agency
(EPA), the American Textile Manufacturers Institute, Inc. (ATMI), and the
Ecological and Toxicological Association of the Dyestuffs Manufacturing
Industry (ETAD). The study's objective was to determine the extent of
textile workers' exposure to dye dust when weighing and mixing powder dyes.
The sites to be visited were selected to obtain a random sampling of eligible
sites. Contact with the site representative to schedule the site visit was
made by William L. Dyson, Ph.D., C.I.H. of Health and Hygiene, Inc.,
representing ATMI and ETAD. In attendance at the site were Ronald H. Hill,
C.I.H. of Health and Hygiene, Inc. and Donald L. Unruh, C.I.H., IT
Corporation, subcontractor for PEI Associates, Inc., representing EPA. The
pre-survey meeting was held with company officials on March 30, 1987. The
industrial hygiene monitoring and recording of data were performed during the
third shift (11:00 p.m. to 7:00 a.m.) on March 30-31, 1987. Company
representatives were very cooperative in assisting with this survey.
70
-------
SITE CHARACTERIZATION
GENERAL
The drug room at site 3/3 1s part of a captive dye house operating on an
integrated basis. Approximately 2.16 million pounds of upholstery fabric per
year are printed at this privately owned facility. Two printing machines
were available but only one was operating at the time of the survey. Fibers
printed are acrylic/modacryllc, rayon, polyester, cotton, and nylon. Liquid
Disperse Dyes are used for acrylic/modacrylic or polyester fibers; pigments
are used for cotton or rayon fibers; and powder Acid Dyes are used for nylon
fibers. Site operations Include storage, preparation, printing (application
and fixation), and finishing.
DRUG ROOM
The drug room is a rectangular room approximately 45 feet long and 15
feet wide, with a 10-foot ceiling. The room is accessed by a door at the
north end of the room which leads to the print shop area and a door at the
south end of the room which leads to the dye mix area. The dye mix area is a
separate room outside of the drug room. The drug room Includes drum storage
areas, one dye weighing station equipped with two scales, an oven, a washer,
and a dryer. Figure 1 presents a sketch of the drug room and the adjacent
dye mix area.
Powder dyes are stored in drums located against the east wall of the
drug room. Disperse liquid dyes are stored in drums located against the
71
-------
PRINT SHOP AREA
LEGEND
• WEIGHING STATION
• AREA SAMPLER AT DRUM STORAGE
A AREA SAMPLER AT WEIGHING STATION
'DENOTES FLOW OF DYES FROM STORAGE
-' THROUGH WEIGHING TO MIXING
AIR FLOW
t,-n ,
Ul
i
i
LfJ
o
o
o
^MM
""FILE '
CABINETS
-4-^°.^
o m
S?
—t •-•
_^_^
POWDERED
DYES
OOOOOO
/ i
DISPERSE r-s •*
LIQUID DYES ^ ^
-1 DRUG ROOMi 1, ^
i x-s m*
-DRYER 1 S
AIR '^
FLOW |f HOT WATER
WASHER \ | HEATERQ
•=iiimiiiiiiiiim iiiiiiwiiimiiiiiEi
=
^Z
DYE MIX 7 * 5 =
AREA r t g =
EYE WASH / \ 8 =
AND SHOWER / \ ^ =
QJT MIXERS \^J \J
4
•
> ft
^> SCALES
r
^HOT WATER
BARREL
UJ
Z
h-
Z
oe
o.
Figure 1. Sketch of drug room area.
72
-------
west wall of the drug room. The drums vary in size from 200 to 250-pound
barrels to 50 to 100-pound containers.
For weighing of the powder dyes, two scales are located on a counter
next to the access door to the dye mix area.
The general appearance of the drug room was poor. The walls, equipment,
and stored drums contained significant accumulations of dyestuff, indicating
infrequent cleaning. It was reported that the floors and weighing tables
were washed down weekly. No immediate clean-up procedures in the case of
spills has been established.
The drug room was not equipped with a local exhaust ventilation system
for the purpose of removing airborne dye particles. The room was equipped
with an air conditioning system in which air was supplied from a ceiling
vent. The general building air was supplied through air supply ducts which
exhausted through roof vents. The ventilation in the drug room created a
slight positive pressure compared to the other plant areas, evidenced by the
flow of air out of the room at each of the access doorways.
A floor drain which surrounds the perimeter of the dye mix area is
located just outside the door at the south end of the drug room to facilitate
drainage when the floor is hosed down weekly.
Environmental conditions of the drug room (i.e., temperature, humidity,
and barometric pressure) were recorded hourly during the survey and are
summarized in Table 1.
73
-------
TABLE 1. ENVIRONMENTAL CONDITIONS RECORDED DURING THE SURVEY*
Parameter
Temperature, °F
Relative humidity, %
Barometric pressure, in. Hg.
Mean,
8-hour value
68
76
28.64
Minimum
66
70
28.61
Range
Maximum
73
81
28.68
Readings of each parameter were recorded hourly over the 8-hour work shift.
DYE WEIGHER ACTIVITIES
The company employs four full-time dye weighers on the first shift and
one dye weigher on each of the second and third shifts. Their duties include:
0 Relocating drums of dye material within the drug room by use of a
drum dolly.
0 Weighing dyes and recording weights on batch tickets.
0 Transferring dyes from the scale to buckets.
0 Emptying buckets of weighed dyestuff mixed with water into mixing
barrels.
0 Adding liquid chemicals to the mixing barrels.
0 Mixing the dyes and chemical materials in the mixing barrels with
portable mixers.
0 Cleaning dye storage, mixing, and weighing areas.
The dye weighers employed at this facility are Involved in the handling,
transferring, and weighing of dry and liquid dyes and chemicals.
The monitored dye weigher was a 24-year old male. He has been employed
at the company for one year; all of that time has been spent handling dyes.
He had no previous dye handling experience.
Training
Specific dye weigher training regarding the safe handling of dyes was
provided by the company as Instructions as to when to wear a dust mask and
74
-------
chemical goggles, and training on how to read Material Safety Data Sheets
(MSDS's). A file of dye and chemical MSDS's Is kept In the dye storage and
weighing room.
Personal Protective Equipment
Personal protective equipment utilized by the monitored dye weigher in
the drug room included a Gerson Model No. 1710 disposable dust respirator and
steel-toed shoes. The monitored dye weigher used the dust mask during all
weighing activities; however, the effectiveness of the respirator may be
limited for the following reasons: 1) only one strap was used on the mask,
2) the same disposable respirator is often worn for several consecutive days,
and 3) the monitored dye weigher had a long, full beard, which could prevent
a proper air tight seal.
Personal Habits
The monitored dye weigher was observed smoking In the weigh room after
the dyes were weighed and in the print shop area outside of the weigh room.
He did not eat or drink In the drug room area. The monitored dye weigher
washed his hands after all of the powder dyes were weighed.
Work Activities
The dye weigher's activities In filling each batch ticket order were as
follows: dyes were obtained by walking to a drum in the storage area con-
taining the appropriate dye, using a hand scoop to remove an approximate
quantity of the dye, transferring the scoop of dye to the weigh station and
spooning out the required amount Into the scale dish with a wooden tongue
depressor, returning the unused portion of the dye to the drum, and trans-
ferring the weighed portion of the dye to a bucket. The bucket was then
filled two-thirds full with hot water and emptied Into barrels. This
75
-------
operation was repeated until all of the dye weighings specified on the batch
ticket had been completed. Other liquid chemicals were then added, and the
solution was mixed in the barrels by use of portable mixers. On the day of
the survey, most of the dye weighing activities took place during the first
two hours of the shift. Finally, the barrels were manually transported to
the printing machines by drum dolly. Fourteen color combinations were
weighed by the dye weigher.
SPECIFIC MEASUREMENTS AND OBSERVATIONS
The monitored dye weigher was in the drug room for a total of 125 min-
ute* over the 8-hour period (480 minutes). During that time, his duties
required him to enter the drug room eighteen times. He was monitored for
exposure to particulates over a 447-minute period from 11:20 p.m. to 6:47
a.m. Table 2 presents a summary of the data and information recorded during
the survey. Table 3 presents a list of the dye materials handled during the
survey, including the dye color index number, the number of weighings of each
dye, and the total weight of the weighings of each dye.
ANALYTICAL RESULTS
Solids filtered from the air in this facility were analyzed by EPA for
total dye content. Total weight of all solids and analytical results from
the four filtering devices, corrected for recovery, follow (in milligrams dye
per cubic meter air):
Active Total
Colorants Commercial Dyes Weight
Average of 2 monitoring 0.01 0.02 0.13
devices in worker's breathing
zone
Drug room area sampler at <0.01 0.01 0.05
weighing station
Drug room area sampler at drum <0.01 <0.01 0.05
storage, remote from weighing
area
76
-------
TABLE 2. SUMMARY OF DATA AND INFORMATION RECORDED DURING SURVEY
A.
Time 1n work area
Percent of
monitoring
Time, minutes period
Total time monitored
Total time in drug room
Lunch and breaks
B.
C.
D.
E.
F.
Work capacity
Maximum work load
Units in operation at
Powder dyes weighed
Total
Acid
Neutral Premetallized
Dyes
Total
Acid
Neutral Premetallized
Dry chemicals weighed
Urea
All chemicals weighed
Total
Dyes
Dry chemicals
time of survey
447
125
NA
Number
process
2
1
of
units
Number of dyes
Number of
weighings
42
14
28
Number of
weighings
3
Number of
weighings
45
42
3
8
3
5
Weight of dyes
Percent grams
100
33
67
Percent
100
Percent
100
93
7
4,488.52
2,019.83
2,468.69
Weight of
chemicals,
pounds
40.5
Weight of
dry chemicals
grams
22,859.52
4,488.52
18,371.0
100
28
NA
Percent
100
50
Percent
100
38
62
*
Percent
100
45
55
Percent
100
»
Percent
100
20
80
(continued)
77
-------
TABLE 2 (continued)
(i.
H.
Dyes weighed most
frequently
Add Black 107
Acid Brown 298
Acid Orange 3
Largest quantity
of dyes weighed
Acid Orange 3
Acid Brown 298
Acid Black 107
Number of
weighings
11
9
7
Number of
weighings
7
9
11
Percent
26
21
17
Percent
17
21
26
Weight of dyes,
grams
932.25
1306.05
1911.23
Weight of dyes,
grams
1911.23
1306.05
932.25
Percent
2l'
29
43
Percent
43
29
21
NA - Not available.
78
-------
TABLE 3. POWDER DYE MATERIALS HANDLED DURING THE SURVEY
Dye color index number
Number of
weighings
Total weight
of weighings,
grams
Acid Dyes:
Acid Yellow 49
Acid Orange 3
Acid Blue 25
Neutral Premetallized Dyes
Acid Yellow 151
Acid Orange 60
Acid Red 399
Acid Brown 298
Acid Black 107
2
7
5
1
1
6
9
11
28.50
1911.23
80.10
26.25
3.37
200.77
1306.05
932.25
79
-------
TEXTILE DRUG ROOM MONITORING STUDY
SITE VISIT REPORT
Site Number 3/8
William L. Dyson, Ph.D., C.I.H. Leslir Ji Uhgers, C.I.H.
Health and Hygiene, Inc. PEI Associates, Inc.
Prepared for:
U.S. ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF TOXIC SUBSTANCES
401 M STREET. S.W.
WASHINGTON, DC 20460
81
-------
INTRODUCTION
This survey was conducted as part of an exposure study being performed
as a cooperative effort between the U.S. Environmental Protection Agency
(EPA), the American Textile Manufacturers Institute, Inc. (ATMI), and the
Ecological and Toxicological Association of the Dyestuffs Manufacturing
Industry (ETAD). The study's objective was to determine the extent of
textile workers' exposure to dye dust when weighing and mixing powder dyes.
The sites to be visited were selected to obtain a random sampling of eligible
sites. Contact with the site representative to schedule the site visit was
made by William L. Dyson, Ph.D., C.I.H. of Health and Hygiene, Inc.,
representing ATMI and ETAD. In attendance at the site were Dr. Dyson and
Robert D. Will son, C.I.H. of Beta Associates, subcontractor for PEI
Associates, Inc., representing EPA. The pre-survey meeting was held with
company officials on the afternoon of June 17, 1986. The industrial hygiene
monitoring and recording of data was performed during the first shift (7:00
a.m. to 3:00 p.m.) on June 18, 1986. Company representatives were very
cooperative in assisting with this survey.
82
-------
SITE CHARACTERIZATION
GENERAL
The drug room at site 3/8 is part of a captive dyehouse operating on an
integrated and commission basis. Approximately 24 million pounds of yarn per
year are dyed in batch operations at this privately owned facility. Thirty-
five dyeing machines were available and 31 were in operation during the
entire monitoring period. Equipment included package and skein dyeing
machines, and machines for producing variegated yarns from stock dyed yarns.
Yarns dyed at this site are composed of wool, polyester, rayon, cotton,
acrylic/modacryllc, and occasionally nylon; or various combinations of these
fibers. Site operations include storage, preparation, dyeing, and finishing.
DRUG ROOM
The drug room 1s a square room approximately 36 feet long and 46 feet
wide with a celling 12 feet in height. The room 1s located 1n the northwest
corner of the first floor of the facility. It Includes areas for drum stor-
age and a weighing station equipped with two dye scales. There is a pass
through door on the north side of the room for receiving batch tickets, and a
pass through window on the south side of the room for transporting weighed
dyes to the adjacent mixing room, which is separate from the drug room.
The mixing area is located to the south of the drug room; dye machines
83
-------
COMPUTER ROOM
PASS THROUGH DOOR
FOR BATCH TICKETS
12 ft CEILING
X U.
LU O
ae »-
< o
DUCTWORK- SUPPLY AIR \W/A 1
1
DRUM AIRFLOW
STORAGE IN
*•
DRUM LJ
STORAGE SINK
Nx CONCRETE BLOCK WALL |
\ " '
x N
""•^^ > >
DRUM "'fcs. n
STORAGE
~* ^^'>U
1 PASS
1 THROUGH
t t t is T t
DRUM
STORAGE
_ WEIGH STATION
• (2 SCALES)
/
AIR DISTRIBUTION 1 ,,7infItNC
\ flfif> °°OR 1 »
36 ft |
1
ALL DYE
DRUMS BROUGHT
• INTO DRUG
ROOM HERE
LEGEND
A AREA SAMPLER NEAR
WEIGHING STATION
• AREA SAMPLER NEAR
DRUM STORAGE
• WEIGHING STATION
,-^FLOW OF DYES FROM
STORAGE THROUGH
MIXING
MIXING ROOM
NET AIRFLOW
•UT
Figure 1. Sketch of Drug Room.
84
-------
are located to the east of the drug room. Figure 1 presents a sketch of the
drug room area.
Dyes are stored 1n drums utilizing the floor space throughout the drug
room. The containers vary in size from 200-250 pound barrels to smaller
50-100 pound containers. One weighing station, which measures 2J feet by
6 feet, is located in the center of the drug room where two scales are locat-
ed. The weighing station is equipped with a computer terminal for video
display of batch tickets. Dry chemicals are both stored and weighed in an
area outside of the drug room. Occasionally, the dye weigher must perform a
dry, "non-dye" weighing. During this survey, a fluorescent whitening agent
(FWA) was weighed by the dye weigher. Within the scope of this study, this
material Is not considered a dye but it is stored in the drug room.
The general appearance of the drug room was clean. There was no accumu-
lation of dye on the floor, walls, or equipment. All drums were covered when
in storage. Very few spills of powder dyes occurred during this survey,
which maintained the overall cleanliness of the area. Reportedly, the floor
was hosed down with water after each shift.
The drug room environmental conditions (I.e., temperature, humidity, and
barometric pressure) were recorded hourly during the survey and are summa-
rized in Table 1.
The ventilation system within the drug room created a negative pressure
thereby generating air movement Into the drug room from the computer room.
Similarly, the drug room was urider positive pressure as compared to the
adjacent mixing room so that air flowed out of the drug room and into the
mixing room. No specific engineering controls had been installed for the
purpose of removing airborne dye particles.
85
-------
TABLE 1. ENVIRONMENTAL CONDITIONS RECORDED DURING THE SURVEY*
Parameter
Temperature, °F
Relative humidity, %
Barometric pressure, torr
Mean,
8-hour value
77
54
749
Range
Minimum Maximum
76 78
50 60
748 750
*Readings of each parameter were recorded hourly over the 8-hour
work shift.
DYE WEIGHER ACTIVITIES
The company employs one full-time dye weigher on each of three shifts.
His duties include:
0 Transporting new drums of dye into the storage areas and removing
empty drums.
0 Relocating drums within the storage area.
0 Weighing dyes and recording weights on dye batch tickets.
0 Transferring weighed dyes from the scale to buckets, and then
hand-passing the buckets through the pass through window to the
mixing room.
0 Obtaining quality control samples from new drums and carrying those
samples to the laboratory.
0 Cleaning dye storage and weighing areas.
The dye weighers employed at this facility are only Involved in the handling,
transfer, and weighing of dyes. These Individuals are not Involved in mixing
or handling of dry chemicals during normal process operations.
86
-------
The monitored dye weigher was a 43-year old male. He has been employed
at the company for 9 years; eight of those years have been spent handling
dyes. He had no previous dye-handling experience.
Training
Employee training is provided by the company. This training covers the
label information contained on the dyes and is performed in connection with
the company's Hazard Communication Program.
Personal Protective Equipment
Dye weighers are provided with rubber boots and gloves, Tyvek aprons and
dust mask respirators (MSA Model 2200). It was noted that the monitored dye
weigher removed Ms rubber gloves frequently; evidence of skin exposure to
the dye material was seen in the discoloration of the dye weigher's hands by
the dyes. The dye weigher did not wear his respirator properly; both elastic
straps were not positioned for proper fit and optimum protection.
Personal Habits
Eating and drinking were not permitted in the drug room. The dye weigher
was observed smoking both inside and outside of the drug room, although
company policy prohibits smoking in the drug room. The dye weigher did not
wash his hands prior to smoking.
Work Activities
The dye weigher activities in filling each batch ticket order were as
follows: dyes were obtained by walking to a drum containing the appropriate
dye, using a hand scoop to remove an excess quantity of the dye, transferring
the scoop of dye to the weighing station, pouring the required amount onto
the scale dish, returning the unused portion of the dye to the drum and,
87
-------
transferring the weighed portion of the dye to a bucket. Larger quantities
of dye were sometimes transported in paper bags. This operation was repeated
until all of the dye weighings specified on the batch ticket had been com-
pleted. The bucket was transferred by hand to the mixing room through the
pass through window.
When a barrel of dye was almost empty, the drum was no longer used. The
dye weigher did not transfer the dregs of one drum into a new barrel.
SPECIFIC MEASUREMENTS AND OBSERVATIONS
The monitored employee was in the drug room for a total of 342 minutes
over the 8-hour (480 minute) first work shift. He was monitored for exposure
to particulates over a 469 minute period from 7:03 a.m. to 2:51 p.m. During
that time, his duties required him to enter the drug room twelve times.
Table 2 presents a summary of the data and Information recorded during
the survey. Table 3 presents a list of the dye materials handled during the
survey including the dye color index number, the number of weighings of each
dye, and the total weight of the weighings of each dye.
ANALYTICAL RESULTS
Solids filtered from the air in this facility were analyzed by EPA for
total dye content. Total weight of all solids and analytical results from
the four filtering devices, corrected for recovery, follow (in milligrams dye
per cubic meter air):
Active Total
Colorants Commercial Dyes Weight
Average of 2 monitoring 0.08 0.16 0.29
devices in worker's breathing
zone
Drug room area sampler at 0.03 0.07 0.16
weighing station
Drug room area sampler ?.t drum 0.03 0.07 0.21
storage, remote from weighing
area
88
-------
TABLE 2. SUMMARY OF DATA AND INFORMATION RECORDED DURING SURVEY
A.
B.
Time in work area
Total time monitored
Total time in drug room
Lunch break
Work capacity
Maximum work load
Units in operation at time of survey
Time, minutes
469
342
Not available
Number of
process units
35
31
Percent
of moni-
toring
period
.JO
73
Percent
100
88
C.
Powder dyes weighed
Total weighed
Acid
Basic
Chrome
Disperse
Acid Metallized
Neutral PremetalUzed
Number of dyes
46
8
18
1
11
5
3
Percent
100
17
39
2
24
11
6
D.
Dyes
Total
Acid
Basic
Chrome
Disperse
Add Metallized
Neutral Premetallized
Number of
weighings Percent
149 100
15 10
112 75
2 1
11 7
6 4
3 2
Weight of dyes,
grams
74,576.84
872.40
23,166.25
18.956.00
18,680.30
6,397.89
6,504.00
Percent
100
1
31
25
25
8
9
E.
Dry "non-dyes" weighed
Number of
weighings Percent
Weight of
dry chemicals,
grams
Percent
Fluorescent Whitening
Agent (FWA) #61
100
44.8
100
89
-------
TABLE 2 (continued)
F.
All solids weighed
Total
Dyes
Dry "non-dyes"
Number of
weighings
150
149
1
Percent
100
99
1
Weight of
solids,
grams
74,621.64
74,576.84
44.8
Percent
100
99.9
<1
G.
Dyes weighed most
frequently
Basic Red 51
Basic Blue 41
Basic Blue 124
Basic Red 46
Basic Yellow 11
Number of
weighings
16
16
13
10
9
Percent
11
11
9
7
6
Weight of dyes,
grams
2,834.89
2,664.94
285.59
384.82
1,930.56
Percent
3.8
3.6
0.4
0.5
2.6
H.
Largest quantity
of dyes weighed
Mordant Black 11
Disperse Yellow 23
Basic Red 29
Acid Yellow 129
Add Blue 158
Basic Red 51
Number of
weighings
2
1
5
1
. 2
A6
Percent
1.3
0.7
3.3
0.7
1.3
11
Weight of dyes,
grams
18,956.00
13,276.00
4,194.70
3,025.00
2,902.00
2,834.89
Percent
25
18
6
4
4
4
90
-------
TABLE 3. DYE MATERIALS HANDLED DURING THE SURVEY
Number of Total Weight
Dye color Index number weighings weighed, grams
Add Dyes:
Add Yellow 127 1 1.70
Acid Yellow 17 3 437.00
Add Orange 10 1 66.60
Add Red 1 2 80.60
Add Violet 7 • 2 7.90
Add Blue 90 1 7.20
Add Blue 45 4 270.10
Acid Blue 7 1 1.30
Neutral Premetalllzed Dyes:
Acid Yellow 129 1 3,025.00
Add Brown 227 1 1.768.00
Add Black 58 1 1,711.00
Chrome Dyes:
Mordant Black 11 2 18,956.00
Add Metallized Dyes:
Add Yellow 99 1 496.49
Add Orange 74 1 432.20
Add Red 186 1 481.20
Add Red 194 1 2,086.00
Acid Blue 158 2 2,902.00
Disperse Dyes:
Disperse Yellow 218 1 716.30
Disperse Yellow 3 1 77.30
Disperse Yellow 23 1 13,276.00
Disperse Red 65 1 1,552.00
Disperse Red 60 1 1.60
Disperse Red 82 1 144.70
Disperse Red 4 1 21.40
Disperse Blue 3 1 11.90
Disperse Blue 56 1 2,400.00
Disperse Blue 60 1 401 40
Disperse Blue 139 1 77 0
(continued)
91
-------
TABLE 3 (continued)
Number of Total Weight
Dye color index number weighings weighed, grams
Basic Dyes:
Basic Yellow 24 2 1,072.44
Basic Yellow 11 9 1,930.56
Basic Yellow 87 8 432.49
Basic Yellow 29 2 1,635.30
Basic Yellow 28 8 1,140.90
Basic Yellow 91 1 333.40
Basic Yellow 25 3 2,661.50
Basic Red 14 3 108.79
Basic Red 29 5 4,194.70
Basic Red 46 10 384.82
Basic Red 51 16 2,834.89
Basic Red 15 6 1,828.40
"Basic Blue U-l" 2 69.86
Basic Blue 54 4 701.27
Basic Blue 124 13 285.59
Basic Blue 41 16 2,664.94
Basic Blue 3 3 882.30
Basic Green 4 1 4.10
92
-------
TEXTILE DRUG ROOM MONITORING STUDY
SITE VISIT REPORT
Site Number 4/1
p
WW1am L. Dyson, Ph.D., C.I.H. Le>tfe J/Ungers, C.I.H.
Health and Hygiene, Inc. PEI Associates, Inc.
U.S. ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF TOXIC SUBSTANCES
401 M STREET, S.W.
WASHINGTON. D.C. 20460
93
-------
INTRODUCTION
This survey was conducted as part of an exposure study being performed
as a cooperative effort between the U.S. Environmental Protection Agency
(EPA), the American Textile Manufacturers Institute, Inc. (ATMI), and the
Ecological and Toxicological Association of the Dyestuffs Manufacturing
Industry (ETAD). The study's objective was to determine the extent of
textile workers' exposure to dye dust when weighing and mixing powder dyes.
The sites to be visited were selected to obtain a random sampling of eligible
sites. Contact with the site representative to schedule the site visit was
made by William L. Dyson, Ph.D., C.I.H. of Health and Hygiene, Inc.,
representing ATMI and ETAD. In attendance at the site were Dr. Dyson and Ken
Troutman, C.I.H., subcontractor for PEI Associates, Inc., representing EPA.
The pre-survey meeting was held with company officials on the afternoon of
October 22, 1986. The industrial hygiene monitoring and recording of data
were performed during the first shift (7:00 a.m. to 3:00 p.m.) of the next
day (October 23, 1986). Company representatives were very helpful in as-
sisting with this survey.
94
-------
SITE CHARACTERIZATION
GENERAL
The drug room at site 4/1 is part of a captive dyehouse operating on an
integrated basis. Approximately 6 million pounds per year of raw stock are
dyed in batch operations at this publicly owned facility. Seven Morton
atmospheric dyeing machines were available at this location; all seven of
which were in operation during this survey. Fibers dyed are acrylic/mod-
acrylic, wool, and nylon. Site operations include storage, dyeing, and
drying.
DRUG ROOM
The drug room 1s rectangular in shape and 1s approximately 30 feet long
and 18 feet wide with a celling 10 feet in height. The room, at the north
end of the plant, 1s accessed by a door on the east side which leads to the
adjacent mixing area. The drug room Includes dye storage areas, a dye scale,
and a workbench area. Dry chemicals are not stored or weighed In the drug
room. The dye machines are located in an area just outside the drug room.
Figure 1 presents a sketch of the drug room area.
Pye storage is accomplished utilizing the floor space along the south
and west walls of the drug room. Dye containers vary in size from 200-250
pound barrels to smaller, 50-100 pound containers. One weighing station
housing a dye scale is located 1n the northwest corner of the drug room,
opposite the room entrance.
95
-------
AIR
INLET
30 ft
12 ft CEILING
WORK BENCH
BACK END OF PLANT
MIXING
AREA
DOOR
WITH
WINDOW
O
O
O
O
DRAIN
«
X-\
CUPBOARD
CABINETS
O
O O
O O O O O O OO
•*-
18 ft
LEGEND
• WEIGHING STATION
• AREA SAMPLER AT DRUM STORAGE
A AREA SAMPLER AT WEIGHING STATION
"DENOTES FLOW OF DYES FROM STORAGE
-' THROUGH WEIGHING TO MIXING
Figure 1. Sketch of drug room area.
SLIGHT
OUTWARD
AIR FLOW
DYE MACHINES
96
-------
The general appearance of the drug room was clean. There was no ac-
cumulation of dye material on the floor, walls, equipment, or stored drums.
No spillage of dye material was observed during the survey.
The drug room has no exhaust ventilation installed for the purpose of
removing airborne dye particles. An air vent for the drug room is located on
the west wall near the weighing station, which created a slight outward flow
of air at the drug room entrance. One floor drain is located in the center
of the drug room to facilitate drainage during clean-up operations.
Environmental conditions of the drug room (i.e., temperature and
humidity) were recorded hourly during the survey. Hourly barometric pressures
were obtained from the local weather bureau subsequent to the survey. The
recorded environmental conditions are summarized in Table 1.
TABLE 1. ENVIRONMENTAL CONDITIONS RECORDED DURING THE SURVEY
Parameter
Temperature, °F
Relative humidity, %
Barometric pressure, 1n. Hg.
Mean,
8-hour value
78
56
29.30
Minimum
74
51
29.26
Range
Maximum
79
58
29.32
DYE WEIGHER ACTIVITIES
The company employs one full-time dye weigher on each of two shifts.
His duties Include:
0 Relocating dye drums within the storage area.
0 Weighing dyes and recording the weights on dye batch tickets.
97
-------
0 Transferring weighed dyes from the scale pan to a separate con-
tainer, and hand carrying that container to the mixing area outside
of the drug room.
c Mixing dyes with water near the dye machines outside of the drug
room.
- Transporting mixed dyes from mixing area to the dye machine area.
0 Cleaning dye storage and weighing areas.
The dye weighers employed at this facility are only involved in the
handling, transfer, weighing, and mixing of dyes. These individuals do not
handle dry chemicals during normal process operations.
The monitored dye weigher was a 61-year old male. He has been employed
at the company for 34 years; 25 of those years have been spent handling dyes.
He had no previous dye handling experience.
Training
Employee training specific to the safe handling of dyes is included as
part of the company's Hazard Communication program. Material safety data
sheets (MSDS's) are used as information sources for the training sessions.
Personal Protective Equipment
Two models of respirators are available for the dye weighers' use, 3M
Model 8710 Dust and Mist respirators and the 3M Model 8500 Nontoxic Particle
Mask respirators. The monitored dye weigher wore a model 8710 respirator.
Gloves were also worn by the dye weigher during all dye weighing activities
as part of his personal protective equipment.
Personal Habits
The monitored dye weigher did not eat, drink, or smoke in the drug room.
It was noted that the dye weigher's personal hygiene practices were good.
98
-------
Work Activities
The dye weigher activities In filling each batch ticket order were as
follow: dyes were obtained by walking to a drum containing the appropriate
dye, using a hand scoop to remove an approximate quantity of the dye, trans-
ferring the scoop of dye to the weighing station and pouring the required
amount onto the scale dish, returning the unused portion of the dye to the
drum, and transferring the weighed portion of the dye to a separate con-
tainer. This operation was repeated until all of the dye weighings specified
on the batch ticket had been completed. The container of weighed dyes was
then carried to the mixing area near the dye machines outside of the drug
room, and the weighed dyes were mixed with water.
SPECIFIC MEASUREMENTS AND OBSERVATIONS
The monitored employee was 1n the drug room for a total of 94 minutes
over the 8-hour (480 minute) first work-shift. During that time, his duties
required him to enter the drug room 14 times. He was monitored for exposure
to particulates over a 445 minute period from 7:09 am to 2:34 pm. The data
collected and observations made during the survey are presented in Table 2.
Table 3 presents a 11st of the dye materials handled during the survey,
including the dye color Index number, the number of weighings of each dye,
and the total weight of all weighings of each dye.
ANALYTICAL RESULTS
Solids filtered from the air In this facility were analyzed by EPA for
total dye content. Total weight of all solIds and analytical results from
the four filtering devices, corrected for recovery, follow (in milligrams dye
per cubic meter air):
99
-------
Active Total
Colorants Commercial Dyes Weight
Average of 2 monitoring 0.06 0.13 0.73
devices in worker's breathing
zone
Drug room area sampler at 0.18 0.37 0.59
weighing station
Drug room area sampler at drum 0.04 0.09 0.19
storage, remote from weighing
area
100
-------
TABLE 2. SUMMARY OF DATA AND INFORMATION RECORDED DURING SURVEY
A. Time in work area
Percent of
monitoring
Time, minutes period
Total time monitored
Total time in drug room
Lunch break
445 100
94 21
Not available
B.
Work capacity
Maximum work load
Units in operation at time of survey
Number of
process units Percent
7 100
7 100
C.
Powder dyes weighed
Total weighed
Acid
Neutral PremetalUzed
Number of dyes Percent
17 100
9 53
8 47
D.
Number of
Dyes weighings Percent
Total 38 100
Acid 28 74
Neutral 10 26
PremetalUzed
Weight of dyes,
pounds Percent
68.0048 100
12.2256 18
55.7792 82
(continued)
101
-------
TABLE 2 (continued)
C. Dry chtmlcaU wtlghtd
Numbir of
wtlgMngi
Total
F. All chtfflkilt wtlghtd
Totil
Dyti
Dry chtmlcilt
Numbtr of
wtlgMngi
38
38
0
Ptrctnt
100
100
0
Wtlght of
• 11 chtmlcili,
poundt
68.0048
68,0048
0
Pi rein t
100
100
0
G. Dytt wtlghtd
moit frtqutntly
Add Rtd 361
Add Blut 268
Add Ytllow 49
Add Ytllow 216
Numbtr of
wtlghlngi
7
6
4
3
Ptrctnt
18
16
11
8
Wtlght of dyti,
poundt
1,8696
1.3376
1,1035
1,911
Ptrctnt
2
2
2
3
H. Largtit quantity
of dyti wtlghtd
Numbtr of
wtlghlngi
Ptrctnt
Wtlght of dyti,
poundi
Ptrctnt
Add Vloltt 121
Acid Black 68
Add Rtd 359
Add Ytllow 79
3
3
3
3
26,72
13,70
7,612
5,94
39
20
11
9
102
-------
TABLE 3, DYE MATERIALS HANDLED DURING THE SURVEY
Totil wtioht of
Number of all wtlghlngi,
Dyt color 1ndt* numbtr wtlgMngt pounds
Add Dyts:
Add Ytllow 79 1 5,9400
Add Ytllow 216 3 1.9110
Add Ytllow 49 4 1,1035
Add Rtd 260 2 0,040?
Add Rtd 361 7 1.5695
Add Vloltt 48 2 0.0250
Add Blut 277 1 0.2425
Add Blut 80 2 0,0564
Add Bluf 258 6 1..H75
Ntutnl PrtmttilHitd Dyts:
Add Ytllow 121 1 1.5720
Add Rtd 259 2 0.1022
Add Rtd 359 1 7.6120
Add Vloltt 121 1 26,7200
Add Blut 284 1 2.1910
Add Brown 227 1 3.8060
Add Brown 45 2 0.0760
Add Black 58 1 13.7000
103
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TEXTILE DRUG ROOM MONITORING STUDY
SITE VISIT REPORT
Site Number 4/3
William L. Dyson, Ph.D., .I.H.TL/STrtirj.TngerS, C.I,
Health and Hygiene, Inc. */ Pw Associates, Inc.
Prepared for:
U.S. ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF TOXIC SUBSTANCES
401 M STREET, S.U.
WASHINGTON, DC 20460
105
-------
INTRODUCTION
This survey was conducted as part of an exposure study being performed
as a cooperative effort between the U.S. Environmental Protection Agency
(EPA), the American Textile Manufacturers Institute, Inc. (ATMI), and the
Ecological and Toxicological Association of the Dyestuffs Manufacturing
Industry (ETAD). The study's objective was to determine the extent of
textile workers' exposure to dye dust when weighing and mixing powder dyes.
The sites to be visited were selected to obtain a random sampling of eligible
sites. Contact with the site representative to schedule the site visit was
made by William L. Dyson, Ph.D., C.I.H. of Health and Hygiene, Inc.,
representing ATMI and ETAD. In attendance at the site were Ronald H. H111,
C.I.H. of Health and Hygiene, and Donald L. Unruh, C.I.H., IT Corporation,
subcontractor for PEI Associates, Inc., representing EPA. The pre-survey
meeting was held with company officials on the morning of March 31, 1987.
The industrial hygiene monitoring and recording of data were performed during
the second shift (2:00 p.m. to 10:00 p.m.) of the same day. Company
representatives were very cooperative in assisting with this survey.
106
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SITE CHARACTERIZATION
GENERAL
The drug room at site 4/3 is part of a dyehouse operating on both an
Integrated and commission basis. Approximately 14 million pounds of yarn per
year are dyed in batch operations at this publicly owned facility. Fifteen
package dyeing machines were available, all of which were in operation during
the monitoring period. Fibers dyed are cotton (90% production volume),
acryllc/modacryllc, rayon, wool, nylon, and polyester. Site operations
include storage, preparation, dyeing, and drying.
DRUG ROOM
The drug room is a rectangular room approximately 60 feet long and 40
feet wide, with a 16-foot ceiling. It 1s sectioned into separate drum
storage, weighing, and mixing areas. The drum storage area is accessed by a
door at the west end of the room which leads to the weighing area, a door at
the south end of the room which leads to the mixing areas, and a door at the
east end of the room which leads downstairs. The weighing area is accessed
by a door from the west side of the drum storage area. The weighing area
includes two dye weighing stations, each equipped with one scale. A weighing
station housing one scale is also located In the mixing area. Figure 1
presents a sketch of the drug room areas.
107
-------
N
i
AIR FLOW
40 ft
T
10 ft
20 ft
WINDOW .
(FIXED)
LIQUID
CHEMICALS
TO
ADDITIONAL
MIXING
VATS
LOCKERS
-I
DRY DYES
\ /
o-
O V O
O
O
o
o
o
o
O45
O
O
/ r
-Ox /O
o Y
o o
o i o
-Ox /O
o Y o
o I o
o
o
oo
pipoooo
t
O
AIR SUPPLY DUCT
FLOW
iQ 0 O 0
LE6INO
• WEIGHING STATION
• AREA SAMPLER AT DRUM STORME
A AREA SAJVLER AT WEIGHING STATION
MIXING VATS
*
DENOTES FLOU OF DYES FROM STORAGE
THROUGH WEIGHING TO HIKING
i FLOOR DRAIN
60 ft
DOWN
AIR
FLOW
Figure 1. Sketch of drug room area.
108
-------
Dyes are stored in drums in both the storage area, and the mixing area
near the mixing vats. The drums vary in size from 200- to 250-pound barrels
to smaller 50- to 100-pound containers. Small quantities of liquid chemicals
are also stored in the drug room near the mixing vats.
The general appearance of the drug room was fair. The walls, equipment,
and stored drums were fairly clean of accumulated dye material. Spills of
dye and chemical material were cleaned by washing down the floor. The floors
are routinely washed down after each shift. Floor drains are located in the
mixing and weighing areas of the drug room to facilitate drainage during
these operations.
The drug room was equipped with no local exhaust ventilation system for
the purpose of removing airborne dye particles. The building was equipped
with a general central forced air conditioning system. The weighing area was
also air conditioned. The drum storage and mixing areas were under a slight
positive pressure compared to the other plant areas, Indicated by the flow of
air out of these areas at the door ways.
Environmental conditions of the drug room (i.e., temperature, humidity,
and barometric pressure) were recorded hourly during the survey and are
summarized in Table 1.
TABLE 1. ENVIRONMENTAL CONDITIONS RECORDED DURING THE SURVEY*
Parameter
Temperature, °F
Relative humidity, %
Barometric pressure, in. Hg.
Mean,
8-hour value
74
48
29.30
Minimum
72
33
29.18
Range
Maximum
77
59
29.45
Readings of each parameter were recorded hourly over the 8-hour work shift.
109
-------
DYE WEIGHER ACTIVITIES
The company employs two full-time dye weigher/mixers on each of three
shifts. Their duties include:
0 Relocating dye drums with a drum dolly within the storage area.
0 Weighing dyes and chemicals and recording weights on batch tickets.
0 Transferring dyes and chemicals from the scale to buckets and hand
carrying the buckets into the mixing areas.
0 Adding dyes and chemicals to the mixing vats and blending them with
water.
0 Cleaning dye storage, mixing, and weighing areas.
The dye weighers employed at this facility are involved in the handling,
transferring, and weighing of powder dyes and dry and liquid chemicals. On
the day of the survey, the majority of the monitored dye weigher/mixer's time
was spent in the mixing vat area.
The monitored dye weigher/mixer was a 24-year old male. He has been
employed at the company for eight years; five of those years have been spent
handling dyes. He had no previous dye handling experience.
Training
Specific dye weigher/mixer training by the company regarding the safe
handling of dyes was provided in the form of chemical hazard training and
review of the material safety data sheets (MSDS) maintained in the operations
room.
Personal Protective Equipment
Personal protective equipment utilized by the monitored dye weigher/
mixer included steel-toed shoes, safety glasses, and rubber gloves. No
respirator was worn. The monitored dye weigher/mixer used his safety glasses
and gloves only when handling liquid chemicals and caustics, not during dye
weighing activities.
110
-------
Personal Habits
The monitored dye weigher/mixer was observed smoking in the weighing
area between dye weighings, and in the mixing area after transferring the
weighed material into the mixing vats. The weigher/mixer washed his hands
after each dye weighing.
Work Activities
The dye weigher's activities in filling each batch ticket order were as
follows: dyes were obtained by walking to a drum in the storage area con-
taining the appropriate dye, using a hand scoop to remove an approximate
quantity of the dye, transferring the scoop of dye to the weigh station and
pouring the required amount into a stainless steel bucket, and returning the
unused portion of the dye to the drum. This operation was repeated until all
of the dye weighings specified on the batch ticket had been completed. The
batch was then hand carried to the mixing area and emptied into the mixing
vats where it was mixed with hot water. The dye/chemical mixtures were
pumped directly from the mixing vats into the kiers.
SPECIFIC MEASUREMENTS AND OBSERVATIONS
The monitored dye weigher was in the drug room for a total of 96 minutes
over the 8-hour period (480 minutes). During that time, his duties required
him to enter the drug room nine times. He was monitored for exposure to
particulates over a 457-minute period from 2:10 p.m. to 9:47 p.m. Table 2
presents a summary of the data and information recorded during the survey.
Table 3 presents a 11st of the dye materials handled during the survey,
including the dye color Index number, the number of weighings of each dye,
and the total weight of the weighings of each dye.
ill
-------
ANALYTICAL RESULTS
Solids filtered from the air in this facility were analyzed by EPA for
total dye content. Total weight of all solids and analytical results from
the four filtering devices, corrected for recovery, follow (in milligrams dye
per cubic meter air):
Active Total
Colorants Commercial Dyes Weight
Average of 2 monitoring 0.03 0.06 0.43
devices in worker's breathing
zone
Drug room area sampler at 0.02 0.04 0.09
weighing station
Drug room area sampler at drum 0.01 0.01 0.05
storage, remote from weighing
area
112
-------
TABLE 2. SUMMARY OF DATA AND INFORMATION RECORDED DURING SURVEY
A.
B.
Time 1n work area
Total time monitored
Total time in drug room
Lunch and breaks
Work capacity
Percent of
monitoring
Time, minutes period
Maximum work load
Units 1n operation at time of survey
C.
D.
E.
F.
Powder dyes weighed
Total
Disperse
Reactive
Dyes
Total
Disperse
Reactive
Dry chemicals weighed
Total
Alkaline Reducing Agent
Anhydrous Sodium
Hydroxide (NaOH)
Sodum Hydrosulfite
(Na2S2Ott)
Tri sodium phosphate
(Na3POJ
All chemicals weighed
Total
Dyes
Dry chemicals
457
96
NA
Number of
process units
15
15
100
21
NA
Percent
100
100
Number of dyes Percent
Number of
weighings
29
7
22
Number of
weighings
22
3
8
1
10
Number of
weighings
51
29
22
18
6
12
Weight of dyes
Percent pounds
100 132.341
24 19.526
76 112.815
Weight of
chemicals,
Percent pounds
100 1095.25
14 44.40
36 48.05
5 20.00
45 982.80
Weight of all
dry chemicals
Percent pounds
100 1227.591
57 132.341
43 1095.25
100
33
67
i
Percent
100
15
85
Percent
100
4
4
2
90
*
Percent
100
11
89
(continued)
113
-------
TABLE 2 (continued)
G.
H.
Dyes weighed most
frequently
Reactive Red 180
Reactive Orange 16
Reactive Yellow 15
"Reactive Blue U-4"
Largest quantity
of dyes weighed
Reactive Red 94
Reactive Red 198
Reactive Black 5
Reactive Red 180
Number of
weighings
3
3
3
3
Number of
weighings
2
2
1
3
Percent
10
10
10
10
Percent
7
7
3
10
Weight of dyes,
pounds
12.815
8.437
1.915
0.075
Weight of dyes,
pounds
37.46
19.95
19.35
12.815
Percent
10
6
1
0.1
Percent
28
15
15
10
NA - Not available.
114
-------
TABLE 3. DYE MATERIALS HANDLED DURING THE SURVEY
Dye color Index number
Number of
weighings
Total weight
of weighings,
pounds
Disperse Dyes:
Disperse Yellow 114
Disperse Yellow 42
Disperse Red 135
Disperse Red 151
Disperse Red 88
Disperse Blue 73
Reactive Dyes:
Reactive Yellow 160
Reactive Yellow 15
Reactive Orange 82
Reactive Orange 16
Reactive Red 94
Reactive Red 198
Reactive Red 180
Reactive Violet 5
"Reactive Blue U-4"
Reactive Blue 27
Reactive Blue 21
Reactive Black 5
1
1
1
1
2
1
1
3
1
3
2
2
3
1
3
1
1
1
0.252
0.300
1.820
11.11
6.020
0.024
0.222
1.915
0.150
8.437
37.46
19.95
12.815
0.100
0.075
0.341
12.00
19.35
115
-------
TEXTILE DRUG ROOM MONITORING STUDY
SITE VISIT REPORT
Site Number 4/6
William L. Dyson, Ph.D., C.I.H. /'yt.es!/e J. UngeTrs, C.I.H,
Health and Hygiene, Inc. ^ m Associates, Inc.
Prepared for:
U.S. ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF TOXIC SUBSTANCES
401 M STREET, S.K.
WASHINGTON. DC 20460
117
-------
INTRODUCTION
This survey was conducted as part of an exposure study being performed
as a cooperative effort between the U.S. Environmental Protection Agency
[EPA), the American Textile Manufacturers Institute, Inc. (ATMI), and the
Ecological and Toxicological Association of the Dyestuffs Manufacturing
Industry (ETAD). The study's objective was to determine the extent of
textile workers' exposure to dye dust when weighing and mixing powder dyes.
The sites to be visited were selected to obtain a random sampling of eligible
sites. Contact with the site representative to schedule the site visit was
made by William L. Dyson, Ph.D., C.I.H. of Health and Hygiene, Inc.,
representing ATMI and ETAD. In attendance at the site were Melvin R.
Witcher, Jr., C.I.H. of Health and Hygiene and Donald L. Unruh, C.I.H., IT
Corporation, subcontractor for PEI Associates, Inc., representing EPA. The
pre-survey meeting was held with company officials on May 18, 1987. The
industrial hygiene monitoring and recording of data were performed during the
first part of the first 12-hour shift (8:00 a.m. to 8:00 p.m.) on May 19,
1987. Company representatives were very cooperative 1n assisting with this
"W*
survey.
118
-------
SITE CHARACTERIZATION
GENERAL
The drug room at site 4/6 1s part of a captive dyehouse operating on an
Integrated basis. Approximately 2 million pounds of carpet yarns per year
are dyed in continuous operations at this privately owned facility. Two
continuous dyeing machines were available, one of which was in operation at
the time of the survey. Nylon is the only fiber dyed. Site operations
include storage, preparation, dyeing, and drying. The dyed yarns are pro-
cessed Into carpets at another location.
DRUG ROOM
The drug room, located on the first floor of the plant building, is a
rectangular room approximately 25 feet long and 15 feet wide, with a 10-foot
ceiling. The room is accessed by a door at the southeast end of the room
which leads to the mixing area. The mixing area is a separate area outside
of the drug room. The drug room includes drum storage areas and a dye weigh-
ing station equipped with one scale. Figure 1 presents a sketch of the drug
room.
Dyes are stored in drums utilizing the floor spaces against the walls of
the drug room. The drums vary In size from 200- to 250-pound barrels to 50-
to 100-pound containers.
For weighing of the powder dyes, a small scale 1s located on a table
situated against the west wall of the drug room.
119
-------
N
pH METER
WINDOW —
25 ft
WINDOW—
DYE DRUMS
DYE DRUMS
\^ ^J wit urvunj » » ^^^
OOOO6OO0O
»• TO MIXING VATS
• AIR FLOW
LEGEND
• WEIGHING STATION
• AREA SAMPLER AT DRUM STORAGE
A AREA SAMPLER AT WEIGHING STATION
'DENOTES FLOW OF DYES FROM STORAGE
- THROUGH WEIGHING TO MIXING
DRUG ROOM
SOUTHWEST CORNER
OF YARN DYEING AREA
Figure 1. Sketch of drug room area.
120
-------
The general appearance of the drug room was poor. The walls, equipment,
inventory, and floors contained heavy accumulations of dye material. Spills
were reportedly left on the floor until washing occurred, but the accumula-
tion of dust indicated that floor washing took place infrequently. A drain
was located in the drug room floor to facilitate drainage during cleaning;
however, this activity did not occur during the survey.
The drug room was not equipped with a local exhaust ventilation system
for the purpose of removing airborne dye particles. General building ventila-
tion was provided through open windows. No net airflow at the drug room
entrance was observed.
Environmental conditions of the drug room (i.e., temperature, humidity,
and barometric pressure) were recorded hourly during the survey and are
summarized in Table 1.
TABLE 1. ENVIRONMENTAL CONDITIONS RECORDED DURING THE SURVEY*
Parameter
Temperature, °F
Relative humidity, %
Barometric pressure, in. Hg.
Mean,
8-hour value
78
86
29.29
Minimum
74
76
29.28
Range
Maximum
83
97
29.29
Readings of each parameter were recorded hourly over the 8-hour work shift.
DYE WEIGHER ACTIVITIES
The company employs one full-time dye weigher/mixer on each of two
12-hour shifts. His duties Include:
0 Relocating dye drums from the receiving area to the drug room.
121
-------
0 Weighing dyes and recording weights on batch tickets.
0 Transferring weighed dyes from the scale to 5-gallon plastic pails.
0 Adding the dry dye to the mixing vats.
0 Mixing chemicals in separate mixing vats Into which the dye solu-
tion from the initial mixing vat is pumped for additional mixing.
0 Cleaning dye .torage, weighing, and mixing areas.
The dye weighers employed at this facility are involved 1n the handling,
transferring, weighing, and mixing of dyes and dry chemicals.
The monitored dye weigher was a 42-year old male. He has been employed
at the company for 1.5 years; approximately 9 months of that time has been
spent handling dyes. He had no previous dye handling experience.
Training
No dye weigher training programs were provided by the company regarding
the safe handling of dyes.
Personal Protective Equipment
No personal protective equipment was required by the company or utilized
by the monitored dye weigher in the drug room. Significant dermal contact
with the dyestuffs was observed because he wore a sleveless shirt and often
handled powder dyes with his bare hands.
Personal Habits
The monitored dye weigher was observed smoking In the drug room and
mixing area. He did not routinely wash his hands before smoking or after
skin contact with the dyes.
Work Activities
The dye weigher's activities in filling each batch ticket order were as
follows: dyes were obtained by walking to a drum in the storage area contain-
ing the appropriate dye, using a hand scoop to remove an approximate quantity
122
-------
of the dye, transferring the scoop of dye to the weigh station and pouring
the required amount Into a 5-gallon plastic pail, and returning the unused
portion of the dye to the drum. This operation was repeated until all of the
dye weighings specified on the batch ticket had been completed. The batch
was then hand carried to the mixing area and dumped into the mixing vat. The
plastic pail was then rinsed with a small amount of water, and this rinse
water was added to the mixing vat. A guar gum slurry was added to a separate
mixing vat, into which the mixed dye solutions were pumped. The final dye
solutions were pumped to the dyeing machines via pipelines.
When a dye drum was almost empty, the monitored dye weigher transferred
the dregs from the old drum Into the new drum by inverting the old drum over
the new drum. About 3 or 4 such drum transfers were observed during the
survey.
SPECIFIC MEASUREMENTS AND OBSERVATIONS
The monitored dye weigher was in the drug room for a total of 46 minutes
over the 8-hour period (480 minutes). During that time, his duties required
him to enter the drug room sixteen times. He was monitored for exposure to
particulates over a 447-minute period from 8:28 a.m. to 3:55 p.m. Table 2
presents a summary of the data and Information recorded during the survey.
Table 3 presents a 11st of the dyes handled during the survey, Including the
dye color Index number, the number of weighings of each dye, and the total
weight of the weighings of each dye.
123
-------
ANALYTICAL RESULTS
Solids filtered from the air in this facility were analyzed by EPA for
total dye content. Total weight of all solids and analytical results from
the four filtering devices, corrected for recovery, follow (in milligrams dye
per cubic meter air):
Active Total
Colorants Commercial Dyes Weight
Average of 2 monitoring 0.06 0.09 0.48
devices in worker's breathing
zone
Drug room area sampler at 0.10 0.15 0.47
weighing station
Drug room area sampler at drum 0.01 0.02 0.11
storage, remote from weighing
area
124
-------
TABLE 2. SUMMARY OF DATA AND INFORMATION RECORDED DURING SURVEY
A.
B.
Time in work area
Total time monitored
Total time in drug room
Lunch and breaks
Work capacity
Percent of
monitoring
Time, minutes period
447
46
NA
Number of
process units
Maximum work load
Units in operation at time of survey
C.
D.
E.
F.
Powder dyes weighed
Total
Acid
Neutral Premetallized
Acid Metallized
Dyes
Total
Acid
Neutral Premetallized
Add Metallized
Dry chemicals weighed
Celcagum D49D-1
All chemicals weighed
Total
Dyes
Dry chemicals
Number of
weighings
15
11
1
3
Number of
weighings
8
Number of
weighings
23
15
8
Number
Percent
100
73
7
20
Percent
100
Percent
100
65
35
2
1
of dyes
6
4
1
1
Weight of dyes,
pounds
119.59
59.85
45.43
14.31
Weight of
chemicals,
pounds
65.39
Weight of
dry chemicals,
pounds
184.98
119.59
65.39
100
10
NA
Percent
100
50
Percent
100
67
17
17
•
Percent
100
50
38
12
Percent
100
Percent
100
65
35
(continued)
125
-------
TABLE 2 (continued)
G.
H.
Dyes weighed most
frequently
Acid Orange 156
Acid Black 52
Acid Red 266
Largest quantity
of dyes weighed
Acid Brown 298
Acid Orange 156
Acid Black 52
Number of
weighings
5
3
3
Number of
weighings
1
5
3
Percent
33
20
20
Percent
7
33
20
Weight of dyes,
pounds
44.55
14.31
4.81
Weight of dyes,
pounds
45.43
44.55
14.31
Percent
37
12
4
Percent
38
37
12
NA - Not available.
126
-------
TABLE 3. DYE MATERIALS HANDLED DURING THE SURVEY
Dye color index number
Number of
weighings
Total weight
of weighings,
pounds
Acid Dyes:
Acid Orange 156
Acid Red 266
Acid Red 361
Acid Red 299
Neutral Premetallized Dyes:
Acid Brown 298
Acid Metallized Dyes:
Acid Black 52
5
3
1
2
44.55
4.81
5.33
5.16
45.43
14.31
127
-------
TEXTILE DRUG ROOM MONITORING STUDY
SITE VISIT REPORT
Site Number 4/9
William L. Dyson, Ph.D., C.I.H. Letlle J/Ungers, C.I.H.
Health and Hygiene, Inc. PEI Associates, Inc.
Prepared for:
U.S. Environmental Protection Agency
Office of Toxic Substances
401 M Street S.W.
Washington. DC 20460
129
-------
INTRODUCTION
This survey was conducted as part of an exposure study being performed
as a cooperative effort between the U.S. Environmental Protection Agency
(EPA), the American Textile Manufacturers Institute, Inc. (ATMI), and the
Ecological and Toxicological Association of the Dyestuffs Manufacturing
Industry (ETAD). The study's objective was to determine the extent of
textile workers' exposure to dye dust when weighing and mixing powder dyes.
The sites to be visited were selected to obtain a random sampling of eligible
sites. Contact with the site representative to schedule the site visit was
made by William L. Dyson, Ph.D., C.I.H. of Health and Hygiene, Inc.,
representing ATMI and ETAD. In attendance at the site were Dr. Dyson and
Leslie J. Ungers, C.I.H., Senior Industrial Hygienist for PEI Associates,
Inc., representing EPA. The pre-survey meeting was held with company
officials on the afternoon of May 16, 1986. The monitoring and recording of
data was performed during the second shift (4:00 p.m. to 12 midnight) on the
same day. Company representatives were very cooperative 1n assisting with
this survey.
130
-------
SITE CHARACTERIZATION
GENERAL
The drug room at site 4/9 is part of a captive dye house operating in a
vertical integrated production facility. The company is publicly owned and
dyes approximately 12 million pounds of yarn per year. The yarn is dyed in
batch operations performed in 15 high pressure package dye machines, all of
which were in operation on the day of the survey. Fibers dyed may be wool,
polyester, rayon, cotton, silk, or flax; or various combinations of these
fibers. A majority of the dyeing is performed on a blend yarn composed of
polyester and wool. Site operations include storage, preparation, dyeing,
and drying.
DRUG ROOM
The drug room is a rectangular room approximately 150 feet in length, 30
feet in width, with a celling 12 feet in height. The room is located on the
second floor of the dye house and is accessed by a personnel door at one end,
and a freight elevator at the opposite end. The drug room includes a combined
dye and dry chemical storage area, dye scales, dry chemical scales, and
mixing machines. Figure 1 presents a sketch of the drug room area.
Mixing Machine Area
Along the south wall of the drug room, separated by a 4-inch concrete
dike, are 17 homogenizers which are used for mixing. The homogenizers and
their holding tanks supply the dyeing operations located on the floor below.
Dry chemicals and dyes are manually added to the tanks as the final step
131
-------
CO
DRY CHEMICAL
SCALE (NOT USED
BY DYE WEIGHER)
-30 ft
WITH 12 ft
CEILING
-150 ft
- STAIRS
o
o
o
ooc5o
I DYE
J STUFF
I DRUM
j STORAGE
DYE STUFF DRUM STORAGE
\
EXIT/ENTRANCE
'
FREIGHT
ELEVATOR
(DOOR CLOSED
DURING SURVEY)
MIXERS
RETURN
PLENUM
OPEN ACCESS
TO ROOF (OPEN
DURING SURVEY)
OVERHEAD
DUCTING
FOR HVAC
LEGEND
• WEIGHING STATION
• AREA SAMPLER AT DRUM STORAGE
A AREA SAMPLER AT WEIGHING STATION
'DENOTES FLOW OF DYES FROM STORAGE
~ THROUGH WEIGHING TO MIXING
DENOTES DYE STUFF DRUM
STORAGE AREAS
SUPPLY
AIR
DUCTS
COMMENTS
• NO WINDOWS
• LOCATION OF DRUG
ROOM IS ON PENT-
HOUSE OVER PROCESS
AREA
• NO AIR FLOW
EXCHANGED WITH
MAIN PART OF PLANT
Figure 1. Sketch of Drug Room Area.
-------
in the dye formulation. Wet chemicals and water are supplied to the indi-
vidual homogenizers through pipelines. The floor of the mixing area is
covered with a rubberized material to facilitate water spray washing of the
floor and machinery. Drains are located below the homogenizers and in the
general work area.
Powder Dye Storage and Weighing Area
Dyes storage is accomplished using floor space throughout the drug room.
Containers of dyes are located along most of the length of the room opposite
the homogenizers. The containers vary in size from 200-250 pound barrels to
smaller 50-100 pound containers. The floor of the storage area is rubberized
to facilitate cleaning between shifts. Two weighing areas are located in the
drug room. The dry chemicals are weighed on a scale located at the west end
of the room; approximately 30 feet from the scale used to weigh the powder
dyes. The dry chemical scale and associated weighing operations are not
conducted by the employee responsible for weighing the dyes. The dyes are
weighed on a scale located in the center of the drug room. The company has
installed a computer terminal for video display of the batch ticket; however,
at the time of the survey the system had not gone on line.
The general appearance of the drug room is very clean. There is no
accumulation of dye on the floor or walls. The cleanliness is believed to be
a direct result of the frequent water washing conducted by employees;
reportedly, employees clean the floor and homogenizers after every shift.
During the survey, the relative humidity of the room ranged from 78 to 96
percent. These high values are a result of the open homogenizers, moisture
from the dyeing machines, and frequent water cleaning operations, activities
133
-------
which maintain the water vapor level and high humidity in the drug room air.
Pipes and fixtures located near the ceiling and on the upper portion of the
wall are relatively free of dye particulate. These structures are stained
with dye that has settled as particulate, acquired water from the surrounding
air, and dissolved to form a liquid stain.
The drug room environmental conditions recorded during the survey are
presented in Table 1.
The drug room has no exhaust ventilation installed for the purpose of
removing airborne dye particles. The room is equipped with a heating and
air-conditioning system separate from the rest of the facility. Makeup air
for this system is taken from the outside. Three overhead air supply vents
are located at equal distances down the length of the room. The overhead
exhaust air ducts and plenum are also located near the ceiling approximately
5 feet from the air supply vents.
TABLE 1. ENVIRONMENTAL CONDITIONS RECORDED DURING THE SURVEY*
Parameter
Temperature, °F
Relative humidity, %
Barometric pressure,
torr
Mean,
8-hour value
79
87
755
Range
Minimum
78
78
754
Maximum
80
96
756
*
Readings of each parameter were recorded hourly over the 8-hour work shift.
DYE WEIGHER ACTIVITIES
The company employs one full-time dye weigher on each of three shifts.
His duties include:
134
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0 Transporting barrels of dye from the freight elevator to storage
areas in the drug room.
0 Relocating barrels within the storage area.
0 Weighing dyes and recording weights on dye batch tickets.
0 Transferring weighed dyes from scale pan to buckets, and carrying
buckets to homogenizers.
0 Pouring weighed dyestuff into mixing tanks.
0 Operating the homogenizers.
0 Cleaning dye storage, weighing, and mixing areas.
The dye weighers employed at this facility are only involved in the handling,
transfer, weighing, and mixing of dyes. These individuals do not handle dry
chemicals during normal process operations.
The dye weigher monitored was a 27-year old male. He has been employed
at the company for 10 years, five of these years were spent handling dyes.
During the previous 5 years he did not handle dyes.
Training
The company provides'employees with training as a part of the firm's
Hazard Communication program. The Material Safety Data Sheets (MSDS's) are
the primary source of Information for the training sessions.
Personal Protective Equipment
p
Company policy requires dye weighers to wear Alrstream powered air-
purifying respirators, aprons, chemical splash shields, and natural latex
rubber gloves. It should be recognized that a powered air-purifying respi-
rator provides filtered air to the employee's helmet. This helmet directs
the air down across the employee's face and breathing zone. The air then
exits the respirator at a point near the employee's chin and neck area.
These respirators are known to create turbulence outside the faceplece over
135
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an area of the employee's body used to position the air sampling filters.
Such air turbulence can have an impact on the air monitoring results.
The monitored dye weigher wore his respirator only during dye weighing activ-
ities and routinely wore the other required forms of personal protective
equipment while in the drug room.
Personal Habits
The company does not permit employees to eat, drink, or smoke on the
job. The monitored dye weigher frequently washed his hands after transfer-
ring dye material or following the removal of his gloves.
Work Activities
The following steps were taken each time the dye weigher being monitored
filled an order on a batch ticket. Dyes were obtained by walking to a barrel
containing the appropriate dye, using a hand scoop to remove an approximate
quantity, transporting the scoop of dye to the scale, pouring out the re-
quired amount onto the balance pan, returning the unused portion to the
barrel, and transferring the weighed portion to a stainless steel bucket.
This operation was repeated until all the dye weighings specified on the
batch ticket had been completed and transferred to the same bucket. The
bucket was then transferred to the dry chemical area for additions of non-dye
substances, or directly to a homogenizer.
When a barrel of dye was almost empty, the dye weigher manually trans-
ferred the dregs into the next barrel by inverting the barrel, or if avail-
able, by lifting the plastic liner out of the used barrel. Operations of
this nature resulted in some minor loss of dye; significant spillage was
immediately cleaned up. The number of transfers of this type were not
recorded.
136
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SPECIFIC MEASUREMENTS AND OBSERVATIONS
The employee monitored was in the drug room for a total of 359 minutes
over an 8-hour period (480 minutes). During that time, his duties required
him to enter the drug room four times. He was monitored for exposure to
particulates over a 426 minute period from 4:15 p.m. to 11:21 p.m. The
employee arrived 15 minutes after the shifted started and left the drug room
39 minutes before the shift was finished.
Table 2 presents a summary of the data and information recorded during
the survey. Table 3 presents a list of the dyes handled during the survey,
including the dye color index number, the number of weighings of each dye,
and the total weight of the weighings of each dye.
ANALYTICAL RESULTS
Solids filtered from the air in this facility were analyzed by EPA for
total dye content. Total weight of all solids and analytical results from
the four filtering devices, corrected for recovery, follow (in milligrams dye
per cubic meter air):
Active Total
Colorants Commercial Dyes Weight
Average of 2 monitoring 0.56 1.20 1.37
devices in worker's breathing
zone
Drug room area sampler at 0.14 0,30 0.47
weighing station
Drug room area sampler at drum 0.03 0.05 0.12
storage, remote from weighing
area
137
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TABLE 2. SUMMARY OF DATA AND INFORMATION RECORDED DURING SURVEY
Percent of
monitoring
A. Time in work area Time, minutes period
Total time monitored 426
Total time in drug room 359
Lunch break 50
No. of
B. Work Capacity process units
Maximum work load 15
Units in operation at time of survey 15
C. Powder dyes weighed No. of dyes
Total weighed 31
Acid 7
Neutral Premetallized 6
Chrome 3
Disperse 8
Reactive 7
No. of No. of Weight of dyes,
D. Dyes dyer weighings Percent kilograms
Total 31 62 100 197.837
Acid 7 9 14.5 20.669
Neutral 6 17 27.4 39.898
Premetallized
Chrome 3 5 8.1 51.255
Disperse 8 22 35.5 85.214
Reactive 7 9 14.5 0.801
100
84
12
Percent
100
100
Percent
100
23
19
10
26
23
Percent
100
10.4
20.2
25.9
43.1
0.4
(continued)
138
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TABLE 2 (continued)
E.
F.
G.
H.
Dry chemicals No. of
weighed weighings
Total 3
Bichromate of soda 1
Celco D-49-D 2
(modified guar gum)
All solids No. of
weighed weighings
Total 65
Dyes 62
Dry chemicals 3
Dyes weighed No. of
most frequently weighings
Acid Yellow 235 5
"Disperse Black M-l" 4
Disperse Blue 77 4
Disperse Orange 37 4
Mordant Black 11 3
Acid Black 60 3
Add Brown 330 3
Largest quantity No. of
of dyes weighed weighings
"Disperse Black M-l" 4
Mordant Black 11 3
Add Yellow 235 5
Disperse Blue 77 4,
Mordant Black 9 1
Percent
100
33
66
Percent
100
95
5
Percent
8
6
6
6
5
5
5
Percent
6
5
8
6
2
Weight of dyes,
kilograms
8.902
7.082
1.820
Weight of solids,
kilograms
206.739
197.837
8.902
Mass of dyes,
kilograms
18.5
41.645
17.975
4.126
34.085
4.020
2.183
Weight of dyes,
kilograms
41.645
34.085
18.5
17.975
15.400
Percent
100
80
20
Percent
100
96
4
Percent
9
21
9
«
L.
17
2
1
Percent
21
17
9
9
8
139
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TABLE 3. DYE MATERIALS HANDLED DURING THE SURVEY
Dye color Index number
Acid Dyes:
Acid Yellow 241
Acid Orange 142
Acid Violet 90
Acid Blue 80
Acid Blue 185
Acid Green 108
Acid Green 104
Acid Black 187
Neutral Premetallized Dyes:
Acid Yellow 235
Acid Yellow 129
Acid Red 182
Acid Brown 330
Acid Black 60
Acid Black 107
Chrome Dyes:
Mordant Orange 3
Mordant Black 11
Mordant Black 9
Disperse Dyes:
Disperse Orange 37
Disperse Red 60
Disperse Red 73
Disperse Blue 56
Disperse Blue 77
Disperse Blue 79
"Disperse Black M-l"
Reactive Dyes:
"Reactive Yellow U-l"
Reactive Yellow 37:1
Reactive Red 168
"Reactive Red U-2"
"Reactive Red U-3"
Reactive Blue 27
"Reactive Blue U-l"
Number of
weighings
2
1
1
2
0
1
1
1
5
2
2
3
3
2
1
3
1
4
4
2
3
4
1
4
1
1
2
1
1
1
2
Total weight
of weighings, kg
1.334
0.247
0.760
4.480
-
8.009
3.718
2.121
18.500
2.815
1.200
2.183
4.020
11.180
1.770
34.085
15.400
4.126
2.583
1.680
10.340
17.975
6.865
41.645
0.043
0.004
0.247
0.030
0.036
0.239
0.202
140
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TEXTILE DRUG ROOM MONITORING STUDY
SITE VISIT REPORT
Site Number 5/2
William L. Dyson, Ph.D., C.I.H. Leslife //Ungers, C.I.H.
Health and Hygiene, Inc. PEVAssoeiates, Inc.
Prepared for:
U.S. Environmental Protection Agency
Office of Toxic Substances
401 M Street S.W.
Washington, D.C. 20460
141
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INTRODUCTION
This survey was conducted as part of an exposure study being performed
as a cooperative effort between the U.S. Environmental Protection Agency
(EPA), the American Textile Manufacturers Institute, Inc. (ATMI), and the
Ecological and Toxicological Association of the Dyestuffs Manufacturing
Industry (ETAD). The study's objective was to determine the extent of
textile workers' exposure to dye dust when weighing and mixing powder dyes.
The sites to be visited were selected to obtain a random sampling of eligible
sites. Contact with the site representative to schedule the site visit was
made by William L. Dyson, Ph.D., C.I.H. of Health and Hygiene, Inc.,
representing ATMI and ETAD. In attendance at the site were Dr. Dyson and
Leslie J. Ungers, C.I.H., Senior Industrial Hygienist for PEI Associates,
Inc., representing EPA. The pre-survey meeting was held with company
officials on the morning of October 8, 1986. The industrial hygiene
monitoring anH recording of data were performed during the first shift (10:00
a.m. to 6:00 p.m.) on the same day. Company representatives were very
cooperative in assisting with this survey.
142
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SITE CHARACTERIZATION
GENERAL
The drug room at site 5/2 is part of a captive dyehouse operating on an
integrated basis. Approximately 4.75 million pounds of carpet per year are
produced at this publicly owned facility. Nylon carpet yarns and roll goods
are dyed in batch operations on skein and beck dyeing machines, respectively.
Eight machines were available and seven were in operation throughout the
survey period. The only fiber dyed is nylon. Site operations include stor-
age, preparation, dyeing, and finishing.
DRUG ROOM
The drug room is a rectangular room approximately 45 feet long and 20
feet wide, with a ceiling 8 feet 1n height. The room is located on the
second floor (penthouse) and is accessed by a door at one end of the room
which leads to the adjacent mixing area. Dye weighing and storage areas are
located in the drug room; the mixing area is a separate area outside of the
drug room. A window In the wall adjacent the mixing area was closed at all
times during the survey. The window has a large glass pane and 1s used only
to observe activities outside the drug room, not as an opening for trans-
ferring dyes to the mixing room. Figure 1 presents a sketch of the drug
room.
Dyes are stored In drums utilizing the floor space along the walls of
the drug room. At the time of the survey, several drums were also located
143
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EXHAUST
FAN
MIXING AREA
WINDOW
ob off/
EXIT/ENTRANCE
I
DYE SCALES
OYE DRUMS /
/
f
SINK
i
6
20 ft
45 ft
•AIR CONDITIONING
WALL UNIT
8 ft CEILING
LEGEND
• WEIGHING STATION
• AREA SAMPLER AT DRUM STORAGE
A AREA SAMPLER AT WEIGHING STATION
'DENOTES FLOW OF DYES FROM STORAGE
- THROUGH WEIGHING TO MIXING
Figure 1. Sketch of drum room area.
144
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in the area of the room behind the weighing station. The drums vary in size
from 200-250 pound barrels to smaller, 50-100 pound containers. One weighing
station housing two scales is located at the end of the drug room near the
door. Dry chemicals are neither stored nor weighed in the drug room.
The general appearance of the drug room was very clean. There was no
accumulation of dye on the floor or walls. There was a slight accumulation
of dye material on the equipment and stored drums. Although no spillage of
powder dyes was observed during the survey, the lack of accumulated dye on
the floor indicates adequate spill cleanup procedures.
Environmental conditions of the drug room (i.e., temperature, humidity,
and barometric pressure) were recorded hourly during the survey and are
summarized in Table 1.
A small 10-inch exhaust fan was located in the wall near the weighing
station for the purpose of removing airborne dye particles. An air condition-
ing unit was located at the other end of the room on the wall opposite the
exhaust fan. A slight negative pressure was created within the drug room,
probably due to the operation of the drug room air conditioning unit.
No floor drains were located in the drug room for drainage purposes.
TABLE 1. ENVIRONMENTAL CONDITIONS RECORDED DURING THE SURVEY*
Parameter
Temperature, °F
Relative humidity, %
Barometric pressure, In. Hg.
Mean,
8-hour value
73
61
30.12
Range
Minimum Maximum
62
57
30.08
78
72
30.19
Readings of each parameter were recorded hourly over the 8-hour work shift.
145
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DYE WEIGHER/MIXER ACTIVITIES
The company employs one full-time dye weigher/mixer on each of two
shifts. The facility does not operate a third shift. His duties include:
0 Relocating drums within the storage area.
0 Weighing dyes and recording weights on dye batch tickets.
0 Transferring dyes from the scale to a heavy, single sheet paper
towel (typical of the type found in restroom dispensers), which is
then hand carried to the mixer outside the dye room.
0 Cleaning dye storage, weighing, and mixing areas.
The dye weighers/mixers employed at this facility are Involved 1n dye and dry
chemical handling, weighing, and mixing. Dry chemicals are stored and handled
in the mixing area. Work activities require the dye weigher/mixer to spend
time 1n both the drug room and the mixing room.
The monitored dye weigher/mixer was a 28-year old male. He has been
employed at the company for approximately 1.5 years; all of that time has
been spent handling dyes. He had no previous dye handling experience.
Training
Specific training regarding the safe handling of dyes 1s not provided by
the company to employees who are engaged in dye handling operations at this
facility.
Personal Protective Equipment
Personal protective equipment required by the company to be worn by dye
weighers/mixers includes dust mask respirators and gloves. It was observed
that the dye weigher/mixer had slight dermal contact with the dye material
during dye transfer to the mixers. Contact was minor and limited to the
hands. The respirator was worn frequently by the monitored dye weigher/mixer
during actual dye weighings and was removed most of the time when he was
outside the drug room.
146
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Personal Habits
The monitored dye weigher/mixer was not observed drinking or eating in
the drug room. He did not smoke inside or outside of the drug room. As part
of his personal hygiene practice, he washed his hands when his shift ended.
Work Activities
The dye weigher/mixer activities in filling each batch ticket order were
as follows: dyes were obtained by walking to a drum containing the appropri-
ate dye, using a hand scoop to remove an approximate quantity of the dye,
transporting the scoop of dye to the weighing station, pouring the required
amount onto the scale dish, returning the unused portion of the dye to the
drum, and pouring the weighed portion of the dye from the scale dish directly
onto a paper towel. This operation was repeated until all of the dye weigh-
ings specified on the batch ticket had been completed. The paper towel
containing the weighed dye material for the batch was hand carried to the
mixer outside the drug room and the dye material was poured into the mixing
vat. Any dry chemicals required were then added to the mixing vat.
SPECIFIC MEASUREMENTS AND OBSERVATIONS
The employee monitored was in the drug room for a total of 137 minutes
over an 8-hour (480 minute) period. He was monitored for exposure to
particulates over a 454 minute period from 10:03 a.m. to 5:37 p.m. During
that time, his duties required him to enter the drug room 19 times. Table 2
presents a summary of the data and information recorded during the survey.
Table 3 presents a list of the dye materials handled during the survey,
Including the dye color Index number, the number of weighings of each dye,
and the total weight of the weighings of each dye.
147
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ANALYTICAL RESULTS
Solids filtered from the air in this facility were analyzed by EPA for
total dye content. Total weight of all solids and analytical results from
the four filtering devices, corrected for recovery, follow (in milligrams dye
per cubic meter air):
Active Total
Colorants Commercial Dyes Weight
Average of 2 monitoring 0.06 0.07 0.36
devices in worker's breathing
zone
Drug room area sampler at 0.19 0.25 0.30
weighing station
Drug room area sampler at drum 0.07 0.09 0.15
storage, remote from weighing
area
148
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TABLE 2. SUMMARY OF DATA AND INFORMATION RECORDED DURING SURVEY
A.
B.
C.
Time in work area
Total time monitored
Total time in drug room
Lunch break
Work capacity
Maximum work load
Units in operation at time of survey
Powder dyes weighed
Total weighed
Acid
Time, minutes
454
137
Not available
Number of
process units
8
7
Number of dyes
3
3
Percent of
monitoring
period
100
30
Percent
100
88
Percent
100
100
D. Dyes
Number of
weighings Percent
Weight of
dyes, pounds
Percent
E.
Total
Acid
Dry chemicals weighed
84 100
84 100
Number of
weighings
11.550
11.550
Percent
100
100
Total
149
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TABLE 2 (continued)
F. Dyes weighed (in
order of frequency Number of Weight of
and quantity) weighings Percent dyes, pounds Percent
"Acid Red M-2" 35 42 5.452 47
Acid Blue 324 29 34 3.106 27
Acid Yellow 219 20 24 2.992 26
150
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TABLE 3. DYE MATERIALS HANDLED DURING THE SURVEY
Total weight of
Dye color Index number Number of weighings weighings, pounds
Add Dyes:
Acid Yellow 219 20 2.992
"Add Red M-2" 35 5.452
Add Blue 324 29 3.106
151
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TEXTILE DRUG ROOM MONITORING STUDY
SITE VISIT REPORT
Site Number 5/4
.
William L. Dyson, Ph.D., C.I.H. Le?ii* 4;/Ungers
Health and Hygiene, Inc. PDI^ssoVlates, Inc.
Prepared for:
U.S. ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF TOXIC SUBSTANCES
401 M STREET, S.W.
WASHINGTON. D.C. 20460
153
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INTRODUCTION
This survey was conducted as part of an exposure study being performed
as a cooperative effort between the U.S. Environmental Protection Agency
(EPA), the American Textile Manufacturers Institute, Inc. (ATMI), and the
Ecological and Toxlcological Association of the Dyestuffs Manufacturing
Industry (ETAD). The study's objective was to determine the extent of
textile workers' exposure to dye dust when weighing and mixing powder dyes.
The sites to be visited were selected to obtain a random sampling of eligible
sites. Contact with the site representative to schedule the site visit was
made by William L. Dyson, Ph.D., C.I.H. of Health and Hygiene, Inc.,
representing ATMI and ETAD. In attendance at the site were Ronald H. Hill,
C.I.H. of Health and Hygiene and Leslie J. Ungers, C.I.H., Senior Industrial
Hygienist for PEI Associates, Inc., representing EPA. The presurvey meeting
was held with company officials on the morning of November 5, 1986. The
industrial hygiene monitoring and recording of the data were performed during
half of the first shift (3:00 p.m. to 7:00 p.m.) and half of the second shift
(7:00 p.m. to 11:00 p.m.) on the same day. Company representatives were very
helpful in assisting with this survey.
154
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SITE CHARACTERIZATION
GENERAL
The drug room at site 5/4 is part of a captive dyehouse operating on an
integrated basis which uses powder dyes. Approximately 13 million pounds of
domestic sheeting and pillowcase fabrics per year are produced at this
publicly-owned facility. Eleven beck dyeing machines were available; all
eleven were performing batch dyeing operations during the entire monitoring
period. Fibers dyed are primarily blends of polyester and cotton, but rayon
and wool are in some products. Site operations include storage, preparation,
dyeing, and finishing.
DRUG ROOM
The drug room is a rectangular room approximately 40 feet long and 20
feet wide, with a 9 foot celling. It 1s located on the second floor and is
accessed by two doors. One door leads into the mixing area and the other
leads Into the plant. Dye weighing and storage areas are located in the drug
room; the mixing area 1s a separate area adjacent to the drug room. Figure 1
presents a sketch of the drug room area.
Dyes are stored in drums located on the floor of the drug room. The
drums vary in size from 200- to 250-pound barrels to smaller 50- to 100-pound
containers.
For weighing the powder dyes, one small scale 1s located on a table in
the corner of the drug room. Dry chemicals are stored in the mixing room
155
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— - -
LIQUID
DRUMS
FLOOR
LEVEL -*•-
AIR -i
SUPPLY
LIQUID^
DRUMS
SLIDING \
GLASS
DOOR
WV*\
AIR
FLOW
DOOR t (
O MIXING ood ' o
>< LIQUID 2
6 ) DRUMS O
X / Oo°0r?
• ^^^^ S ^^ 1 1
£- LIQUID DRUMS
'AND DRY SODA ASH
NOTE:
ALL DYES ARE STORED AND WEIGHED IN
TUP not IP on/Mi cnuc i furTrn cTnoAPC
THE DRUG ROOM. SOME LIMITED STORAGE
OF DRY CHEMICALS ALSO OCCURS.
DRUG
ROOM DIMENSIONS OF DRUG ROOM:
40 ft LONG
20 ft WIDE
9 *t rcfi fur
it LcILlNCi
LOCATED ON SECOND FLOOR
OF PLANT IN SOUTH WING
LEGEND
• WEIGHING STATION
• AREA SAMPLER AT DRUM STORAGE
A AREA SAMPLER AT WEIGHING STATION
'DENOTES FLOW OF DYES FROM STORAGE
- THROUGH WEIGHING TO MIXING
Figure 1. Sketch of drug room area.
156
-------
with the majority of the drums containing liquids. Dry soda ash is also
stored in the mixing room.
The general appearance of the weighing and storage areas was very clean.
There was a small accumulation of dye on the walls, equipment, and drum lids.
The floors did not have an accumulation of dye. Reportedly, the floors were
hosed down frequently.
The drug room is not equipped with a local exhaust ventilation system
for removing airborne dye particles. The drug room is equipped with a
general heating and air conditioning unit. Air is supplied at the floor
level in the mixing area and exhausted by ceiling vents.
Floor drains and grates are located in the drug room to facilitate
drainage when the floor is hosed down during cleaning operations.
Environmental conditions of the drug room (i.e., temperature, humidity,
and barometric pressure) were recorded hourly during the survey and are
summarized in Table 1.
TABLE 1. ENVIRONMENTAL CONDITIONS RECORDED DURING THE SURVEY*
Range
Temperature, °F
Relative humidity
Barometric pressure, in.Hg.
Mean,
8-hour value
67
79
29.97
Minimum
67
77
29.95
Maximum
68
82
29.98
Readings of each parameter were recorded hourly over the 8-hour work shift.
157
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DYE WEIGHER ACTIVITIES
The company employs two full-time weighers on each of two 12-hour
shifts. Their duties include:
0 Relocating drums within the drug room by use of a dolly.
0 Weighing dyes and dry chemicals and recording weights on batch
tickets.
0 Transferring dyes and dry chemicals to stainless steel buckets and
then hand carrying the buckets to the mixing machines.
0 Adding the dyes and dry chemicals to the mixing machines.
0 Cleaning dye storage, weighing, and mixing areas.
The dye weighers employed at this facility are involved 1n the handling,
transferring, weighing, and mixing of dyes and dry chemicals.
Two dye weighers were monitored during this survey. The monitoring team
believed that this facility operated on three 8-hour shifts. They planned to
monitor the second shift commencing at 3:00 pm. Upon arrival at the site, it
was learned that the facility operated two 12-hour shifts. In order to
obtain a representative 8-hour shift sample, half of the eight hour moni-
toring was conducted on each shift. The first weigher was monitored during
the latter part of his 12-hour shift (3:00 p.m. to 7:00 p.m.), and the second
weigher was monitored during the beginning of his 12-hour shift (7:00 p.m. to
11:00 p.m.). Both weighers wore the same sampling devices.
The first shift dye weigher was a 27-year old male. He has been em-
ployed at the company for 5 years; three of those years have been spent in
handling dyes. He had two years previous dye handling experience. The
second shift dye weigher was a 43-year old male. He has been employed at the
company for 7 years; five of those years have been spent handling dyes. He
had no previous dye handling experience.
158
-------
Training
Specific training for dye weighers regarding the safe handling of dyes
is provided by the company in the form of films, text on dye materials,
on-the-job standard operating procedures, and a training program.
Personal Protective Equipment
Personal protection equipment utilized by the monitored dye weighers in
the drug room included 3M 8500 nontoxic dust masks and gloves. It was ob-
served that the dye weighers' hands and forearms had very slight dermal
contact with the dyestuffs in use.
Personal Habits
The monitored dye weighers were not observed drinking or eating in the
drug room. They did not smoke inside the weighing area but did smoke outside
the area. Each monitored dye weigher frequently washed his hands with soap
and water. They changed from work clothes into street clothes and washed
their faces and hands before leaving the plant.
Work Activities
The dye weigher activities in filling each batch ticket order were as
follows: Dyes were obtained by walking to a drum in the storage area con-
taining the appropriate dye, using a hand scoop to remove the approximate
quantity of the dye, transferring the scoop of dye to the weigh station,
pouring the required amount onto the scale dish, returning the unused portion
of the dye to the drum, and transferring the weighed portion of the dye to a
stainless steel bucket. This operation was repeated until all of the dye
weighings specified on the batch ticket had been completed. The bucket
containing the dyes was then transferred to the mixing area where the dye and
other chemicals were added to the mixing tank. The tank was equipped with an
159
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agitator to thoroughly mix the dyes. The dye weigher operated the mixing
equipment.
SPECIFIC MEASUREMENTS AND OBSERVATIONS
The monitored employees were 1n the drug room for a total of 287 minutes
over an 8-hour (480 minutes) period. During that time, their duties required
them to enter the drug room seven times. They were monitored for exposure to
participates over a 400-minute period from 3:07 p.m. to 6:38 p.m., and from
7:10 p.m. to 10:19 p.m. The data collected and observations made during the
survey are presented In Table 2. Table 3 presents a list of the dye
materials handled during the survey, Including the dye color Index number,
the number of weighings of each dye, and the total weight of all weighings of
each dye,
ANALYTICAL RESULTS
Solids filtered from the air 1n this facility were analyzed by EPA for
total dye content. Total weight of all solids and analytical results from
the four filtering devices, corrected for recovery, follow (1n milligrams dye
per cubic meter air):
Active Total
Colorants Commercial Dyes Weight
Average of 2 monitoring 0.01 0.03 0.02
devices 1n workers' breathing
zones
Drug room area sampler at 0.01 0.02 0,043
weighing station
Drug room area sampler at drum <0,01 <0.01 0.04
storage, remote from weighing
area
The total weight on the filter 1s less than the weight of commercial dye as
determined by the analytical method. Weights at such low levels are ap-
proaching the maximum capabilities of most analytical balances and therefore
are subject to much uncertainty.
160
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TABLE 2. SUMMARY OF DATA AND INFORMATION RECORDED DURING THE SURVEY
A.
B.
C.
D.
E.
F.
Time 1n work area
Total time monitoring
Total time 1n drug room
Lunch and breaks
Work capacity
Maximum work load
Units 1n operation at time
Powder dyes weighed
Total weighed
Disperse
Direct
Dyes
Total
Disperse
Direct
Dry chemicals weighed
Total
All chemicals weighed
Total
Dyes
Dry chemicals
Percent of
Time, minutes monitoring period
400 100
287 72
Not available
Number of
process units Percent
11 100
of survey 11 100
Number of dyes Percent
16 100
6 38
10 62
Number of Weight of dyes,
weighings Percent grams Percent
46 100 10,707.74 100
23 50 . 5,799.82 54
23 50 4,907.92 46
Number of weighings
0
Weight of
Number of all chemicals
weighings Percent grams Percent
46 100 10,707.74 100
46 100 10,707.74 100
0 0 0.00 0
(continued)
161
-------
TABLE 2 (continued)
Dyes weighed most Number of Weight of dyes,
F. frequently weighings Percent grams Percent
Disperse Yellow 218
Disperse Red 60
Direct Yellow 142
Disperse Blue 56
Direct Red 243
7
6
6
5
5
15
13
13
11
11
812.12
1,296.03
660.26
2,658.44
368.74
8
12
6
25
3
Largest quantity of Number of Weight of dyes,
H. dyes weighed weighings Percent grams Percent
Disperse Blue 56 5 11 2,658.44 25
Direct Red 9 1 2 2,271.81 21
Disperse Red 60 6 13 1,296.03 12
Direct Blue 80 49 949.06 9
Disperse Yellow 218 7 15 812.12 8
162
-------
TABLE 3. DYE MATERIALS HANDLED DURING THE SURVEY
Dye color index no.
Number of
weighings
Total weight
of weighings,
grams
Disperse dyes:
Disperse Yellow 218
Disperse Orange 29
Disperse Red 60
Disperse Red 338
Disperse Violet 26
Disperse Blue 56
Direct dyes:
Direct Yellow 142
Direct Yellow 58
Direct Orange 34
Direct Red 243
Direct Red 9
Direct Blue 80
Direct Blue 191
Direct Brown 115
Direct Brown 116
Direct Black 62
7
3
6
1
1
5
6
1
1
5
1
4
1
2
1
1
812.12
81.23
1,296.03
793.33
158.67
2,658.44
660.26
77.97
147.28
368.74
2,271.81
949.06
363.87
18.91
12.00
38.00
163
-------
TEXTILE DRUG ROOM MONITORING STUDY
SITE VISIT REPORT
Site Number 5/9
William L. Dyson, Ph.D., C/I.H. Lesne J/ Ungers, C.I.H.
Health and Hygiene, Inc. t/^¥ Associates, Inc.
Prepared for:
U.S. ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF TOXIC SUBSTANCES
401 M STREET, S.W.
WASHINGTON. DC 20460
165
-------
INTRODUCTION
This survey was conducted as part of an exposure study being performed
as a cooperative effort between the U.S. Environmental Protection Agency
(EPA), the American Textile Manufacturers Institute, Inc. (ATMI), and the
Ecological and Toxicological Association of the Dyestuffs Manufacturing
Industry (ETAD). The study's objective was to determine the extent of
textile workers' exposure to dye dust when weighing and mixing powder dyes.
The sites to be visited were selected to obtain a random sampling of eligible
sites. Contact with the site representative to schedule the site visit was
made by William L. Dyson, Ph.D., C.I.H. of Health and Hygiene, Inc.,
representing ATMI and ETAD. In attendance at the site were Dr. Dyson and
Donald L. Unruh, C.I.H., IT Corporation, subcontractor for PEI Associates,
Inc., representing EPA. The pre-survey meeting was held with company
officials on March 9, 1987. The Industrial hygiene monitoring and recording
of data were performed during the second shift (3:00 p.m. to 11:00 p.m.) on
that day. Company representatives were very cooperative in assisting with
this survey.
166
-------
SITE CHARACTERIZATION
GENERAL
The drug room at site 5/9 is part of a captive dye house operating on
both an integrated and commission basis. Approximately 5.5 million pounds of
woven piece goods per year are dyed with powder dyes at this publicly owned
facility. Seven jets and seven becks were available for batch dyeing as well
as four continuous dyeing machines. Two continuous machines were in opera-
tion at the start of the shift; three were in operation at the end. Six jets
were in operation throughout the entire monitoring period. No becks were
operating at the beginning of the shift, but one was in operation at the end.
Fibers dyed in the manufacture of woven fabrics are acrylic/modacrylic,
rayon, nylon, polyester, cotton, occasionally acetate, and wool samples.
Site operations include storage, preparation, dyeing, and finishing.
DRUG ROOM
The drug room, located in the southwest corner of the second floor of
the plant building, is a rectangular room approximately 60 feet long and 60
feet wide, with an 8-foot celling. The room is accessed by a door in the
middle of the room which leads to the dye weighing area. The weighing area,
measuring 25 feet by 20 feet, is a room located Inside the drug room. Inside
the weighing area are stored dye drums, and two dye weighing stations. In
the drug room outside of the weighing area, there are areas of dye drum
storage along the outside walls of the weighing room, as well as in many
167
-------
areas throughout the room. The mixing areas are located along the north and
south walls of the drug room. Figure 1 presents a sketch of the drug room
and mixing areas.
The dye drums vary in size from 200- to 250-pound barrels to 8 to 10-
pound containers.
In the weighing room, a gram scale for weighing small volumes of powder
dyes is located on a table on which small containers of dyes are stored. A
pound scale for weighing large quantities of dyes and dry chemicals is
located next to this table.
The general appearance of the drug room was moderately clean. The
walls, floors, and stored dye drums were fairly free of dyestuff. There was
a small accumulation of dye material on the equipment. Spills were washed up
immediately.
The drug room was not equipped with a local exhaust ventilation system
for the purpose of removing airborne dye particles. Two overhead air supply
vents were located in the mixing vat area. All ventilation ducts in the
weighing area were blocked except for one supply slot as indicated in Figure
1. The air flow was into the weighing room from the hallway, indicating a
slightly negative pressure inside as compared to the rest of the building.
Floor drains are located in the drug room and mixing room to facilitate
drainage when the floor 1s hosed down, an operation which reportedly takes
place at the end of every shift.
Environmental conditions of the drug room (I.e., temperature, humidity,
and barometric pressure) were recorded hourly during the survey and are
summarized in Table 1.
168
-------
MIXING VATS
60 ft
N
i
80 ft
I
1
O
FREIGHT
ELEVATOR
AIR
SUPPLY
DUCT
oo
oo 8OO8 oo
,OO 8OO2 OO
OOO$XN
O V «
\ //LOOOOOOOCfoOOO
oo/
'O'^'DESK
O
DYE DRUMS
\/ to*
I 10
I O
( O
»,"
oooooo
o oooo !>
o
o
o
:V — --.
U
O
o
o
o
O
. ^ ^1^ TAB
WATER/WASH
TABLE
'
AUXILIARY
DYE DRUMS
s^- POUND
U SCALES
ooooo
Ito
oooooooopoo
HOT UATER
HEATER
AIR SUPPLY
DUCT VENT
PORTABLE DRUM
MIXER
AIR FLOW
SMALL
VOLUME
DYE
STORAGE
\
\
\
AIR
SUPPLY
DUCT
HANGS
K FROM
CEILING
OO
^
OO
oo
oo
_ SHOWER/EYE
• WASH STATION
odoo
oo
QO
LEGEND
• WEIGHING STATION
• AREA SAMPLER AT DRUM STORAGE
A AREA SAMPLER AT WEIGHING STATION
'DENOTES FLOW OF DYES FROM STORAGE
"^ THROUGH WEIGHING TO MIXING
O FLOOR DRAIN
MIXING VATS
SOUTHWEST CORNER OF SITE
SECOND FLOOR
Figure 1. Sketch of drug room and mixing areas.
169
-------
TABLE 1. ENVIRONMENTAL CONDITIONS RECORDED DURING THE SURVEY*
Range
Mean,
Parameter 8-hour value Minimum Maximum
Temperature, °F 80 78 81
Relative humidity, % 70 63 88**
Barometric pressure, torr 749 719 760
*
Readings of each parameter were recorded hourly over the 8-hour work shift.
**
Recorded while all floors were being washed.
DYE WEIGHER ACTIVITIES
The company employs one full-time weigher on each of three shifts. His
duties include:
0 Weighing dyes and dry chemicals and recording weights on batch
tickets.
0 Transferring weighed dyes and dry chemicals from the scale to
buckets and hand carrying the buckets to the mixing areas.
0 Relocating dye drums within the drug room using a drum dolly.
0 Cleaning dye storage, weighing and mixing areas.
The dye weighers employed at this facility are involved in the handling,
transferring, and weighing of dyes and dry chemicals.
The monitored dye weigher was a 49-year old male. He has been employed
at the company for 19 years; ten of those years have been spent handling
dyes. He had no previous dye handling experience.
Training
Specific employee training regarding the safe handling of dyes involved
rudimentary verbal training regarding the harmful constituents of certain
classes of dyes. It was reported that no hazard communication training of
any kind has been conducted in the past three years.
170
-------
Personal Protective Equipment
Personal protective equipment utilized by the monitored dye weigher in
the drug room included a Willson half-mask disposable dust respirator during
dye weighings and steel-toed shoes. A Willson full-face cartridge respirator
was worn while performing caustic soda weighings. A safety eye wash station
is located near the mixing vats along the south wall of the room; however, it
was not functional at the time of the survey.
Personal Habits
The monitored dye w—'gher did not smoke or eat inside the weighing area.
He washed his hands after each batch weighing.
Work Activities
The dye weigher's activities in filling each batch ticket order were as
follows: dyes were obtained by walking to a drum in the storage area con-
taining the appropriate dye, using a hand scoop to remove an approximate
quantity of the dye, transferring the scoop of dye to the weigh station,
pouring the required amount into the scale dish, returning the unused portion
of the dye to the drum, and transferring the weighed portion of the dye to a
bucket. This operation was repeated until all of the dye weighings specified
on the batch ticket had been completed. The batch was then hand carried to
the mixing area and added to the mixing vats. When a bucket was used, it was
washed out after transferring the batch to the mixing vat. These rinsings
were also added to the mixing vat. Small quantities of dye were carried in
the weighing pan. At times, liquid chemicals were also added to the mixing
vats.
171
-------
SPECIFIC MEASUREMENTS AND OBSERVATIONS
The monitored dye weigher was in the drug room for a total of 403 min-
utes over the 8-hour period (480 minutes). During that time, his duties
required him to enter the drug room seven times. He was monitored for expo-
sure to particulates over a 452-minute period from 3:07 p.m. to 10:39 p.m.
Table 2 presents a summary of the data and information recorded during the
survey. Table 3 presents a list of the dye materials handled during the
survey, including the dye color index number, the number of weighings of each
dye, and the total weight of the weighings of each dye.
ANALYTICAL RESULTS
Solids filtered from the air in this facility were analyzed by EPA for
total dye content. Total weight of all solids and analytical results from
the four filtering devices, corrected for recovery, follow (in milligrams dye
per cubic meter air):
Active To^al
Colorants Commercial Dyes We.ght
Average of 2 monitoring 0.02 0.07 0.33
devices in worker's breathing
zone
Drug room area sampler at 0.02 0.07 0.12
weighing station
Drug room area sampler at drum <0.01 0.01 0.05
storage, remote from weighing
area
172
-------
TABLE 2. SUMMARY OF DATA AND INFORMATION RECORDED DURING SURVEY
Percent of
monitoring
A.
Time in work area
Total time monitored
Total time in drug room
B.
C.
D.
E.
F.
Lunch and breaks
Work capacity
Maximum work load
Units in operation at
Powder dyes weighed
Total
Acid
Disperse
Basic
Direct
Dyes
Total
Add
Disperse
Basic
Direct
Dry chemicals weighed
Glauber's Salt
(Na2S04.10 H20)
All chemicals weighed
Total
Dyes
Dry chemicals
time of survey
Number of
weighings
44
6
24
5
9
Number of
weighings
10
Number of
weighings
54
44
10
Time, minutes
452
403
NA
Number of
process units
18
9 (avg.)
Number of dyes
18
3
7
4
4
Weight of dyes
Percent grams
100 51,081.4
14 8,258.7
55 40,932.8
11 1,564.0
20 325.9
Weight of
chemicals,
Percent grams
100 92,532.4
Weight of
dry chemicals
Percent grams
100 143,613.8
81 51,081.4
19 92.532.4
period
100
89
NA
Percent
100
50
Percent
100
17
39
22
22
,
Percent
100
16
80
3
1
Percent
100
*
Percent
100
36
64
(continued)
173
-------
TABLE 2 (continued)
G.
H.
Dyes weighed most
frequently
Disperse Orange 30
Disperse Blue 56
Disperse Red 177
Direct Yellow 106
Largest quantity
of dyes weighed
Disperse Orange 30
Disperse Blue 56
Add Blue 25
Disperse Red 177
Number of
weighings
6
6
4
4
Number of
weighings
6
6
2
4
Percent
14
14
9
9
Percent
14
14
5
9
Weight of dyes,
grams
26,573.2
8,661.0
5,125.6
157.5
Weight of dyes,
grams
26,573.2
8,661.0
6,341.1
5,125.6
Percent
52
17
10
<1
Percent
52
17
12
10
NA - Not available.
174
-------
TABLE 3. DYE MATERIALS HANDLED DURING THE SURVEY
Total weight
Number of of weighings,
Dye color index number weighings grams
Acid Dyes:
Acid Yellow 219 2 304.0
"Acid Red U-5" 2 1.613.6
Acid Blue 25 2 6,341.1
Disperse Dyes:
Disperse Yellow 42 3 500.7
Disperse Orange 30 6 26,573.2
Disperse Red 177 4 5,125.6
Disperse Red 60 3 49.3
Disperse Blue 56 6 8,661.0
Disperse Blue 27 1 13.5
Disperse Blue 60 1 9.5
Basic Dyes:
Basic Yellow 21 1 68.0
Basic Orange 30 1 60.0
Basic Blue 21 1 15.0
Basic Blue 41 2 1,421.0
Direct Dyes:
Direct Yellow 106 4 157.5
"Direct Orange M-3" 1 30.3
Direct Red 243 1 1.9
Direct Blue 80 3 136.2
175
-------
TEXTILE DRUG ROOM MONITORING STUDY
SITE VISIT REPORT
Site Number 6/2
_ - __ _^__
W11 HamTTDyson. Ph.D., .I.H. tes)/le ^lingers, C.I.H,
Health and Hygiene, Inc. ft I Associates, Inc.
Prepared for:
U.S. ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF TOXIC SUBSTANCES
401 M STREET, S.W.
WASHINGTON. DC 20460
177
-------
INTRODUCTION
This survey was conducted as part of an exposure study being performed
as a cooperative effort between the U.S. Environmental Protection Agency
(EPA), the American Textile Manufacturers Institute, Inc. (ATMI), and the
Ecological and Toxicological Association of the Dyestuffs Manufacturing
Industry (ETAD). The study's objective was to determine the extent of
textile workers' exposure to dye dust when weighing and mixing powder dyes.
The sites to be visited were selected to obtain a random sampling of eligible
sites. Contact with the site representative to schedule the site visit was
made by William L. Dyson, Ph.D., C.I.H. of Health and Hygiene, Inc.,
representing ATMI and ETAD. In attendance at the site were Ronald H. Hill,
C.I.H. of Health and Hygiene and Donald L. Unruh, C.I.H., IT Corporation,
subcontractor for PEI Associates, Inc., representing EPA. The pre-survey
meeting was held with company officials on the afternoon of April 1, 1987.
The industrial hygiene monitoring and recording of data were performed during
the first shift (7:00 a.m. to 3:00 p.m.) on April 2, 1987. Company
representatives were very cooperative in assisting with this survey.
178
-------
SITE CHARACTERIZATION
GENERAL
The drug room at site 6/2 is part of a captive dyehouse operating on an
integrated basis. Approximately 23 million pounds per year of knitted piece
goods for automotive or apparel use are dyed in batch operations (99 percent
with powder dyes) at this publicly-owned facility. All available dyeing
machines were in operation during the entire survey period. These machines
consisted of fourteen jet and nineteen beam dyeing machines. Of the latter,
nine were open to the atmosphere and ten were pressurized. Fibers dyed are
nylon, polyester, acetate, and triacetate. Site operations include greige
storage, preparation, dyeing, and finishing.
DRUG ROOM
The drug room, located on a second floor mezzanine above the dyehouse,
is a rectangular room approximately 70 feet long and 25 feet wide, with a
10-foot celling. The room 1s accessed by a door at the north end which leads
to the mixing area and descending stairs, and double doors at the south end
which lead to a storage area for chemicals and unopened drums of dyes and an
elevator. A wide aisle running the length of the room provides access to the
drums of dyes. This aisle 1s also used by plant workers to gain access to
the elevator and to transport materials or equipment from the elevator to the
mixing area. Mixing occurs in a separate area outside the drug room. Mixed
179
-------
dye solutions/dispersions are gravity-fed via pipeline Into dyeing equipment.
The drug room Includes drum storage, one dye weighing station equipped with
two scales (a computer-adjusted gram scale and a pound scale) and storage
bins for pre-welghed dye mixes. Figure 1 presents a sketch of the drug room.
Dyes are stored in drums throughout the drug room and outside the south
wall of the drug room. The drums vary 1n size from 200- to 250-pound barrels
to 50- to 100-pound containers. Pre-weighed dye mixes are stored in five
temporary storage bins located against the west wall of the drug room. The
two scales for weighing powder dyes are located against the north wall be-
tween the storage bins and the door to the mixing area.
The general appearance of the drug room was fair. The walls were moder-
ately stained from dyestuff contact. The floor was swept at the end of the
monitored shift and when a spill occurred. It was reported by the company
that the floor is swept at the conclusion of each shift and washed weekly.
The drug room was not equipped with a local exhaust ventilation system
for the purpose of removing airborne dye particles. The room was equipped
with a general heating and air conditioning system. Air is moved through
overhead supply and return ducts in the celling, which creates a slight
positive pressure compared to the other plant areas. This is Indicated by
the flow of air from the drug room at each doorway.
One floor drain is located in the north end of the drug room which
facilitates water removal during weekly floor cleaning.
Environmental conditions of the drug room (I.e., temperature, humidity,
and barometric pressure) were recorded hourly during the survey and are
summarized in Table 1.
180
-------
TO MIXING VAT AREA
NO WINDOWS
IN ROOM
70 ft
DYE ROOM IS ON SECOND
FLOOR ABOVE DYE AREA
DYE DRUMS
AIR RETURNS
O O O O
AIR FLOW
ooooo
SEALED DYE DRUMS
IELEVATOR I
• UtICHlHS SIAIIW
• AREA S»WHt A" OttH ST«*it
A acA SAMPLE* A* VCOING sT»noi
'otKOT£S FLCU OF ores rgon SIOSWE
- IIIIOU&M WEIGH i us ro MU:«
DYE DRUMS
Figure 1. Sketch of drug room area,
181
-------
TABLE 1. ENVIRONMENTAL CONDITIONS RECORDED DURING THE SURVEY*
Parameter
Temperature, °F
Relative humidity, %
Barometric pressure, in. Hg.
Mean,
8-hour value
72
71
30.10
Minimum
65
66
30.07
Range
Maximum
74
78
30.17
Readings of each parameter were recorded hourly over the 8-hour work shift.
DYE WEIGHER ACTIVITIES
The company employs one full-time dye weigher on each of three shifts.
There are twelve employees who rotate duties in this area at this facility.
Their duties include:
0 Weighing dyes and recording weights on batch tickets.
0 Transferring weighed dyes from the scale to plastic bags, buckets,
or stainless steel bowls.
0 Cleaning dye storage and weighing areas.
The dye weighers employed at this facility are Involved in the handling,
transferring, and weighing of dyes. Employees other than dye weighers trans-
fer the weighed dyes to the mixing vats. All incoming dyes are quality
control checked in the receiving lab prior to being released to the drug
room.
The monitored dye weigher was a right-handed 43-year old male. He has
been employed at the company for 17 years; twelve of those years have been
spent handling dyes. He had no previous dye handling experience.
Training
Specific dye weigher training regarding the safe handling of dyes was
provided in the form of monthly safety meetings and training on the hazards
182
-------
of dyes and how to read Material Safety Data Sheets (MSDS). A file of appro-
priate dye MSDS's 1s kept in the Manager's office.
Personal Protective Equipment
Personal protective equipment utilized by the monitored dye weigher in
the drug room included a disposable dust mask respirator, rubber apron,
safety glasses, rubber gloves, and steel-toed shoes. The monitored dye
weigher used the above-mentioned equipment at all times during the survey;
however, because he rolled up his long sleeve shirt to his elbows, the
possibility existed of dermal contact with dyes. It was also observed that
the respirator fit was such that it did not provide a seal necessary to
achieve optimum protection; usually only one of two straps was secured.
Personal Habits
The monitored dye weigher and other workers in the drug room were
observed drinking in the drug room. The monitored dye weigher did not smoke
Inside or outside the weighing area. As part of his personal hygiene
practice, the weigher washed his hands only before taking breaks. He
consistently wore his rubber gloves during all dye weighing activities.
Work Activities
The dye weigher's activities in filling each batch ticket order were as
follows: dyes were obtained by walking to a drum in the storage area contain-
ing the appropriate dye, using a hand scoop to remove an approximate quantity
of the dye, transferring the scoop of dye to the weigh station and pouring
the required amount Into a plastic bucket, plastic bag, or stainless steel
bowl, and returning the unused "portion of the dye to the drum. At times,
drums of dyes requiring relatively large weighings were pushed to a location
near the scales prior to scooping. This operation was repeated until all of
183
-------
the dye weighings specified on the batch ticket had been completed. To
ensure dye containment, the upper portion of the plastic bags were folded and
stapled shut; buckets were covered with plastic sheeting. The containers
remained in the scale area until time for mixing; a time period ranging from
minutes tc greater than an hour. Other workers then transported the weighed
dye mixture to the mixing area where they were transferred into the mixing
vats.
On one occasion, when a drum of dye (Disperse Red 135) was almost empty,
the dye weigher manually transferred the dregs into the next drum by Invert-
ing the old drum over the new drum. On three other occasions, the dregs
remained in the almost depleted drum, which was used as a trash receptacle
and then (presumably) discarded. It was also noted that an unused mixing vat
of dye dispersion for a full-size fresh dyelot was not piped to a dyeing
machine, but was instead diverted to the discard drainage system and released
because the beam of fabric scheduled to be dyed had blown in the scouring
operation, necessitating postponement of dyeing the scheduled dyelot.
SPECIFIC MEASUREMENTS AND OBSERVATIONS
The monitored dye weigher was 1n the drug room for a total of 456
minutes over the 8-hour period (480 minutes). During that time, his duties
required him to enter the drug room four times. He was monitored for expo-
sure to particulates over a 459-minute period from 7:06 a.m. to 2:45 p.m. At
the beginning of the shift, the dye weigher was very active with a full
schedule of weighings to be performed. He worked steadily without a break
for the first 3-1/2 hours of the shift.
Table 2 presents a summary of the data and Information recorded during
the survey. Table 3 presents a 11st of the dye materials handled during the
184
-------
survey, Including the dye color Index number, the number of weighings of each
dye, and the total weight of the weighings of each dye.
ANALYTICAL RESULTS
Solids filtered from the air In this facility were analyzed by EPA for
total dye content. Total weight of all solids and analytical results from
the four filtering devices, corrected for recovery, follow (in milligrams dye
per cubic meter air):
Active Total
Colorants Commercial Dyes Weight
Average of 2 monitoring 0.06 0.18 0.27
devices in worker's breathing
zone
Drug room area sampler at 0.03 0.08 0.15
weighing station
Drug room area sampler at drum <0.01 0.01 0.04
storage, remote from weighing
area
185
-------
TABLE 2. SUMMARY OF DATA AND INFORMATION RECORDED DURING SURVEY
A.
Time in work area
Percent of
monitoring
Time, minutes period
Total time monitored
Total time in drug room
Lunch and breaks
B.
C.
D.
E.
F.
Work capacity
Maximum work load
Units in operation at
Powder dyes weighed
Total
Acid
Neutral Pr erne tal 1 i zed
Disperse
Dyes
Total
Acid
Neutral Premetallized
Disperse
Dry chemicals weighed
Total
All chemicals weighed
Total
Dyes
Dry chemicals
459
456
NA
100
99
NA
Number of
process units Percent
time of survey
Number of
Number of
weighings Percent
88 100
6 7
2 2
80 91
Number of
weighings
0
Number of
weighings Percent
88 100
88 100
0 0
33
33
dyes Percent
30
6
2
22
Weight of dyes,
pounds
625.922
<1.043
0.039
624.84
Weight of
dry chemicals,
pounds
625.922
625.922
0.000
100
100
100
20
7
73
Percent
100
<1
<1
99
Percent
100
100
0
(continued)
186
-------
TABLE 2 (continued)
G.
H.
Dyes weighed most
frequently
Disperse Yellow 42
Disperse Blue 27
Disperse Orange 30
Disperse Blue 60
Largest quantity
of dyes weighed
"Disperse Black M-3"
Disperse Orange 41
Disperse Red 167
Disperse Orange 30
Number of
weighings
10
8
7
7
Number of
weighings
6
3
5
7
Percent
11
9
8
8
Percent
7
3
6
8
Weight of dyes,
pounds
25.48
41.294
56.064
11.49
Weight of dyes,
pounds
118.231
87.22
71.32
56.064
Percent
4
7
9
2
Percent
19
14
11
9
NA • Not available.
187
-------
TABLE 3. DYE MATERIALS HANDLED DURING THE SURVEY
Dye color index number
Add Dyes:
Acid Yellow 49
Acid Yellow 159
Acid Orange 116
Add Red 396
"Acid Blue U-l"
Acid Blue 205
Neutral Premetallized Dyes:
Acid Yellow 116
Acid Blue 177
Disperse Dyes:
Disperse Yellow 64
Disperse Yellow 42
Disperse Yellow 3
Disperse Yellow 86
Disperse Orange 41
Disperse Orange 30
Disperse Red 135
Disperse Red 333
Disperse Red 55
Disperse Red 263
Disperse Red 167
Disperse Red 73
Disperse Red 91
Disperse Violet 57
Disperse Blue 56
"Disperse Blue U-4"
Disperse Blue 77
Disperse Blue 87
Disperse Blue 27
Disperse Blue 60
Disperse Blue 79
"Disperse Black M-3"
Number of
weighings
1
1
1
1
1
1
1
1
1
10
1
1
3
7
1
2
4
3
5
4
3
5
2
2
1
3
8
7
1
6
Total weight
of weighings,
pounds
0.001
0.038
0.001
0.002
<0.001
1.00
0.005
0.034
0.120
25.48
0.007
10.23
87.22
56.064
23.73
30.69
2.638
25.58
71.32
0.676
15.47
28.18
21.66
12.20
17.69
18.44
41.294
11.49
6.43
118.231
188
-------
TEXTILE DRUG ROOK hOMTORING STUDY
SITE VISIT REPORT
Site Number 6/5
William L. Dyson, Ph.D., C.I.H. /Le^TliT
Health and Hygiene, Inc. . ^PEI Associates. Inc.
Prepared for:
U.S. ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF TOXIC SUBSTANCES
401 M STREET. S.U.
WASHINGTON, DC 20460
189
-------
INTRODUCTION
This survey was conducted as part of an exposure study being performed
as a cooperative effort between the U.S. Environmental Protection Agency
(EPA), the American Textile Manufacturers Institute, Inc. (ATMI), and the
Ecological and Toxicological Association of the Dyestuffs Manufacturing
Industry (ETAD). The study's objective was to determine the extent of
textile workers' exposure to dye dust when weighing and mixing powder dyes.
The sites to be visited were selected to obtain a random sampling of eligible
sites. Contact with the site representative to schedule the site visit was
made by William L. Dyson, Ph.D., C.I.H. of Health and Hygiene, Inc.,
representing ATMI and ETAD. In attendance at the site were Melvin
i
R. Witcher, Jr., C.I.H. of Health and Hygiene, and Donald L. Unruh, C.I.H. of
IT Corporation, subcontractor for PEI Associates, Inc., representing EPA.
The pre-survey meeting was held with company officials on May 20, 1987. The
industrial hygiene monitoring and recording of data were performed during the
first shift (7:00 a.m. to 3:00 p.m.) on the next day. Company
representatives were very cooperative in assisting with this survey.
190
-------
SITE CHARACTERIZATION
GENERAL
The drug room at site 6/5 is part of a captive dyehouse operating on an
integrated basis. Approximately 350,000 pounds of whole garments (socks) per
year are dyed in batch operations at this privately-owned facility. Two
Smith Drum and three Milnor rotary dyeing machines were available, all of
which were in operation at the time of the survey. Fibers consist of acrylic,
wool, nylon, cotton, and polypropylene. Site operations include storage,
preparation, dyeing, drying, and steam pressing of the garments.
DRUG ROOM
The drug room, located in the center of the plant building, is a rec-
tangular room approximately 28 feet long and 18 feet wide. It is an open-top
structure inside a larger metal building. The drug room had no structural
roof. The four 8-foot walls of the room served as a support for several
large cylindrical water tanks, which were positioned lengthwise across the
width of the drug room. The tanks did not completely enclose the top of the
drug room. The room is accessed by a door along the east wall of the room
which leads to the general plant area. The drug room includes a drum storage
area and one dye weighing station equipped with one scale. Figure 1 presents
a sketch of the drug room.
A weighing station housing one scale for weighing the powdered dyes, is
located 1n the drug room near the racks which contain the dye bins.
191
-------
O O O DRY
CHEMICAL
v DRUMS
I
FLOOR
TRENCH
DRAIN
A
MILNOR
DYEING
MACHINES
DRUG ROOM AREA
WATER TREATMENT
SYSTEM TO SOFTEN
THE WATER
Os
ox
Q
OOQQOO,
o
000
DRUG ROOM AREA
\ Q ®
* ^^DYE DRUMS *^)
i O /r\
! O\ /°
i o\'
DRUMS ^S , ;
O\ '
\l
i 0 ] 1
Vo i /
**X--^. 1 1
/ O >< » TABLE
/ UkAlN
JOO ooo P
J^^ 0.00 A
28 ft
'8 ft
SMALL CANS' SCALE
OF DYE
LEGEND
• MCIGUIHG STATION
• AREA SAMPLER AT ORl* STORAGE
A AREA SAMPLER AT WEIGHING STATION
'DCHOTT.S rLfly or Of'.S ttff* STORACC
" THMur.ll
Figure 1. Sketch of drug room area
192
-------
Dyes are stored in drums utilizing the floor space against the walls of
the drug room. Drums of dyes are also stored on the floor near the weighing
station and in the center of the room. Small sample size cans of dye of
approximately 10 pounds are located on the weigh station table next to the
scale. Drum sizes vary from 200 to 250 pounds to 100 to 150 pounds. Dry
chemicals are stored outside the drug room near the dye machine area.
One scale for weighing powder dyes is located on a table next to the
drug room entrance. A second scale for weighing dry chemicals is located in
the dye machine area.
The general appearance of the weighing and storage areas was fair.
There Was some evidence of dye stains on the floor and walls. There was also
a small accumulation of dye material on the equipment and inventory. Spills
of the dye material were not cleaned up during the survey period.
The drug room was not equipped with local exhaust ventilation systems
for the purpose of removing airborne dye particles. The general building air
was supplied from overhead roof vent fans. Because the drug room is an
open-top structure, any air flow is the result of normal ambient air flow
throughout the general plant area.
One floor drain was located in the drug room near the weighing station
to facilitate drainage during floor cleaning; however, this activity was not
observed during the survey. The accumulation of dust and the presence of dye
stains on the floor indicated that floor washing occurs infrequently.
Environmental conditions of the drug room (I.e., temperature, humidity,
and barometric pressure) were recorded hourly during the survey and are
summarized in Table 1.
193
-------
TABLE 1. ENVIRONMENTAL CONDITIONS RECORDED DURING THE SURVEY*
Parameter
Temperature, °F
Relative humidity, %
Barometric pressure, in. Hg.
Mean,
8-hour value
85
67
28.52
Minimum
79
58
28.50
Range
Maximum
89
81
28.54
Readings of each parameter were recorded hourly over the 8-hour work shift.
DYE WEIGHER ACTIVITIES
On each of two shifts the company employs one full-time person who
weighs dyes in addition to performing many other duties. His duties include:
0 Weighing dyes and dry chemicals and recording weights on batch
tickets.
0 Transferring powder dyes from the scale to 2-gallon stainless steel
pails and hand carrying the palls to the dye machines.
0 Adding the dry dyes and dry chemicals directly to the addition
spout on the dyeing machines.
0 Loading materials to be dyed Into the dyeing machine and operating
the dyeing machine.
0 Transferring dyed goods to the extractor and operating that
machine.
0 Transferring goods from the extractor to a cart, which was then
pushed to the drying machines in another on-s1te location by a
different worker.
0 Cleaning dye storage and weighing areas.
The operator/dye weighers at this facility are Involved 1n dye handling,
transferring, weighing, adding of dry dyes and dry chemicals to dyeing
machines, loading and unloading dyeing machines, loading and unloading ex-
tractors.
194
-------
The monitored dye weigher was a 31-year old male. He has been employed
at the company for 11 years; all of those years have been spent handling
dyes. He had no previous dye handling experience.
Training
The monitored dye weigher had experience in reading material safety data
sheets (MSDS's); however, no formal training regarding the safe handling of
dyes was provided by the company.
Personal Protective Equipment
Personal protective equipment utilized by the dye weighers in the drug
room Included an MSA half-mask respirator with high-efficiency particulate
filters, an apron, safety glasses, and gloves. The monitored dye weigher
used all of the required personal protective equipment while performing
dye-handling activities. Because the monitored dye weigher wore a short-
sleeved shirt, dermal contact with dyestuffs may have occurred, although this
was not observed.
Personal Habits
The monitored dye weigher was not observed drinking or eating in the
drug room. He did not smoke Inside the weighing area, but he did smoke
outside of that area. As part of this personal hygiene practices, the moni-
tored dye weigher washed his hands after each dye weighing.
Work Activities
The dye weigher's activities in filling each batch ticket order were as
follows: dyes were obtained by walking to a drum in the storage area con-
taining the appropriate dye and using a hand scoop or a large spoon to remove
an approximate quantity of the dye, transferring the scoop of dye to the
weigh station and pouring the required amount Into the scale dish, returning
195
-------
the unused portion of the dye to the drum, and transferring the weighed
portion of the dye to a stainless steel pail. This operation was repeated
until all of the dye weighings specified on the batch ticket had been com-
pleted. Dry chemicals were weighed and added to the batch as specified in
the formulation. The batch was then hand carried to the washing machine-like
rotary dyeing machines and poured into the addition spout on the dyeing
machine. The pail was rinsed and the rinse water was poured into the dyeing
machine. The dye/chemical mixture was gravity fed directly into the garment
dyeing machine. This method of operation—the direct addition of dry dye
into dyeing machines—is significantly different from operations at other
monitored sites where dry dye powders are dissolved or dispersed in hot water
with the aid of a mixer prior to addition to the dyeing machine. Garments
were loaded into the dyeing machine by the dye weigher and the dyeing machine
was operated. After the garments were dyed, the dye weigher transferred the
dyed goods to the extractor. After operating the extractor, the dye weigher
transferred the garments to a cart, which was pushed by another worker to the
dryers at a different location within the plant.
SPECIFIC MEASUREMENTS AND OBSERVATIONS
The monitored dye weigher was in the drug room for a total of 36 minutes
over the 8-hour period (480 minutes). During that time, his duties required
him to enter the drug room nine times. He was monitored for exposure to
particulates over a 463-minute period from 7:10 a.m. to 2:53 p.m. Table 2
presents a summary of the data and Information recorded during the survey.
Table 3 presents a 11st of the dyes handled during the survey, Including the
dye color Index number, the number of weighings of each dye, and the total
weight of the weighings of each dye.
196
-------
ANALYTICAL RESULTS
Solids filtered from the air in this facility were analyzed by EPA for
total dye content. Total weight of all solids and analytical results from
the four filtering devices, corrected for recovery, follow (in milligrams dye
per cubic meter air):
Active Total
Colorants Commercial Dyes Weight
Average of 2 monitoring 0.08 0.10 0.53
devices in worker's breathing
zone
Drug room area sampler at 0..03 0.04 0.14
weighing station
Drug room area sampler at drum 0.01 0.01 0.14
storage, remote from weighing
area
197
-------
TABLE 2. SUMMARY OF DATA AND INFORMATION RECORDED DURING SURVEY
A.
B.
Time in work area
Total time monitored
Total time in drug room
Lunch and breaks
Work capacity
Percent of
monitoring
Time, minutes period
Maximum work load
Units in operation at time of survey
C.
D.
E.
Powder dyes weighed
Total weighed
Acid
Neutral Premetallized
Basic
Reactive
Dyes
Total
Add
Neutral Premetallized
Basic
Reactive
Dry chemicals weighed
Total
Ammonium sulfate
CDB-63
DYL Chem developer
DYL Salt cone.
Soda ash grade 100
(Na2C03)
Sodium bisulfite
Sodium sulfate
Potassium pyrophosphate
463
36
NA
Number
process
5
5
of
units
Number of dyes
Number of
weighings
15
10
1
1
3
Number of
weighings
20
2
1
4
4
1
1
6
1
12
7
1
1
3
Weight of dyes,
Percent grams
100
67
7
7
20
Percent
100
10
5
20
20
5
5
30
5
6,403.62
3,271.37
34.02
303.91
2,795.32
Weight of
chemicals,
pounds
222.00
4.75
1.50
15.50
15.50
24.00
0.75
158.75
1.25
100
8
NA
Percent
100
100
Percent
100
58
8
8
25
>
Percent
100
51
5
44
Percent
100
2
7
7
11
72
(continued)
193
-------
TABLE 2 (continued)
F.
G.
All chemicals weighed
Total
Dyes
Dry chemicals
Dyes weighed most
frequently
Acid Red 260
Acid Yellow 79
Number of
weighings
35
15
20
Number of
weighings
3
2
Percent
100
43
57
Percent
20
13
Weight of
all chemicals,
grams
107,100.60
6,403.62
100,696.98
Weight of dyes,
grams
363.63
47.62
Percent
100
6
94
Percent
6
1
H.
Largest quantity
of dyes weighed
Add Red 158
"Reactive Blue U-5"
Reactive Yellow 27
Number of
weighings
1
1
1
Percent
7
7
7
Weight of dyes,
grams
1,840.45
1,271.64
999.48
Percent
29
20
16
NA - Not available.
199
-------
TABLE 3. DYE MATERIALS HANDLED DURING THE SURVEY
Dye color index number
Number of
weighings
Total weight
of weighings,
grams
Acid Dyes:
Acid Yellow 79
Add Red 111
Add Red 158
Acid Red 260
Acid Blue 264
Acid Blue 102
Acid Blue 113
Neutral PremetalUzed Dyes:
Acid Blue 335
Basic Dyes:
Basic Blue 41
Reactive Dyes:
Reactive Yellow 27
Reactive Red 40
"Reactive Blue U-5"
2
1
1
3
1
1
1
1
1
1
47.62
368.32
1,840.45
363.63
182.34
368.32
100.69
34.02
303.91
999.48
523.20
1,271.64
200
-------
TEXTILE DRUG ROOM MONITORING STUDY
SITE VISIT REPORT
Site Number 6/6
/<
William L. Dyson, Ph.D., C.I.H. Lesmj* Ungers, C.I.H.
Health and Hygiene, Inc. PEKAssoc/ates, Inc.
Prepared for:
U.S. ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF TOXIC SUBSTANCES
4Q1 M STREET S.W.
WASHINGTON. D.C. 20460
201
-------
INTRODUCTION
This survey was conducted as part of an exposure study being performed
as a cooperative effort between the U.S. Environmental Protection Agency
(EPA), the American Textile Manufacturers Institute, Inc. (ATMI), and the
Ecological and Toxicological Association of the Dyestuffs Manufacturing
Industry (ETAD). The study's objective was to determine the extent of
textile workers' exposure to dye dust when weighing and mixing powder dyes.
The sites to be visited were selected to obtain a random sampling of eligible
sites. Contact with the site representative to schedule the site visit was
made by William L. Dyson, Ph.D., C.I.H. of Health and Hygiene, Inc.,
representing ATMI and ETAD. In attendance at the site were Ronald H. Hill,
C.I.H. of Health and Hygiene and Leslie 0. Ungers, C.I.H., Senior Industrial
Hygienist for PEI Associates, Inc., representing EPA. The pre-survey meeting
was held with company officials on the afternoon of November 4, 1986. The
industrial hygiene monitoring and recording of data were performed during the
second shift (3:30 p.m. to 11:00 p.m.) on the same day. Company representa-
tives were very cooperative in assisting with this survey.
202
-------
SITE CHARACTERIZATION
GENERAL
The drug room at site 6/6 1s part of a dyehouse operating on a commis-
sion basis. Approximately 1.2 million pounds per year of piece goods for
apparel use are dyed in semi-continuous/continuous operations at this pri-
vately owned facility. Three dyeing machines were available, two of which
were in operation at the time of monitoring. These machines consist of a pad
for continuous application of dyes or vat pigments and the appropriate
auxiliary equipment for fixation via either thermosol or other continuous or
semi-continous processes. Fibers dyed are rayon, wool, nylon, polyester,
cotton, and flax. Site operations Include storage, preparation, dyeing, and
finishing.
DRUG ROOM
There are two drug rooms In the plant. The major drug room is located
on the second floor and 1s approximately 120 feet long and 30 feet wide with
a celling 12 feet in height. The minor drug room 1s located on the first
floor and 1s 30 feet long and 25 feet wide with a 12-foot celling. There are
two stairways leading from the first floor drug room Into the major drug room
near the mixing equipment on the second floor. No mixing takes place on the
first floor. Figures 1 and 2 present a sketch of the major drug room and the
minor drug room, respectively.
203
-------
SCALES
ELEVATOR TO
FIRST FLOOR
S3
o
. i BEFORE
'r—•——^
L_3
MAJOR DRUM
STORAGE AREA
(DRUMS MOVED
TO MAIN ROOM
OPENING)
MINOR DRUM AREA
MAJOR DRUM
STORAGE
AREA
CEILING HEIGHT 12 ft
< I 1 I—IT-
SCALE
MIXING EQUIPMENT
120 ft
STAIRWAY TO FIRST FLOOR
STAIRWAY TO FIRST FLOOR
30 ft
LEGEND
• WEIGHING STATION
• AREA SAMPLER
'DENOTES FLOW OF DYES FROM STORAGE
-' THROUGH WEIGHING TO MIXING
DENOTES DYE DRUM STORAGE AREAS
NOTE;
NO AIRFLOW IN OR OUT OF THE DRUG r.OOM
Figure 1. Sketch of major drug room area, second floor.
-------
SCALES
LENGTH - 30 ft
WIDTH 25 ft
HEIGHTH- 12 ft
LOCATION OF
OVERHEAD
EXHAUST HOOD
OPEN TO FIRST FLOOR PROCESS AREAS
TO MIXING AREA
ON SECOND FLOOR
LEGEND
• WEIGHING STATION
• AREA SAMPLER
'DENOTES FLOW OF DYES FROM STORAGE
- THROUGH WEIGHING TO MIXING
DENOTES DYE DRUM STORAGE AREAS
NOTE: DRUG ROOM HAD MIXED VENTILATION
Figure 2. Sketch of minor drug room area, first floor.
205
-------
Dyes are stored in drums in both the first and second floor drug rooms.
The major drum storage area for the dyes is located on the second floor. In
both the major and minor drug rooms, small, temporary drum storage areas
exist. The drums vary in size from 200-250 pound barrels to smaller 50-100
pound drums. Dry chemicals (in drums and bags) are stored in these same
storage areas.
Four scales are located in the major drug room for weighing of dyes. In
the minor drug room, there are two scales available for weighing of dyes.
The general appearance of the major drug room was fair. There was
little accumulation of dye on the walls. The equipment and drum lids showed
some accumulation of dye material. The floors had a significant accumulation
of dye indicating that spills are not routinely cleaned up.
The general appearance of the minor drug room was poor. There were
stains and an accumulation of dye on the walls. The equipment showed signifi-
cant accumulation of dye material, while the drum lids showed some accumulation
of dye. The floors had a significant accumulation of dyestuff which indi-
cates that spills are not routinely cleaned up.
The major drug room had no specific engineering controls installed for
the purpose of removing airborne dye particles. The general ventilation in
the major drug room consisted of 3 overhead fans. These fans were not in use
at the time of the survey; no net air flow was measured at the drug room
entrances.
In the minor drug room, one of the weighing stations had been equipped
with an overhead exhaust hood for the purpose of removing airborne dye particles.
The general ventilation in the minor drug room was passive.
206
-------
There were floor grates located in the major drug room to facilitate
drainage aroung the mixing machines.
Environmental conditions at the plant (i.e., -emperature, humidity, and
barometric pressure) were recorded hourly during the survey and are summarized
in Table 1.
TABLE 1. ENVIRONMENTAL CONDITIONS RECORDED DURING THE SURVEY*
Parameter
Mean,
8-hour value
Range
Minimum
Maximum
Temperature, °F
Relative humidity, %
Barometric pressure, in.
Hg
72
77
30.08
68
55
30.07
78
90
30.10
Readings of each parameter were recorded hourly over the 8-hour work shift.
DYE WEIGHER ACTIVITIES
The company employs two full-time weighers on each of three shifts. Two
dye weighers are typically on duty during each shift; however, at the time of
the survey, only one experienced dye weigher was working. The second individual
was a trainee who did not actively participate in most of the dye handling
operations. General duties of the dye weighers include:
0 Relocating drums of dyes using a dolly.
0 Weighing dyes and dry chemicals and recording weights on batch
tickets.
0 Transferring dyes and dry chemicals from the scale to a steel
bucket.
0 Dispensing liquid dyes.
207
-------
0 Manual addition of dry and liquid dyes and dry chemicals to the
mixing tanks.
0 Cleaning dye storage, weighing and mixing areas.
Most of the dyes used on this day were liquids, primarily Vat Dye
pastes. During the monitoring period, only two powder dyes were used, a
single Naphthol (azoic coupling compound) which was applied and then coupled
with a single Naphthol Salt (diazotized azoic base). Technically, these two
substances are intermediates which are applied separately. They react on the
fiber to form the dye "in situ."
The dye weigher monitored during this survey was a 33-year old male. He
has been employed at the company for 3 years; all of those years have been
spent in handling dyes. He had three years of previous dye handling experi-
ence.
Training
Company employee training regarding the safe handling of dyes is provided
through information posted in the work area and booklets.
Personal Protective Equipment
Personal protective equipment provided by the company and utilized by
the dye weigher in the drug rooms included a dust mask respirator and rubber
gloves. It was observed that the monitored dye weigher exhibited work prac-
tices with respect to handling an empty powder dye container which created an
increased potential for exposure to airborne dye material, such as banging
the container to empty the dye'in the bottom. Although gloves were worn
during all weighing operations, the dye weigher's forearms, shirt sleeves,
and pants were contaminated with small amounts of dye powder.
208
-------
Personal Habits
The monitored dye weigher was observed drinking in the drug room. He
was observed smoking inside the drug room between weighing activities as well
as outside the drug room areas. These actions were contrary to the company's
stated policies.
Work Activities
The monitored dye weigher activities in filling each batch ticket order
were as follows: the dye was obtained by walking to a drum in the storage
area containing the appropriate dye and using a hand scoop to remove an
approximate quantity of the dye (a shovel was used to transfer dye material
in the first floor drug room), transferring the scoop or shovel of dye to the
weigh station and pouring the dye onto the scale dish, returning the unused
portion of the dye to the drum, and then transferring the weighed portion of
the dye to a steel bucket. Only two powder dyes were used during the survey,
which were separately weighed and applied to each dyelot. Dry chemical addi-
tion to the batch was made prior to transferring the material to the mixing
area. Following dry chemical addition (if required), the batch was hand
carried to the mixing area. Dyes weighed in the first floor drug room were
transferred to the second floor drug room mixing area using the elevator.
The dye and dry chemical mixture was manually added into the mixing tank and
the stirrer or mixer was activated.
SPECIFIC MEASUREMENTS AND OBSERVATIONS
The employee monitored was in the major drug room 205 minutes and in the
minor drug room 12 minutes over the 8-hour period (480 minutes). He was
monitored for exposure to participates over a 446 minute period from 3:30
209
-------
p.m. to 10:56 p.m. During that time, his duties required him to enter the
major drug room 14 tines and the minor drug room 4 times. Table 2 presents a
summary of the data and information recorded during the survey. Table 3
presents a list of the dye materials handled during the survey, including the
dye color index number, the number of weighings of each dye, and the total
weight of the weighings of each dye.
ANALYTICAL RESULTS
EPA reported that the analytical method was unable to detect Naphthol
Dyes, the only dye class encountered during the monitoring period. There-
fore, no analytical results are available for this site. The total weight of
all solids filtered from the air in this facility follow (In milligrams dye
per cubic meter air):
Average of 4 monitoring devices in
worker's breathing zone
Drug room area sampler at a weighing
station, first floor drug room*
Drug room area sampler at a weighing
station, second floor drug room*
Total weight
0.77
0.07
0.36
Because there were two drug rooms In operation at this site, one area
monitor was placed in the vicinity of the weighing station in each drug
room.
TABLE 2. SUMMARY OF DATA AND INFORMATION RECORDED DURING SURVEY
A.
Time in work area
Total time monitored
Total time in major drug room
Total time in minor drug room
Lunch break
Time, minutes
446
205
12
Not available
Percent of
monitoring
period
100
46
3
210
-------
TABLE 2 CONTI.
B.
C.
D.
Number of
Work capacity process units
Work load
Units in operation at time of survey
3
2
Powder dyes weighed Number of dyes
Total weighed
Naphthol
Naphthol Salt
Number of Percent,
Powder Dyes weighings %
Total 8 100
Azoic Coupling 6 75
Component 17
Azoic Diazo 2 25
Component 13
2
1
1
Weight of
dyes, pounds
87.27
32.37
54.90
Percent
100
67
Percent
100
50
50
Percent
100
37
63
E.
F.
Number of Percent
Dry chemicals weighed weighings %
Total 6 100
Anhydrous Na?C03 3 50
Reducing agent 3 50
All solid chemicals Number of Percent,
weighed weighings %
Total 14 100
Dyes 8 57
Dry chemicals 6 43
Weight of
, dry chemicals,
pounds
405.00
45.00
360.00
Weight of
all chemicals,
pounds
492.27
87.27
405.00
Percent
100
11
89
Percent
100
18
82
211
-------
TABLE 3. DYE MATERIALS HANDLED DURING THE SURVEY
Total weight of
Dye color index number Number of weighings weighings, pounds
Naphthol Dyes:
Azoic Coupling Component 17 6 32.37
Azoic Diazo Component 13 2 54.90
212
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TEXTILE DRUG ROOM MONITORING STUDY
SITE VISIT REPORT
Site Number 7/7
L. Dyson, Pn.D., C7I.H. "^W* J/jJngers
Health and Hygiene, Inc. PEI Assdc/ates. Inc.
.Prepared for:
U.S. Environmental Protection Agency
Office of Toxic Substances
401 M Street S.W.
Washington. D.C. 20460
213
-------
INTRODUCTION
This survey was conducted as part of an exposure study being performed
as a cooperative effort between the U.S. Environmental Protection Agency
(EPA), the American Textile Manufacturers Institute, Inc. (ATMI), and the
Ecological and Toxicological Association of the Dyestuffs Manufacturing
Industry (ETAD). The study's objective was to determine the extent of
textile workers' exposure to dye dust when weighing and mixing powder dyes.
The sites to be visited were selected to obtain a random sampling of eligible
sites. Contact with the site representative to schedule the site visit was
made by William L. Dyson, Ph.D., C.I.H. of Health and Hygiene, Inc.,
representing ATMI and ETAD. In attendance at the site were Dr. Dyson and
Robert D. Will son, C.I.H. of Beta Associates, subcontractor for PEI
Associates, Inc., representing EPA. The pre-survey meeting was held with
company officials on the afternoon of September 9, 1986. The industrial
hygiene monitoring and recording of data were performed during the third
shift (11:00 p.m. to 7:00 a.m.) on the same day. Company representatives
were very cooperative in assisting with this survey.
214
-------
SITE CHARACTERIZATION
GENERAL
The drug room at site 7/7 is part of a captive dyehouse operating on an
integrated basis. Approximately 1.5 million pounds per year of apperel (both
pieces and whole garment) are dyed in batch operations at this privately
owned facility. Paddle dyeing machines were used for dyeing piece goods and
whole garments; package dye machines were used for dyeing the yarn before it
is knitted. Ten dye machines were available, all of which were operating
during the monitoring period. Fibers dyed are acrylic/modacrylic, cotton,
and polyester fibers. Site operations Include storage, preparation, dyeing,
and finishing.
DRUG ROOM
The drug room is a rectangular room approximately 50 feet long and 14
feet wide, with a ceiling 8-feet 1n height. The room is located on the first
floor of the building and is accessed by two doors at opposite ends of the
room, one leading to the adjacent mixing room and the other to the laboratory
area. Dye weighing and storage areas are located in the drug room; the
mixing room is in an area outside of the drug room. Figure 1 presents a
sketch of the drug room.
Dyes are stored in drums utilizing the floor space along the walls of
the drug room. At the time of the survey, a single row of approximately 15
drums was stored along the north wall of the room and a single row of
215
-------
DTE HOUSE
NS
MIXING
ROOM
\
* EXIT/ENTRANCE
:ELING HEIGHT a ft
14
DRUM STORAGE
_^.y i_
\
\
DRUM
STORAGf ^
\
ORW STORAGE
50 ft 6 in.
COMCHTS
-NO ACTIVE EXHAUST VENTILATION
-NO NET AIRFLOW AT EITHER DOORKAY
nan or o»ts ri* S
udMItt W M1IK
LABORATORY
EXIT/ENTRANCE
Figure 1. Sketch of drug room area.
-------
approximately 25 drums was stored along the south wall of the room. Five
drums were stored near the middle of the room. The drums vary 1n size from
200-250 pound barrels to smaller, 50-100 pound containers. One weighing
station with two scales 1s located at the far north corner of the room near
the exit which leads to the dye house. Dye weighing operations are conducted
at this weighing station; dry chemicals are stored and weighed in an area
outside the drug room.
The general appearance of the drug room was clean. There was no accumula-
tion of dye on the floor, walls, or equipment. All drums of dyes were covered
when 1n storage. No spillage of the powder dyes was observed during the
survey.
The drug room has no mechanical exhaust ventilation. Both doors to the
room were kept open to facilitate air movement within the room. No net
airflow was measured at either entrance on the day of the survey.
Environmental conditions of the drug room (I.e., temperature and baro-
metric pressure) were recorded hourly during the survey and are summarized 1n
Table 1.
TABLE 1. ENVIRONMENTAL CONDITIONS RECORDED
DURING THE SURVEY*
Parameter
Temperature, °F
Barometric pressure, 1n. Hg.
Mean,
8-hour value
80
29.47
Range
Minimum Maximum
80 80
29.46 29.50
Temperature readings were recorded hourly over the 8-hour work shift.
Hourly barometric pressure readings were obtained for the monitoring
period from the local airport's weather bureau.
217
-------
DYE WEIGHER ACTIVITIES
The company employs two full-time dye weighers on both the first and
second shifts, and one full-time dye weigher on the third shift. The term
"dye weigher" does not provide an adequate description of the activities of
these workers. The weighing of dyes comprises only a small portion of their
work day. Duties of the machine operator/dye weigher/mixer include:
0 Relocating drums within the storage area.
0 Weighing dyes and recording weights on dye batch tickets.
0 Transferring weighed dyes from the scale to buckets, which are then
hand carried to the mixing room outside the drug room.
0 Adding hot water to the buckets and mixing the contents in the
bucket with an mixer.
0 Transferring the mixed batch to the dye machines and adding it to
the machine.
0 Operating dye application machines.
0 Cleaning dye storage and weighing areas.
Among other duties, the machine operator/dye weighers employed at this
facility handle, transfer, weigh, and mix dyes. These Individuals do not
handle dry chemicals during normal process operations.
The monitored dye weigher was a 34-year old male. He has been employed
at the company for approximately one year; all of that time has been spent
handling dyes. He had one year of previous dye handling experience.
Training
Company training for dye weighers regarding the safe handling of dyes
s.
consists of use of respiratory protection, and personal protective equipment
(aprons and gloves).
218
-------
Personal Protective Equipment
Company policy requires dye weighers to wear half-mask air-purifying
respirators with organic vapor cartridges and particulate filters, aprons,
and rubber gloves. The respirator worn by the monitored dye weigher during
p
all weighing activities was a Willson Model AR700. No incidences of dermal
contact were noted during the survey.
Personal Habits
The company did not permit employees to drink, eat, or smoke in the drug
room. The monitored dye weigher was observed smoking outside of that area on
his breaks.
Work Activities
Activities of the monitored dye weigher 1n filling each batch ticket
order were as follows: dyes were obtained by walking to a drum containing
the appropriate dye, using a hand scoop to remove an approximate quantity of
the dye, transferring the scoop of dye to the weighing station, pouring the
required amount onto the scale dish, and returning the unused portion of the
dye to the drum. The weighed portion of the dye was transferred to a
stainless steel bucket. This operation was repeated until weighings of all
the dyes specified on the batch ticket had been completed. The stainless
steel bucket containing the weighed dye material for the batch was then hand
carried to the mixing room and mixed with water in the bucket. The mixed dye
solution was then transferred to the dyehouse and poured Into the dyeing
machine. No drum transfers were observed during this survey.
SPECIFIC MEASUREMENTS AND OBSERVATIONS
The employee monitored was 1n the drug room for a total of 16 minutes
over an 8-hour period (480 minutes). He was monitored for exposure to
219
-------
participates over a 369 minute period from 10:52 p.m. to 5:01 a.m. During
that time, his duties required him to enter the drug room three times. Only
three batch weighings were performed during the survey. Due to water con-
tamination potential, while the monitored dye weigher was working 1n the
dyehouse, the filter cassettes upon which the samples were being collected
were assembled in a closed face configuration (from approximately 11:45 pm
until shipment to the laboratory). Table 2 presents a summary of the data
and information recorded during the survey. Table 3 presents a list of the
dye materials handled during the survey, including the dye color index
number, the number of weighings of each dye, and the total weight of the
weighings of each dye.
ANALYTICAL RESULTS
EPA reported that analysis of solids filtered from air 1n the breathing
zone of monitored workers was attempted. Solvent used 1n the analytical
method reacted with a high proportion of Basic Dyes (the only dye class
encountered at this site) which were weighed during the monitoring period.
Therefore, analytical results for this site are unacceptable and will not be
included in the final data analysis. Total weight of solids filtered from
the air follow (in milligrams dye per cubic meter air):
Total
Weight
Average of 2 monitoring devices in worker's breathing 0.27
zone
Drug room area samples at weighing station 0.08
Drug room area samples at drum storage, remote from
weighing area 0.06
220
-------
TABLE 2. SUMMARY OF DATA AND INFORMATION RECORDED DURING SURVEY
A.
B.
Time in work area
Total time monitored
Total time in drug room
Lunch break
Work capacity
Percent of
monitoring
Time, minutes period
Maximum work load
Units in operation at time of survey
C.
D.
E.
F.
Each
G.
Powder dyes weighed
Total weighed
Basic
Dyes
Total
Basic
Dry chemicals weighed
Total
Dyes weighed most
frequently
dye weighed was weighed
Largest quantity
of dyes weighed
"Basic Black M-l"
Basic Yellow 28
Basic Red 49
Basic Green 4
Number of
weighings
7
7
Number of
weighings
0
once.
Number of
weighings
1
1
1
1
369
16
Not available
Number of
process units
10
10
Number of dyes
7
7
Weight of dyes,
Percent grams
100 6,033.97
100 6,033.97
Percent
100
Weight of dyes,
Percent grams
14 2,329
14 1,476
14 866
14 834
100
4
Percent
100
100
Percent
100
100
Percent
100
100
Percent
39
24
14
14
221
-------
TABLE 2. SUMMARY OF DATA AND INFORMATION RECORDED DURING SURVEY
A.
Time in work area
Percent of
monitoring
Time, minutes period
Total time monitored
Total time in drug room
Lunch break
B.
C.
D.
E.
Work capacity
Maximum work load
Units in operation at
Powder dyes weighed
Total weighed
Basic
Dyes
Total
Basic
Dry chemicals weighed
Total
time of survey
Number of
weighings Percent
7 100
7 100
Number of
weighings Percent
0 100
369
16
Not available
Number of
process units
10
10
Number of dyes
7
7
Weight of dyes,
grams
6,033.97
6,033.97
100
4
Percent
100
100
Percent
100
100
Percent
100
100
F. Dyes weighed most
frequently
Each dye weighed was weighed once.
G.
Largest quantity
of dyes weighed
"Basic Black M-l"
Basic Yellow 28
Basic Red 49
Basic Green 4
Number of
weighings
1
1
1
1
Percent
14
14
14
14
Weight of dyes,
grams
2,329
1,476
866
834
Percent
39
24
14
14
222
-------
TABLE 3. DYE MATERIALS HANDLED DURING THE SURVEY
Number of Total weight of
Dye color index number weighings weighing, grams
Basic Yellow 28
Basic Red 46
Basic Red 49
Basic Violet 16
Basic Blue 3
Basic Green 4
"Basic Black M-l"
1
1
1
1
1
1
1
1476.0
78.0
866.0
443.0
7.97
834.0
2329.0
223
-------
TEXTILE DRUG ROOM MONITORING STUDY
SITE VISIT REPORT
Site Number 7/9
William L. Dyson, Ph.D., t.I.H.
Health and Hygiene, Inc.
/ Le*11e/J. UngearC.I.H. }
'—'Associates, Inc.
Prepared for:
U.S. ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF TOXIC SUBSTANCES
401 M STREET, S.W.
WASHINGTON, DC 20460
225
-------
INTRODUCTION
This survey was conducted as part of an exposure study being performed
as a cooperative effort between the U.S. Environmental Protection Agency
(EPA), the American Textile Manufacturers Institute, Inc. (ATMI), and the
Ecological and Toxicological Association of the Dyestuffs Manufacturing
Industry (ETAD). The study's objective was to determine the extent of
textile workers' exposure to dye dust when weighing and mixing powder dyes.
The sites to be visited were selected to obtain a random sampling of eligible
sites. Contact with the site representative to schedule the site visit was
made by William L. Dyson, Ph.D., C.I.H. of Health and Hygiene, Inc.,
representing ATMI and ETAD. In attendance at the site were Dr. Dyson and
Donald L. Unruh, C.I.H., IT Corporation, subcontractor for PEI Associates,
Inc., representing EPA. The pre-survey meeting was held with company
officials on May 4, 1987. The industrial hygiene monitoring and recording of
data were performed during the first shift (8:00 a.m. to 4:00 p.m.) on May 5,
1987. Company representatives were very cooperative in assisting with this
survey.
226
-------
SITE CHARACTERIZATION
GENERAL
The drug room at site 7/9 is part of a dyehouse operating on a commis-
sion basis. Approximately 0.9 million pounds of garments per year are dyed
in batch operations at this privately owned facility. Seven paddle dyeing
machines were available, all of which were in operation during the monitoring
period. This operation consists of dyeirvg partially fabricated garments of
cotton and/or nylon fibers. Site operations include storage, preparation,
dyeing, and packaging for shipment back to the garment manufacturer.
DRUG ROOM
The general building is co-leased with a furniture manufacturing com-
pany. The drug room, located in the southeast central portion of the work
area, is a rectangular room approximately 35 feet long and 15 feet wide, with
a 12-foot ceiling. The room is accessed by a door at the west end of the
room which leads to the dye vats. No mixing takes place 1n the drug room.
The drug room includes drum storage areas 1n the western half of the room and
one dye weighing station equipped with two scales in the eastern half of the
room. Figure 1 presents a sketch of the drug room.
Dyes are stored in small drums in open storage bins located against the
north wall of the drum storage room and in larger drums on the floor in the
center and at the south end of the room. Small bottles of liquid chemicals
and dye samples are located in an open cabinet next to the weigh station.
227
-------
NO ROOM VENTILATION OF ANY KIND.
ROOMS WERE ONCE A LOCKED STORAGE VAULT.
NJ
NJ
00
TA ftVF *•
IU UTt * _-~~
VA1S *
FLOOR TO CEILING OPEN STORAGE
BINS FOR SMALL DRUMS OF DYES
i /
DYES \ |
•^' VQOQO ™f •
fc. AID pi nu V » \ *
60606000®
SMALL BOTTLES OF
LIQUID CHEMICALS
AND DYE SAMPLES
IN OPEN CABINET
LOCKER
* ». cO it *n
^ DYES ^
A
• •
^SCALES *"
1 t
/;'
/ /
BOOKCASE -
'
-+-
SINK AND WORKTABLE
g DD
\
15
FINISH
.WEIGHINGS
CART
ft
1 J 1 I v -
HOT PLATE-USED
FOR COFFEE
UHNO
• UEKMIN6 STATIOH
• MC* S/WUH AT DIUN STOMCe
A *U SAmCR A! MCIGMIK STAIIW
'HNOTCS FLOM Of OTES FMH STOMEC
-•* TMBOUCH UCICHIKG 10 NIIING
LOCATION: SOUTHEAST
CENTRAL AREA OF WORK AREA
Figure 1. Sketch of drug room area.
-------
The drums vary in size from 200 to 250-pound barrels to smaller, 50 to 100-
pound containers.
For weighing of the powder dyes, two scales are located on a table which
is situated in the northeast corner of the weighing room.
The general appearance of the drug room was very clean. The walls,
equipment, floors, and inventory were clean of accumulated dye material. No
spills were observed on the day of the survey.
The drug room was not equipped with a local exhaust ventilation system
for the purpose of removing airborne dye particles. Because the drug room
area occupies what was once a locked storage vault, no room ventilation
exists. The general building was equipped with wall and roof fans and gas
heaters for winter heating. Air flows both in and out of the drug room at
its entrance.
A floor drain is located in the drug room drum storage area. Reportedly,
the floor is hosed down during cleaning activities.
Environmental conditions of the drug room (i.e., temperature, humidity,
and barometric pressure) were recorded hourly during the survey and are
summarized in Table 1.
TABLE 1. ENVIRONMENTAL CONDITIONS RECORDED DURING THE SURVEY*
Parameter
Temperature, °F
Relative humidity, %
Barometric pressure, in. Hg.
Mean,
8-hour value
73
72
29.60
Minimum
67
63
29.51
Range
Maximum
75
81
29.66
*
Readings of each parameter were recorded hourly over the 8-hour work shift.
229
-------
DYE WEIGHER ACTIVITIES
The company employs one full-time dye weigher on the first shift only.
Her duties include:
0 Weighing dyes and recording weights on batch tickets.
0 Transferring dyes from the scale to a sealed plastic container.
0 Cleaning dye storage and weighing areas.
The dye weigher employed at this facility is Involved 1n the handling and
weighing of dyes only. There is no transferring of weighed dyes to the
dyeing machines by the dye weigher; the workers from the dyehouse retrieve
their own dye batches from the drug room. Dyes are mixed in the paddle tanks
prior to addition of the garments to be dyed.
The monitored dye weigher was a 42-year old female. She has been em-
ployed at the company for approximately one year, all of which time has been
spent handling dyes. She had no previous dye handling experience.
Training
The monitored dye weigher received no specific training regarding the
safe handling of dyes. She reads the labels on the dye drums for information
concerning the dyes.
Personal Protective Equipment
Personal protective equipment utilized by the monitored dye weigher in
the drug room included a smock top with long sleeves and rubber gloves. The
monitored dye weigher wore her gloves during all weighing activities. No
other personal protective equipment was available at the site.
Personal Habits
The monitored dye weigher did not smoke, eat or drink inside the weigh-
ing area. As part of her personal hygiene, she washed her gloves after each
230
-------
weighing. In prior employment, this worker was a technician in a micro-
biology laboratory, and some of the previously learned safe work practices
have been carried over to this job.
Work Activities
The dye weigher's activities in filling each batch ticket order were as
follows: dyes were obtained by walking to a drum in the storage area con-
taining the appropriate dye and using a hand scoop or a plastic tub to remove
an approximate quantity of the dye, transferring the scoop of dye to the
weigh station and pouring the required amount into the scale dish, returning
the unused portion of the dye to the drum, and transferring the weighed
portion of the dye to a plastic container. This operation was repeated until
all of the dye weighings specified on the batch ticket had been completed.
The plastic container was then sealed closed. A dyehouse worker collects the
container of dye and manually transports it to the use area.
SPECIFIC MEASUREMENTS AND OBSERVATIONS
The monitored dye weigher was in the drug room for a total of 320 min-
utes over the 8-hour period (480 minutes). During that time, her duties
required her to enter the drug room six times. She was monitored for expo-
sure to particulates over a 435-minute period from 8:15 a.m. to 3:30 p.m.
Table 2 presents a summary of the data and Information recorded during the
survey. Table 3 presents a list of the dye materials handled during the
survey, including the dye color Index number, the number of weighings of each
dye, and the total weight of the weighings of each dye.
231
-------
ANALYTICAL RESULTS
Solids filtered from the air in this facility were analyzed by EPA for
total dye content. Total weight of all solids and analytical results from
the four filtering devices, corrected for recovery, follow (in milligrams dye
per cubic meter air):
Active Total
Colorants Commercial Dyes Weight
Average of 2 monitoring 0.01 0.01 0.19
devices in worker's breathing
zone
Drug room area sampler at <0.01 0.01 0.11
weighing station
Drug room area sampler at drum <0.01 <0.01 0.10
storage, remote from weighing
area
232
-------
TABLE 2. SUMMARY OF DATA AND INFORMATION RECORDED DURING SURVEY
Percent of
monitoring
A.
Time in work area
Total time monitored
Total time in drug room
B.
C.
D.
E.
F.
Lunch and breaks
Work capacity
Maximum work load
Units in operation at
Powder dyes weighed
Total
Direct
Dyes
Total
Direct
Dry chemicals weighed
Total
All chemicals weighed
Total
Dyes
Dry chemicals
time of survey
Number of
weighings
33
33
Number of
weighings
0
Number of
weighings
33
33
0
Time, minutes
435
320
NA
Number of
process units
7
7
Number of dyes
9
9
Weight of dyes
Percent grams
100 15,510.00
100 15,510.00
Weight of
dry chemicals
Percent grams
100 15,510.00
100 15,510.00
0 0.000
period
100
74
NA
Percent
100
100
Percent
100
100
>
Percent
100
100
*
Percent
100
100
0
(continued)
233
-------
TABLE 2 (continued)
G.
H.
Dyes weighed most
frequently
Direct Red 75
Direct Yellow 106
Direct Red 72
Largest quantity
of dyes weighed
Direct Red 72
Direct Blue 160
Direct Red 75
Number of
weighings
9
8
6
Number of
weighings
6
2
9
Percent
27
24
18
Percent
18
6
27
Weight of dyes,
grams
2278.13
673.95
8150.94
Weight of dyes,
grams
8150.94
3895.40
2278.13
Percent
15
4
53
Percent
53
25
15
NA - Not available.
234
-------
TABLE 3. DYE MATERIALS HANDLED DURING THE SURVEY
Total weight
Number of of weighings,
Dye color index number weighings grams
Direct Dyes:
Direct Yellow 106 8 673.95
Direct Red 72 6 8150.94
Direct Red 75 9 2278.13
Direct Red 9 1 2.33
Direct Violet 9 1 1.74
Direct Blue 25 1 18.60
Direct Blue 218 4 462.70
Direct Blue 189 1 26.21
Direct Blue 160 2 3895.40
!35
-------
TEXTILE DRUG ROOM MONITORING STUDY
SITE VISIT REPORT
Site Nuirber 8/0
William L. Dyson, Ph.D., C7
Health and Hygiene, Inc.
XUn
Associates, Inc
Prepared for:
U.S. ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF TOXIC SUBSTANCES
401 M STREET, S.W.
WASHINGTON, DC 20460
237
-------
INTRODUCTION
This survey was conducted as part of an exposure study being performed
as a cooperative effort between the U.S. Environmental Protection Agency
(EPA), the American Textile Manufacturers Institute, Inc. (ATMI), and the
Ecological and Toxicological Association of the Dyestuffs Manufacturing
Industry (ETAD). The study's objective was to determine the extent of
textile workers' exposure to dye dust when weighing and mixing powder dyes.
The sites to be visited were selected to obtain a random sampling of eligible
sites. Contact with the site representative to schedule the site visit was
made by William L. Dyson, Ph.D., C.I.H. of Health and Hygiene, Inc.,
representing ATMI and ETAD. In attendance at the site were Dr. Dyson and
Donald L. Unruh, C.I.H., IT Corporation, subcontractor for PEI Associates,
Inc., representing EPA. The pre-survey meeting was held with company
officials on March 10, 1987. The industrial hygiene monitoring and recording
of data were performed during the first shift (7:00 a.m. to 7:00 p.m.) on the
following day. Company representatives were very cooperative in assisting
with this survey.
238
-------
SITE CHARACTERIZATION
GENERAL
The drug room at site 8/0 is part of a captive dye house operating on an
integrated basis. Approximately six million pounds of belting per year are
dyed at this privately owned facility. Four continuous dyeing machines were
available, but only one was in operation at the time of the survey. Fibers
dyed are nylon, polyester, and cotton. Site operations include storage,
preparation, dyeing, and finishing.
DRUG ROOM
There was no drug room isolated from the balance of the plant. Dyes
were weighed in the production area which is a rectangular room approximately
110 feet long and 105 feet wide. In this study, the entire production area
was considered to be the drug room. A weighing station housing one scale is
located at the northeast corner. Dye drums are stored next to the weighing
station and the adjacent stairwell. The majority of the room Is occupied by
four dye machines and their associated elevated mixing vats. Feed boxes of
greige seat belt materials are stored along the southeast wall. Figure 1
presents a sketch of the dye weighing/production area.
Dyes are stored In drums next to the weigh station. The drums vary in
size from 200- to 250-pound barrels to smaller 50- to 100-pound containers.
239
-------
N
V
WEIGH SCALE AND SINK
UNDER PLATFORM THAT
HOLDS DYE VATS
,DYE DRUMS
MIXING -
VATS — ""fc
CONTINUOUS DYE MACHINE
O O O O
CONTINUOUS DYE MACHINE
i^p jo o o &VQ O-,
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VENTILATION DUCT ^
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II UPHILLS J
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ol \
^"^MIXING \
VATS .
n
o o o/;|
a
O O O O
CONTINUOUS DYE MACHINE
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VATS |
CEILING /
FAN /
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/
Ililiniif
aor*™
VATS
aaa
aaa
oac*
aaa
aaa
aaa
aaa
aaa
ft
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aaa
aaa
aaa
aaa
aaa
aaa
aaa
i
BELT
STOCK
FEED
BOXES
?S
C
u.
I
LJ
O
ae
a.
105 ft : ^
DRUG AREA IS IN THE PLANT AND THERE ARE NO BOUNDARIES TO BLOCK ANY AIR FLOWS.
LEGEND
• WEIGHING STATION
• AREA SAMPLER AT DRUM STORAGE
A AREA SAMPLER AT WEIGHING STATION
'DENOTES FLOW OF DYES FROM STORAGE
~ THROUGH WEIGHING TO MIXING
NOTE: DRUG AREA IS IN THE PLANT AREA
-THE AREA IS OPEN, THEREFORE
GENERAL AREA AIR FLOW IS NOT
RESTRICTED.
Figure 1. Sketch of dye weighing/production area.
240
-------
The general appearance of the area was good. The walls and equipment
were clean of dyestuff; the inventory was moderately clean. It was reported
that the floors are cleaned weekly.
The production room was equipped with no local exhaust ventilation
systems for the purpose of removing airborne dye particles. Air is supplied
to the room by overhead ventilation ducts situated between the dyeing
machines and circulated by two ceiling fans.
Floor drains are located in the area to facilitate drainage for the
continuous wash baths. The floors are cleaned weekly. Spills of dye mate-
rial were left on the floor for the cleaning man to sweep and mop up.
Environmental conditions of the production area (i.e., temperature,
humidity, and barometric pressure) were recorded hourly during the survey and
are summarized in Table 1.
TABLE 1. ENVIRONMENTAL CONDITIONS RECORDED DURING THE SURVEY*
Parameter
Temperature, °F
Relative humidity, %
Barometric pressure, torr
Mean,
8-hour value
64
62
735
Minimum
63
52
733
Range
Maximum
67
70
736
*
Readings of each parameter were recorded hourly over the 8-hour work shift.
DYE WEIGHER ACTIVITIES
On each of two 12-hour shifts, four continuous dye machine front end
operators (one per range) are responsible for dye weighing operations for his
own unit. Their primary duty, however, 1s operating the dyeing machines.
Their specific duties relating to dye handling Include:
241
-------
0 Weighing dyes and chemicals and recording weights on batch tickets.
Typically, weighings to supply the initial charge and color cor-
rections occur about four times per shift.*
c Transferring dyes from the scale to a bucket and carrying the
bucket to the mixing vats.
0 Dumping the dye material into the open mixing vat.
0 Cleaning dye storage, mixing, dyeing, and weighing areas.
The dye weighers employed at this facility are involved in the handling,
transferring, and weighing of powder and liquid dyes and chemicals.
The monitored dye weigher was a 30-year old male. He has been employed
at the company for 14 years; ten of those years have been spent handling
dyes. He had no previous dye handling experience.
Training
No formal dye weigher training regarding the safe handling of dyes was
provided by the company. Dye weighers are given a respirator and instructed
to wear it when weighing powder dyes. A file of Material Safety Data Sheets
(MSDS's) was maintained in the production office.
Personal Protective Equipment
Personal protective equipment utilized by the monitored dye weigher
during all weighing activities included a 3M half-mask respirator with high
efficiency filters and steel-toed shoes. The monitored dye weigher utilized
his respirator but also has a full beard which may prevent it from maintain-
ing an adequate seal.
Dye batches reportedly are weighed about 4 times per shift. On this day,
the first dyelot on the range in operation required weighing of the initial
charge and 3 or 4 color corrections. At the conclusion of the monitoring
period, the second dyelot on the range had required weighing of the Initial
charge and one color correction.
242
-------
Personal Habits
The monitored dye weigher/machine operator was observed eating and
smoking in the work area. The machine operators are given no official breaks
or meal periods; therefore, the operator next to him must cover for a worker
when he goes to the restroom or the canteen*. The monitored dye weigher
washed his hands after each batch weighing.
Work Activities
The dye weigher's activities in filling each batch ticket order were as
follows: dyes were obtained by walking to a drum in the storage area con-
taining the appropriate dye, using a hand scoop to remove an approximate
quantity of the dye, transferring the scoop of dye to the weigh station,
pouring the required amount into the scale dish, returning the unused portion
of the dye to the drum, and transferring the weighed portion of the dye to a
bucket. This operation was repeated until all of the dye weighings specified
on the batch ticket had been completed. The batch was then hand carried and
emptied into the open mixing vat.
SPECIFIC MEASUREMENTS AND OBSERVATIONS
The monitored dye weigher was in the production area for a total of 437
minutes over the 8-hour period (480 minutes) of study which covered the first
two-thirds of his 12-hour shift. During that time, his duties required him
to be at the weighing station or at his continuous dyeing machine eight
times. He was monitored for exposure to particulates over a 474-minute
The work area is essentially a dye application area, although dyes are
weighed within the confines of this room. As the operation Is continuous,
the application equipment is monitored by a worker whenever it is in opera-
tion.
243
-------
period from 7:07 a.m. to 3:01 p.m. Table 2 presents a summary of the data
and information recorded during the survey. Table 3 presents a list of the
dye materials handled during the survey, including the dye color index
number, the number of weighings of each dye, and the total weight of the
weighings of each dye.
ANALYTICAL RESULTS
Solids filtered from the air in this facility were analyzed by EPA for
total dye content. Total weight of all solids and analytical results from
the four filtering devices, corrected for recovery, follow (in milligrams dye
per cubic meter air):
Active Total
Colorants Commercial Dyes Weight
Average of 2 monitoring 0.01 0.04 0.21
devices in worker's breathing
zone
Drug room area sampler at 0.01 0.03 0.13
weighing station
Drug room area sampler at drum 0.01 0.04 0.16
storage, remote from weighing
area
244
-------
TABLE 2. SUMMARY OF DATA AND INFORMATION RECORDED DURING SURVEY
A.
Time in work area
Total time monitored
Total time in production room
Lunch and breaks
B.
C.
D.
E.
F.
Work capacity
Maximum work load
Units in operation at
Powder dyes weighed
Total
Disperse
Dyes
Total
Disperse
Dry chemicals weighed
Total
All dry
materials weighed
Total
Dyes
Dry chemicals
Percent of
monitoring
Time, minutes period
474 100
437 92
NA NA
Number of
process units Percent
4 100
time of survey 1 25
Number of
weighings
11
11
Number of
weighings
0
Number of
weighings
11
11
0
Number of dyes Percent
3 100
3 100
Weight of dyes,
Percent pounds Percent
100 4.66 100
100 4.66 100
Weight of
all chemicals,
Percent pounds Percent
100 4.66 100
100 4.66 100
0 0.00 0
G.
Dye weighed most
frequently
Disperse Red 72
Number of
weighings
6
Weight of dyes,
Percent pounds Percent
55 1.78 38
(continued)
245
-------
TABLE 2 (continued)
W. Largest quantity Number of Weight of dyes,
of dye weighed weighings Percent pounds Percent
Disperse Blue 27 3 27 2.48 53
NA - Not available.
246
-------
TABLE 3. DYE MATERIALS HANDLED DURING THE SURVEY
Total weight
Number of of weighings,
Dye color index number weighings pounds
Disperse Dyes:
Disperse Red 72 6 1.78
Disperse Blue 27 3 2.48
Disperse Blue 60 2 0.40
247
-------
TEXTILE DRUG ROOK MONITORING STUDY
SITE VISIT REPORT
Site Number 8/6
William L. Dyson, Ph.D., C7I.H.
Health and Hygiene, Inc.
ssedates, Inc.
Prepared for:
U.S. ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF TOXIC SUBSTANCES
401 M STREET. S.W.
WASHINGTON, DC 20460
249
-------
INTRODUCTION
This survey was conducted as part of an exposure study being performed
as a cooperative effort between the U.S. Environmental Protection Agency
(EPA), the American Textile Manufacturers Institute, Inc. (ATMI), and the
Ecological and Toxicological Association of the Dyestuffs Manufacturing
Industry (ETAD). The study's objective was to determine the extent of
textile workers' exposure to dye dust when weighing and mixing powder dyes.
The sites to be visited were selected to obtain a random sampling of eligible
sites. Contact with the site representative to schedule the site visit was
made by William L. Dyson, Ph.D., C.I.H. of Health and Hygiene, Inc.,
representing ATMI and ETAD. In attendance at the site were Dr. Dyson and
Leslie J. Ungers, C.I.H., Senior Industrial Hyglenist for PEI Associates,
Inc., representing EPA. The pre-survey meeting was held with company
officials on the morning of October 7, 1986. The industrial hygiene
monitoring and recording of data were performed during the first shift (7:00
a.m. to 3:00 p.m.) on October 9, 1986. Company representatives were very
cooperative in assisting with this survey.
250
-------
SITE CHARACTERIZATION
GENERAL
The drug room at site 8/6 is part of a dyehouse operating on both an
integrated and commission basis. Approximately 3 million pounds of novelty
yarns per year are dyed with powder dyes in batch operations at this private-
ly owned facility. Nine dyeing machines were available, seven of which were
in operation at the time of the survey. The machines were developed and
constructed by the company. Fibers dyed are acrylic/modacrylic, acetate,
rayon, wool, nylon, polyester, cotton, polypropylene, and silk. Site opera-
tions include storage, preparation, dyeing, and drying.
DRUG ROOM
The drug room, located on the first floor of the plant building, is a
rectangular room approximately 40 feet long and 25 feet wide, with a 12-foot
celling. The room is accessed by a door at one end of the room which leads
to the mixing area. The mixing area is a separate area outside of the drug
room. The drug room Includes drum storage areas and two dye weighing sta-
tions, each equipped with one scale. Figure 1 presents a sketch of the drug
room.
Dyes are stored in drums on drum shelves located against the walls of
the drug room. Drums of dyes used frequently are stored on the floor near
the weighing stations. The drums vary in size from 200- to 250- pound barrels
to 50- to 100-pound containers.
251
-------
ENTRANCE
MIXING
AREAS
TEN TRANSFER BAYS
WITH ACCESS DOORS
TO MIXING AREA
, L J , t ^
xORUM SHELVES
-*.
TLN BAYS FOR TEMPORARY STORAGE
odoooooo
G
(
(
, o
A
D O
5 6
1?
^ N f~*\
1 I w
1 » Or
; 1 o
-x \ O
1
\ Q
~^2nd SCALE O
(NOT USED O
DURING SURVEY) ^
*•
DRUM
-SHELVES
AIR
-* CONDITIONER
JC
JC
,-»
)
L-HYDROTHERMOGRAPH DRUMs""^ f^\
O O O O
DRUM
.-SHELVES
12 ft
CEILINGS
40 ft
NOTE: HEATED AIR SUPPLIED FROM
OVERHEAD DUCTING. NO MAKEUP
AIR PLENUM.
IEGEND
• WEIGHING STATION
• AREA SAMPLER AT DRUM STORAGE
A ARCA SAMPLER AT WEIGHING STATION
'DENOTES FLOW OF DYES FROM STORAGE
-^ THROUGH WEIGHING TO NIXING
Figure 1. Sketch of the drug room area.
252
-------
For weighing of the powder dyes, two "all scales are located on two
tables, which are situated next to 10 temporary storage bays with access
doors to the mixing area. One of the scales was not used during the survey.
Small quantities of dry chemicals are stored in the drug room, however, no
dry chemicals were weighed during the survey.
The general appearance of the drug room was fair. There were small
stains and some accumulation of dust on the walls. There was also a small
accumulation of dye powder on the equipment, drum tops, and floors.
The drug room was not equipped with a local exhaust ventilation system
for the purpose of removing airborne dye particles. The room was equipped
with general heating and air conditioning separate from the rest of the
building. Air is supplied from overhead ducts and there is no makeup air
plenum, thereby causing a slight positive pressure compared to the other
plant areas.
Floor drains are located in the drug room to facilitate drainage when
the floor is hosed down during cleaning activities; however, this activity
was not observed during the survey. The accumulation of dye powder on the
floor indicates that floor washing activities are infrequent.
Environmental conditions of the drug room (i.e., temperature, humidity,
and barometric pressure) were recorded hourly during the survey and are
summarized in Table 1.
253
-------
TABLE 1. ENVIRONMENTAL CONDITIONS RECORDED DURING THE SURVEY*
Parameter
Temperature, °F
Relative humidity, %
Barometric pressure, in. Hg.
Mean,
8-hour value
69
72
30.15
Minimum
68
70
30.11
Range
Maximum
76
73
30.17
*
Readings of each parameter were recorded hourly over the 8-hour work shift.
DYE WEIGHER ACTIVITIES
The company employs one full-time weigher on each of two shifts. Duties
include:
0 Weighing dyes and recording weights on batch tickets.
0 Transferring dyes from the scale to a paper bag and passing the bag
through the bay doors into the mixing areas. A person in the mixing
room receives the dyes and transfers the material into the mixing
vessel.
0 Cleaning dye storage, and weighing areas.
The dye weighers employed at this facility are involved in the handling,
transferring, and weighing of dyes and dry chemicals, although no handling of
dry chemicals was observed on the day of the survey. All dye weigher activities
outside of the drug room were associated with non-dye related tasks, e.g.,
coffee breaks and discussions with the supervisor.
The monitored dye weigher was a 25-year old female. She has been employed
at the company for 6.5 years; four of those years have been spent handling
dyes. She had no previous dye handling experience.
Training
Specific employee training regarding the safe handling of dyes was
provided in the literature included in the company hazard communications
program.
254
-------
Personal Protective Equipment
Personal protective equipment utilized by the dye weighers in the drug
room included a 3M particulate dust mask, apron, safety glasses, and latex
gloves. The monitored dye weigher used the dust mask and gloves at all times
during the survey; however, it was observed that dermal contact occurred on
the monitored dye weigher's arms as a result of her need to reach into the
drums to scoop out dye.
Personal Habits
The weigher was observed drinking in the drug room. She did not smoke
inside the weighing area. The weigher washed her hands before taking breaks
and before leaving for lunch.
Work Activities
The dye weigher's activities 1n filling each batch ticket order were as
follows: dyes were obtained by walking to a drum in the storage area con-
taining the appropriate dye and using a hand scoop to remove an approximate
quantity of the dye, transferring the scoop of dye to the weigh station and
pouring the required amount into the scale dish, returning the unused portion
of the dye to the drum, and transferring the weighed portion of the dye to a
paper bag. This operation was repeated until all of the dye weighings spe-
cified on the batch ticket had been completed. The batch was then hand
carried to the mixing area by passing the paper bag containing the batch of
dye through one of 10 bay access doors.
SPECIFIC MEASUREMENTS AND OBSERVATIONS
The monitored dye weigher was in the drug room for a total of 413
minutes over the 8-hour period (480 minutes). During that time, her duties
255
-------
required her to enter the drug room four times. She was monitored for expo-
sure to particulates over a 434-minute period from 7:28 a.m. to 2:42 p.m.
Table 2 presents a summary of the data and Information recorded during the
survey. Table 3 presents a list of the dye materials handled during the
survey, including the dye color index number, the number of weighings of each
dye, and the total weight of the weighings of each dye.
ANALYTICAL RESULTS
Solids filtered from the air in this facility were analyzed by EPA for
total dye content. Total weight of all solids and analytical results from
the four filtering devices, corrected for recovery, follow (in milligrams dye
per cubic meter air):
Active Total
Colorants Commercial Dyes Weight
Average of 2 monitoring 0.19 0.51 0.55
devices in worker's breathing
zone
Drug room area sampler at 0.03 0.09 0.11
weighing station
Drug room area sampler at drum 0.06 0.16 0.23
storage, remote from weighing
area
256
-------
TABLE 2. SUMMARY OF DATA AND INFORMATION RECORDED DURING SURVEY
A.
B.
Time in work area
Total time monitored
Total time in drug room
Lunch and breaks
Work capacity
Maximum work load
Time,
Percent of
monitoring
minutes period
434
413
NA
Number of
process units
Units in operation at time of survey
C.
D.
E.
F.
Powder dyes weighed
Total
Acid
Neutral Premetallized
Acid Metallized
Disperse
Basic
Reactive
Dyes
Total
Acid
Neutral Premetallized
Acid Metallized
Disperse
Basic
Reactive
Dry chemicals weighed
Total
All chemicals weighed
Total
Dyes
Dry chemicals
Number of
weighings
259
6
8
4
33
58
150
Number of
weighings
0
Number of
weighings
259
259
0
Number
Percent
100
2
3
2
13
22
58
Percent
100
100
0
9
7
of dyes
25
1
2
1
5
4
12
Weight of dyes
grams
73,496
702
1,110
617
4,225
15,841
51,001
Weight of
dry chemicals
grams
73,496
73,496
0.000
100
95
NA
Percent
100
78
Percent
100
4
8
4
20
16
48
»
Percent
100
1
2
<1
6
22
69
*
Percent
100
100
0
(continued)
257
-------
TABLE 2 (continued)
G.
H.
Dyes weighed most
frequently
"Reactive Red U-4"
Reactive Yellow 125
"Reactive Blue U-3"
Basic Red 29
Basic Yellow 11
Largest quantity
of dyes weighed
"Reactive Red U-4"
Reactive Yellow 125
Reactive Blue 116
Basic Red 29
Basic Yellow 11
Number of
weighings
41
39
32
20
20
Number of
weighings
41
39
2
20
20
Percent
16
15
12
8
8
Percent
16
15
1
8
8
Weight of dyes,
grams
' 15,664
13,267
4,130
7,626
6,114
Weight of dyes,
grams
15,664
13,267
13,161
7,626
6,114
Percent
21
18
6
10
8
Percent
21
18
18
10
8
NA - Not available.
258
-------
TABLE 3. DYE MATERIALS HANDLED DURING THE SURVEY
Dye color index number
Number of
weighings
Total weight
of weighings,
grams
Acid Dyes:
Acid Red 357
Neutral Premetallized Dyes;
Acid Yellow 121
Acid Brown 384
Acid Metallized Dyes:
Acid Blue 158
Disperse Dyes:
2
6
702
51
1,059
617
Disperse Orange 30
Disperse Red 211
Disperse Red 82
Disperse Blue 60
Disperse Blue 79
Basic Dyes:
Basic Yellow 11
Basic Red 29 ,
Basic Blue 69*
Basic Blue 45
Reactive Dyes:
Reactive Yellow 25a
Reactive Yellow 27
Reactive Yellow 125
"Reactive Red U-4"
Reactive Red 40
Reactive Violet 33
Reactive Blue 29
Reactive Blue 114a
Reactive Blue 116
Reactive Blue 21
"Reactive Blue U-3"
"Reactive Black U-l"
10
9
2
1
11
20
20
16
2
2
7
39
41
10
2
5
1
2
3
32
6
1,923
914
123
180
1,085
6,114
7,626
2,071
30
230
448
13,267
15,664
673
852
810
960
13,161
480
4,130
326
Characterized by dye weigher as relatively dusty.
259
-------
TEXTILE DRUG ROOM MONITORING STUDY
SITE VISIT REPORT
Site Number 8/8
William L. Dyson, Ph.D..I.H.
Health and Hygiene, Inc.
ssociates , Inc.
Prepared for:
U.S. ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF TOXIC SUBSTANCES
401 M STREET, S.W.
WASHINGTON, DC 20460
261
-------
INTRODUCTION
This survey was conducted as part of an exposure study being performed
as a cooperative effort between the U.S. Environmental Protection Agency
(EPA), the American Textile Manufacturers Institute, Inc. (ATMI), and the
Ecological and Toxicological Association of the Dyestuffs Manufacturing
Industry (ETAD). The study's objective was to determine the extent of
textile workers' exposure to dye dust when weighing and mixing powder dyes.
The sites to be visited were selected to obtain a random sampling of eligible
sites. Contact with the site representative to schedule the site visit was
made by William L. Dyson, Ph.D., C.I.H. of Health and Hygiene, Inc.,
representing ATMI and ETAD. In attendance at the site were Dr. Dyson and
Donald L. Unruh, C.I.H., subcontractor for PEI Associates, Inc., representing
EPA. The pre-survey meeting was held with company officials on the afternoon
of March 12, 1987. The industrial hygiene monitoring and recording of data
were performed during the second shift (4:00 p.m. to 12:00 a.m.) of the same
day. Company representatives were very cooperative in assisting with this
survey.
262
-------
SITE CHARACTERIZATION
GENERAL
The drug room at site 8/8 is part of a captive dye house operating on an
integrated basis. Approximately 2.25 million pounds of warp yarn per year
are dyed in batch operations at this privately owned facility. Four beam
dyeing machines were available, all of which were in operation at the time of
the survey. Fibers dyed are rayon, polyester, and cotton. Site operations
include storage, preparation, dyeing, drying, and weaving of Me dyed yarn.
DRUG ROOM
The drug room, located in the south end of the plant building, is a
rectangular room approximately 20 feet long and 14 feet wide, with a 18-foot
ceiling. The room is directly connected to the mixing and drum storage
areas. The drug room includes drum storage areas and two dye weighing sta-
tions, the first with one scale and the second with two scales. Figure 1
presents a sketch of the drug room.
Dyes are stored in drums in a drum storage room that measures approxi-
mately 55 feet by 25 feet and connects to the drug room. Drums of dyes used
frequently are stored on the floor near the weighing stations. The drums
vary 1n size from 200- to 250-pound barrels to smaller, 50- to 100-pound
containers.
263
-------
MIX
TANKS
HOODS
FAN IN
WINDOW
WINDOW
MIX
TANKS
1
^
-
N
W
50
)W-
t
.
^
— ^
V \
\
^
ft
/
1
1 /
/
I
OFFICE/
QC LAB
DRY DYES
/ I
Op C
o°
x*^lf^ S
ff
r*iFS>* x-\
SSK 8
^-y^ \ /-V
—, / \ O
z / >^*Q
r*% / nov nvcc '^'x
"» / 0R¥ DYES ^.
PC"
d)°
'O
OD
1
.OQ
OOO O
ooo o
ooo o
ooo o
ooo, p
OOC£Y J&
ooo t>
ooo o
ooo\ /o
OOO \ i O
OOO \l O
ooo 'i o
OOO 1 O
OOO i O
OOO | O
OOO 1 O
ooo ; o
ooo/ o
'06.00000060000
ALL PASSAGEWAYS OPEN
TO THE PLANT
GENERAL AIR FLOWS
TWO OF WEIGH SCALES ARE IN
A HOOD-LIKE STRUCTURE BUT
THERE IS NO VENTILATION.
DYE ROOM IS ON SOUTH END
OF BUILDING.
LEGEND
N
55 ft
26 ft
WEIGHING STATION
• AREA SAMPLER AT DRUM STORAGE
A AREA SAMPLER AT WEIGHING STATION
'DENOTES FLOW OF DYES FROM STORAGE
- THROUGH WEIGHING TO MIXING
Figure 1. Sketch of drug room area.
254
-------
For weighing of the powder dyes, two small scales are located on a
table, and one scale is located on the floor.
The general appearance of the drug room was poor. There was some ac-
cumulation of dye material on the walls. There were also stains and an
accumulation of dye material on the equipment, drum tops, and floors. The
floor was swept only along the main passageways, leaving an accumulation of
dyestuff between the dye drums and equipment.
The largest of the weigh station scales was equipped with a hood-like
structure, but it was not connected to any active local exhaust ventilation.
A similar hood was in place on one of the dye drums which appeared to be
dustiest and was used frequently. This location is likewise not provided
with local exhaust ventilation. Air is supplied to the room from open win-
dows and window exhaust fans.
The floor is composed of wood, in which there are no floor drains.
Environmental conditions of the drug room (i.e., temperature, humidity,
and barometric pressure) were recorded hourly during the survey and are
summarized in Table 1.
TABLE 1. ENVIRONMENTAL CONDITIONS RECORDED DURING THE SURVEY*
Parameter
Temperature, °F
Relative humidity, %
Barometric pressure, torr
Mean,
8-hour value
76
53
729
Minimum
71
48
728
Range
Maximum
80
57
729
Readings of each parameter were recorded hourly over the 8-hour work shift.
265
-------
DYE WEIGHER ACTIVITIES
The company employs one dye weigher on each of three Shifts who performs
other tasks in addition to weighing dyes. Dye batches are mixed in the drug
room two or three times a shift; the dye weigher spends the remainder of the
shift in other areas of the plant. His duties include:
0 Weighing dyes and recording weights on batch tickets.
0 Transferring dyes in the weigh pan from the scale to the mix tank.
0 Pouring dye into the water filled mix tank.
0 Mixing dye solutions.
0 Transferring dye solutions to kiers by pump.
0 Loading undyed beams into kiers.
0 Unloading dyed beams from kiers.
0 Cleaning dye storage and weighing and mixing areas.
The dye weighers employed at this facility are Involved in the handling,
transferring and weighing of dyes, and handling and transferring of greige
and dyed yarn beams.
The monitored dye weigher was a 25-year old male. He has been employed
at the company for eight years; 7.5 of those years have been spent handling
dyes. He had no previous dye handling experience.
Training
Company provided dye weigher training regarding the safe handling of
dyes was provided by posting procedures for safe handling of dyes on the
walls. No formalized instruction was provided by the company.
Personal Protective Equipment
Personal protective equipment utilized by the monitored dye weigher
included a 3M-8710 disposable, half-mask dust respirator. The monitored dye
weigher used the dust mask during all dye weighing activities. It was
266
-------
noted that dermal contact occurred, since the dye weigher did not wear gloves
and did not avoid skin contact with the dye material.
Personal Habits
The monitored dye weigher did not eat, drink, or smoke in the weigh
area. The weigher washed his hands after loading each batch into the mixing
vat.
Work Activities
The dye weigher's activities in filling each batch ticket order were as
follows: dyes were obtained by walking to a drum in the storage area con-
taining the appropriate dye and using a hand scoop to remove an approximate
quantity of the dye, transferring the scoop of dye to the weigh station and
pouring the required amount into the scale dish, and returning the unused
portion of the dye to the drum. The weighed dye was then hand carried in the
scale dish to the mixing vat containing water and dumped in. This operation
was repeated until all dye weighings specified on the batch ticket had been
completed. Chemicals used in dyeing were weighed and added as needed. Once
the dye was mixed, the solution was pumped into the kier.
SPECIFIC MEASUREMENTS AND OBSERVATIONS
The monitored dye weigher was in the drug room for a total of 146
minutes over the 8-hour period (480 minutes). During that time, his duties
required him to enter the drug room eight times. He was monitored for expo-
sure to particulates over a 458-minute period from 3:58 p.m. to 11:36 p.m.
Table 2 presents a summary of the data and Information recorded during the
survey. Table 3 presents a list of the dye materials handled during the
survey, including the dye color index number, the number of weighings of each
dye, and the total weight of the weighings of each dye.
267
-------
ANALYTICAL RESULTS
Solids filtered from the air in this facility were analyzed by EPA for
Disperse Dye content. Vat Dyes could not be determined by the analytical
procedure that was used. Total dye content was estimated by extrapolation on
a weight basis. Total weight of all solids and analytical results from the
four filtering devices, corrected for recovery, follow (in milligrams dye per
cubic meter air):
Active Total
Colorants Commercial Dyes Weight
Average of 2 monitoring 0.02 0.10 0.53
devices in worker's breathing
zone
Drug room area sampler at 0.03 0.11 0.16
weighing station
Drug room area sampler at drum 0.01 0.03 0.16
storage, remote from weighing
area
268
-------
TABLE 2. SUMMARY OF DATA AND INFORMATION RECORDED DURING SURVEY
A.
Time in work area
Percent of
monitoring
Time, minutes period
Total time monitored
Total time in drug room
Lunch and breaks
B.
C.
D.
E.
F.
Work capacity
Maximum work load
Units in operation at
Powder dyes weighed
Total
Vat
Disperse
Dyes
Total
Vat
Disperse
Dry chemicals
Total
Citric Acid
Soda Ash (Na2C03)
Sodium Hydrosulfite
All chemicals weighed
Total
Dyes
Dry chemicals
458
146
NA
Number of
process units
time of survey
Number of
weighings
17
8
9
Number of
weighings
9
4
1
4
Number of
weighings
26
17
9
Number of
Percent
100
47
53
Percent
100
44
11
44
Percent
100
65
35
4
4
100
32
NA
Percent
100
100
dyes Percent
11
6
5
Weight of dyes,
pounds
22.215
19.487
2.728
Weight of
chemicals,
pounds
107.40
11.10
0.30
96.00
Weight of
dry chemicals
pounds
129.615
22.215
107.40
100
55
45
i
Percent
100
88
12
Percent
100
10
89
Percent
100
17
83
(continued)
269
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TABLE 2 (continued)
G.
H.
Dyes weighed most
frequently
Disperse Red 86
Disperse Yellow 108
Vat Violet 13
Vat Blue 6
Largest quantity
of dyes weighed
Vat Orange 2
"Vat Brown M-l"
Vat Violet 1
Number of
weighings
3
3
2
2
Number of
weighings
1
1
1
Percent
18
18
12
12
Percent
6
6
6
Weight of dyes,
pounds
0.969
0.377
2.922
1.896
Weight of dyes,
pounds
5.180
4.320
3.440
Percent
4
2
13
9
Percent
23
19
15
NA - Not available.
270
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TABLE 3. DYE MATERIALS HANDLED DURING THE SURVEY
Dye color index number
Number of
weighings
Total weight
of weighings,
pounds
Disperse Dyes:
Disperse Yellow 67
Disperse Yellow 108
Disperse Red 86
Disperse Blue 73
Disperse Blue 109
Vat Dyes:
Vat Yellow 2
Vat.Orange 2
Vat Violet 1
Vat Violet
Vat Blue 6
"Vat Brown M-l"
13
1
3
3
1
1
1
1
1
2
2
1
0.240
0.377
0.969
0.305
0.837
1.729
5,
3,
2,
,180
,440
,922
1.896
4.320
271
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TEXTILE DRUG ROOM MONITORING STUDY
SITE VISIT REPORT
Site Number 9/1
,;*
William L. Dyson, Ph.D., C.I. H.
Health and Hygiene, Inc.
. Ungers/T.I.H,
Associates, Inc.
Prepared for:
U.S. ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF TOXIC SUBSTANCES
401 H STREET, S.W.
WASHINGTON, DC 20460
273
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INTRODUCTION
This survey was conducted as part of an exposure study being performed
as a cooperative effort between the U.S. Environmental Protection Agency
(EPA), the American Textile Manufacturers Institute, Inc. (ATMI), and the
Ecological and Toxicological Association of the Dyestuffs Manufacturing
Industry (ETAD). The study's objective was to determine the extent of
textile workers' exposure to dye dust when weighing and mixing powder dyes.
The sites to be visited were selected to obtain a random sampling of eligible
sites. Contact with the site representative to schedule the site visit was
made by William L. Dyson, Ph.D., C.I.H. of Health and Hygiene, Inc.,
representing ATMI and ETAD. In attendance at the site were Melvin R.
Witcher, Jr., C.I.H. of Health and Hygiene, and Donald L. Unruh, C.I.H., IT
Corporation, subcontractor for PEI Associates, Inc., representing EPA. The
pre-survey meeting was held with company officials May 27, 1987. The
industrial hygiene monitoring and recording of data were performed during the
first shift (6:00 a.m. to 2:00 p.m.) on May 28, 1987. Company
representatives were very cooperative in assisting with this survey.
274
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SITE CHARACTERIZATION
GENERAL
The drug room at site 9/1 is part of a captive dyehouse operating or an
integrated basis. Approximately 300,000 pounds per year of whole garments
(socks) are dyed in batch operations at this privately owned facility.
Eleven rotary dyeing machines were available, seven of which were in opera-
tion at the initiation of the monitoring period. By the end of the shift,
this number had Increased to nine. Fibers dyed are acrylic/modacrylic, wool,
nylon, polyester, and cotton. Site operations include storage, dyeing, and
finishing.
DRUG ROOM
The drug room is a rectangular room approximately 60 feet long and 35
feet wide, with a 8-foot ceiling. The room is accessed by a door at the west
end of the room which leads to the mixing area and an emergency exit at the
east end of the room. The mixing area is a separate area outside of the drug
room. The drug room Includes drum storage areas and a dye weighing station
equipped with two scales. Figure 1 presents a sketch of the drug room.
Dyes are stored in drums utilizing the floor space along the center por-
tion of the drug room. Pallets of soda ash and ammonium sulfate are located
against the east wall next to the emergency exit. Drums of liquid chemicals
are also stored in the drug room, against the south wall. The drums vary in
size from 200- to 250-pound barrels to smaller 50- to 100-pound containers.
275
-------
60 ft
J
SCALES v-
10
^ ELECTRICAL
-f SWITCH BOXES
POWDERED DYE DRUMS
OOOOOO
oooooo
V \
oooooo
OOOOOO-
TO MIXING VATS
AIR FLOW
\
' oooooo
oooooo
oooo
oooo
^ POWDERED DYE DRUMS C^^^
oo oo 00^0*0
OOvOOvOO-, OO
OOIOO'OO l-OO
OO OO OO i OO
OO OO OO I OO
oo
oo
oo
oo
oo
oo
oo
oo
oo
OO|OO OO I
L
T QOOOOOOOQQO
I
^
EKflCEMCY
EXIT
35 ft
J
PALLETS OF SODA
>ASH AND AMMONIUM
SULFATE
UCt Ml
• k, IOIIBC •,i»iio«
• MIA ItrtlUL M WIW MOSACi
A-Mt* i«»lt« At MIGlllKC STAIIOt
LIQUID CHEMICAL
DRUMS
«otnou''
of o>cs
HHOUI.il "I I Oil I "C 10 NI1IM
Figure 1. Sketch of drug room area.
-------
Two scales are located on a table near the exit to the mixing area. The
gram scale at this weighing station is used most frequently for weighing of
powder dyes.
The general appearance of the drug room was fair. There were many
stains caused by dyes and a small accumulation of dye powder on the floor.
There was also an accumulation of dye powder on the stored drums. The walls
and equipment were moderately clean of accumulated dyestuff. Approximately
one month prior to the survey, the location of drug room had been moved, at
which time a concentrated clean-up effort was made. Routinely, spills of dry
dye or chemical material are not cleaned up immediately. Reportedly, they are
left on the floor to be swept up during weekly floor cleaning.
The drug room was not equipped with a local exhaust ventilation system
for the purpose of removing airborne dye particles. The genera building
ventilation consisted of steam space heaters and roof fans. There was no net
airflow observed at the entrance to the drug room.
No floor drains were located within the drug room. The floor is swept
weekly as part of routine clean-up procedures.
Environmental conditions of the drug room (I.e., temperature, humidity,
and barometric pressure) were recorded hourly during the survey and are
summarized in Table 1.
TABLE 1. ENVIRONMENTAL CONDITIONS RECORDED DURING THE SURVEY*
Parameter
Temperature, °F
Relative humidity, %
Barometric pressure, In. Hg.
Mean,
8-hour value
79
74
29.90
Minimum
73
68
29.95
Range
Maximum
84
83
29.93
*
Readings of each parameter were recorded hourly over the 8-hour work shift.
277
-------
DYE WEIGHER ACTIVITIES
The company employs one full-time worker who combines dye weighing and
color matching activities during the first shift only. His duties include:
0 Transferring dye drums within the drug room using a drum dolly.
0 Weighing dyes and recording weights on batch tickets.
0 Transferring dyes from the scale to a stainless steel pail.
0 Preparing batch orders.
0 Cleaning dye storage and weighing areas.
0 Performing color matching.
The dye weigher employed at this facility is involved In the handling and
weighing of dyes and liquid chemicals. He Is not involved in dye batch
mixing operations.
The monitored dye weigher was a 77-year old male. He has been employed
at the company for 17 years; all of those years have been spent handling
dyes. He had 38 years of previous dye handling experience.
Training
Specific dye weigher training regarding the safe handling of dyes was
provided by the company in the form of training on how to read Material
Safety Data sheets (MSDS).
Personal Protective Equipment
Personal protective equipment utilized by the monitored dye weigher in
the drug room included leather work gloves. The monitored dye weigher used
the gloves during all dye weighing activities. No other forms of personal
protection were provided or used.
Personal Habits
The monitored dye weigher was not observed drinking or smoking 1n the
drug room; however, he did smoke in the office area. As part of his personal
278
-------
hygiene practice, the dye weigher washed his hands after each batch weighing.
The monitored dye weigher used no special precautions in handling the dye
material.
Work Activities
The dye weigher's activities in filling each batch ticket order were as
follows: dyes were obtained by walking to a drum in the storage area con-
taining the appropriate dye, using a hand scoop to remove an approximate
quantity of the dye, transferring the scoop of dye to the weigh station and
pouring the required amount into the scale dish, returning the unused portion
of the dye to the drum, and transferring the weighed portion of the dye to a
stainless steel pail. This operation was repeated until all of the dye
weighings specified on the batch ticket had been completed. The batch was
then hand carried to the mixing area. Mixing and transfer operations were
the responsibility of other workers. When a dye barrel was almost empty, the
dye weigher transferred the dregs from the depleted barrel into the new
barrel by inverting the former over the latter.
SPECIFIC MEASUREMENTS AND OBSERVATIONS
The monitored dye weigher was in the drug room for a total of 127 min-
utes over the 8-hour period (480 minutes). During that time, his duties
required him to enter the drug room 12 times. He was monitored for exposure
to participates over a 465-minute period from 6:10 a.m. to 1:55 p.m. Table 2
presents a summary of the data and information recorded during the survey.
Table 3 presents a list of the. dyestuffs handled during the survey, including
the dye color index number, the number of weighings of each dye, and the
total weight of the weighings of each dye.
279
-------
ANALYTICAL RESULTS
Solids filtered from the air in this facility were analyzed by EPA for
total dye content. Total weight of all solids and analytical results from
the four filtering devices, corrected for recovery, follow (1n milligrams dye
per cubic meter air):
Active Total
Colorants Commercial Dyes Weight
Average of 2 monitoring 0.09 0.22 0.45
devices in worker's breathing
zone
Drug room area sampler at 0.07 0.16 0.28
weighing station
Drug room area sampler at drum <0.01 0.01 0.18
storage, remote from weighing
area
280
-------
TABLE 2. SUMMARY OF DATA AND INFORMATION RECORDED DURING SURVEY
A.
B.
Time in work area
Total time monitored
Total time in drug room
Lunch and breaks
Work capacity
Percent of
monitoring
Time, minutes period
Maximum work load
Units in operation at time of survey
C.
D.
E.
F.
Powder dyes weighed
Total
Acid
Disperse
Basic
Reactive
Direct
Dyes
Total
Acid
Disperse
Basic
Reactive
Direct
Dry chemicals weighed
Revatol S powder (sodium
m-nitrobenzene sulfonate)
All chemicals weighed
Total
Dyes
Dry chemicals
Number of
weighings
103
61
5
4
7
26
Number of
weighings
1
Number of
weighings
104
103
1
465
127
NA
Number of
process units
11
(avg.) 8
Number of dyes
41
17
5
4
6
9
Weight of dyes
Percent grains
100 24,082.00
59 7,443.10
5 8,068.60
4 675.00
7 2,908.00
25 4,987.30
Weight of dry
chemicals,
Percent grams
100 34.00
Weight of
dry chemicals
Percent grams
100 24,116.00
99 24,082.00
1 34.00
100
27
NA
Percent
100
73
Percent
100
41
12
10
15
22
,
Percent
100
31
33
3
12
21
Percent
100
*
Percent
100
99+
<1
(continued)
281
-------
TABLE 2 (continued)
G.
Dyes weighed most
frequently
"Acid Red U-6"
Add Yellow 159
Acid Blue 281
Direct Yellow 106
Number of
weighings
12
10
6
6
Percent
12
10
6
6
Weight of dyes,
grams
257.7
104.6
173.6
9.0
Percent
1
<1
1
<1
FTT Largest quantity Number of Weight of dyes,
of dye weighed weighings Percent grams Percent
"Acid Black M-3" 4 4 4,460.0 19
Disperse Blue 109 1 1 4,390.0 18
"Disperse Black M-4" 1 1 2,789.0 12
Direct Black 80 3 3 2,745.0 11
NA - Not available.
282
-------
TABLE 3. DYE MATERIALS HANDLED DURING THE SURVEY
Dye color index number
Acid Dyes:
Acid Yellow 40
"Acid Yellow U-l"
Acid Yellow 65
Acid Yellow 159
Acid Orange 116
Acid Orange 51
"Acid Red U-6"
Acid Blue 281
Acid Blue 40
Acid Blue 239
Acid Blue 345
Acid Blue 113
Acid Green 25
"Acid Brown M-l"
"Acid Brown U-2"
"Acid Black M-3"
"Acid Black M-2"
Disperse Dyes:
Disperse Red 60
Disperse Blue * 109
Disperse Blue 3
Disperse Blue 56
"Disperse Black M-4"
Basic Dyes:
Basic Orange 21
Basic Violet 14
Basic Blue 54
Basic Green 4
Number of
weighings
2
2
1
10
4
1
12
6
2
3
1
2
2
3
4
4
2
1
1
1
1
1
1
1
1
1
Total weight
of weighings,
grams
1.1
70.0
175.0
104.6
86.4
320.0
257.7
173.6
15.8
92.1
419.0
446.0
3.7
45.1
292.0
4460.0
481.0
256.0
4390.0
4.6
629.0
2789.0
85.0
74.0
392.0
124.0
(continued)
283
-------
Dye color Index number
Number of
weighings
Total weight
of weighings,
grams
Reactive Dyes:
Reactive Yellow ^ 58
Reactive Yellow 64
Reactive Red 43
Reactive Red 120
Reactive Blue 52
Reactive Blue 18
Direct Dyes:
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Yellow % 106
Orange 72
Orange 80
Red 80
Red 149
Blue 78
Brown 113
Black 2
Black 80
2
1
1
1
1
1
6
3
1
4
1
4
3
1
3
642.0
117.0
414.0
562.0
166.0
1007.0
9.0
12.7
1345.0
14.5
117.0
51.1
49.0
644.0
2745.0
284
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