DHA Evaluation and EHS Consulting for a Major U.S. Plastics Facility

A Spark of Prevention: Trinity Mitigates Manufacturer’s Combustible Dust Risks

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Environmental ConsultingEnvironmental Consulting

Industry

Plastics Manufacturing

Location

United States

A global leader in healthcare solutions faced a critical need to address combustible dust hazards at one of its major U.S., facilities, which
produces healthcare support products using high volumes of plastic materials. Concerned about safeguarding both its workforce and operational
integrity, the manufacturer needed a reliable way to identify potential dust explosions and bring its operations in line with rigorous safety
standards. Already familiar with Trinity Consultants’ expertise from other environmental initiatives, the EHS&S team enlisted Trinity’s help to
conduct a thorough Dust Hazard Analysis (DHA) and recommend effective risk-reduction measures.

Challenge

One of the global healthcare manufacturer’s U.S. facilities specializes in producing personal healthcare products that require large amounts of plastic materials. When processed at high volumes, these plastics can generate significant fine dust particles, leaving the facility vulnerable to potential fires or explosions if the dust accumulates or ignites. The EHS&S team wanted to stay ahead of any potential problems by understanding exactly where dust hazards existed, how severe they were, and what engineering or procedural improvements might be necessary.

The company also needed to maintain compliance with multiple layers of regulation, including OSHA’s General Duty Clause, which requires employers to provide a workplace free from recognized hazards that are causing or are likely to cause death or serious physical harm, and the National Fire Protection Association (NFPA) standards. These regulations also served as a roadmap for the company’s global facilities, creating the additional challenge of developing a cohesive strategy that could be adapted to regional regulatory requirements around the world. Eager to be proactive rather than reactive, the client’s leadership team understood that the company needed expert support to conduct a formal DHA and identify the best path forward.

Solution

Trinity was brought in as the manufacturer’s leadership team was confident in the firm’s previous track record delivering practical, effective solutions in other environmental and safety areas. Trinity’s experts began by carefully examining each step in the plastics manufacturing process to determine where dust was generated and where it could accumulate. Through site visits and in-depth discussions with the manufacturer’s teams, Trinity assessed the equipment currently in use, highlighted possible dust hot spots, and documented potential ignition sources.

Building on these findings, Trinity developed a highly detailed DHA that delved into the explosibility properties of the plastic materials and established clear risk tolerance criteria. This comprehensive evaluation outlined hazard classifications, described potential ignition sources and their likelihood of occurrence, and rated each piece of equipment according to severity and risk. Trinity’s DHA offered equipment-specific recommendations—from specialized dust collection and venting systems to grounding and bonding measures—while also emphasizing updated safe work procedures, personal protective equipment, and a robust change management process. Trinity also suggested the client formalize an SOP that aligned with U.S. regulatory requirements yet remained flexible enough to be adapted to regional regulations around the world.

Services Performed

Trinity collaborated with a major U.S. plastics facility to conduct a thorough Dust Hazard Analysis (DHA) and recommended effective risk-reduction measures to safeguard both its workforce and operational integrity.

Results

Following Trinity’s thorough DHA and targeted recommendations, the EHS&S team moved swiftly to implement a range of corrective actions at its U.S. facility. The company installed enhanced dust collection systems, introduced new suppression and venting equipment, and adopted a rigorous maintenance and inspection program to ensure long-term effectiveness. Employees received updated training and clear guidance on safe work practices, creating a culture of proactive safety and accountability.

Buoyed by the success of the first site, the manufacturer replicated the analysis at several other US facilities and a facility in Latin America. By adapting Trinity’s recommendations to local regulations, the local team gained corporate approval to roll out similar systems and operational procedures, ensuring that each site follows a consistent, high standard of safety. Looking ahead, the manufacturer anticipates expanding this combustible dust management framework to other facilities around the globe. The teams continue to maintain close communication to address new challenges and regulatory requirements as they emerge, ensuring that their successful partnership continues to evolve.

Trinity’s deep expertise and attention to detail made all the difference as we worked to proactively manage our combustible dust challenges. Trinity’s recommendations didn’t just help us meet regulations; they empowered us to think differently about risk and safety across our facilities. We are a stronger organization because of their guidance.

Associate | EHS&S Training and Development at Global Healthcare Product Manufacturer