Shrikant Deshpande
Asst Manager (Safety)
Gammon India Limited










Cotton godown
Blow room / Mixing
Carding
Combers
Draw frames
Speed frames
Ring Frame
Auto coners
Packing
Warehouse
•Cotton comes in the
textile mills in the
form of compressed
bales which are stored
in the godown and
released to the process
as and when required
• Average weight of
cotton bale is 200 to
250 kg
•Dimension of bale is
0.75 X0.75X1.25 meter

Since the space is
limitation so bales
are stacked as high
as
roof
height.
Either
manually
and in few cases
mechanically.


Accidental falling of bales
At the time of stacking
ensure that the stack is in
adequate
equilibrium
means it should be such
that when one bale is
disturbed for unloading
the stack should not
collapse this is usually
achieved by stacking them
in along and across in
alternate layers like bricks
placed in the wall




Accident by contact
with sharp edges of
the straps on the
bales.
Fire due to improper
wiring
Smoke in the godown
due to moving of
forklift
Chance s of accidents
by fork lift


Bales are transported from godown to blow
room either manually , or by means of trolleys
or by means of forklifts.
Blow room consists of




Hopper openers
Bale breakers
Beaters and condensers
Feeding unit assembly


Through pneumatic line section lumped mass
cotton in the form of bales is opened , beaten
up, torn apart and converted into soft, fluffy
lap of cotton.
Here major part is to remove





Stalk
Motes
Some sand
Dust
Etc.






Transmission machine parts
Belts
Pulleys
Gears
Shafts
Revolving



Beaters
Spiced lattices or apron
Other moving parts

Generally blow room consists of units of
hopper openers , bale breakers, beaters
condensers and feeding unit assembly and
cotton is transferred from one unit to other by
pneumatic section. Using these units the lump
mass of cotton in the bales is opened , beaten
up, torn apart and converted into a soft fluffy
lap of cotton. In this process the major part of
impurities such as bits of leaves, stalk, motes
some sand , dust etc get removed from the
cotton



Sudden opening of cotton bale results into
sudden disengage of steel strap and chances of
accident.
Since all the machinery consists of belts , pulleys,
gears, shafts and they are rotating so as per The
Factories act 1948 all the transmission machinery
and other dangerous parts should be made
inaccessible by proper guards.
All gears and toothed wheels which do not
required frequent adjustment should be fully
enclosed.



Suitable and safe belt shifting device and
emergency stopping device should be provided
to all the machinery.
On all these machines the beater covers and
other openings which provide access to the
dangerous parts should be effectively
interlocked.
Opening gibing access to dust chambers should
be so fenced that while light is admitted to the
chambers access to the beater guard is
prevented.



Chances of accidents while releasing chokes
and removing dirt from under casing of beaters
and such opening must be interlock effictively.
Absence of ladder for reaching on certain
points of machine may result into falling of
person.
Improper housekeeping also may lead to
accident and fire in the cotton textile industry.
Carding Machine consists of
 Cylinder
 Doffer
 Licker in
 Calendar roll nip


Here cotton comes in the form of lap and leaves
the machine as sliver.
Sliver rope is about an inch in diameter and
made up of clean while fiber.


Accident due to cylinder
Interlock guard to be provided to the stripping
door on cylinder. Door cannot be open without
cylinder stopping and cylinder can not be start
without securely closing the stripping door.

Accident in licker in


Access to licker in securely closed by panels
Gauging clearance

Clearance between cylinder, licker in or doffer or flat
is done by using feeler gauges . AT the time of this
activity following steps to be followed in order to
prevent accident.


1) Stop the machine before using filler gauge and
should never be done when parts of machine is in
motion.
2) Operator should not remove fluff, lint, from
moving parts of machine specially from
cylinder, licker in doffer and flat.

In this process cotton in
the form of ribbon laps
is combed in short
length of about 6mm
by a series of needles
placed on revolving
cylinders. . The fiber
become longer,
straighter and brighter
as compare to those in
card sliver.



To provide guard to the unguarded
transmission parts and other gears
To provide interlock arrangement in order to
avoid contact with cylinder needles.
To provide interlock guard to the nipper knife
in order to avoid dropping of nipper knife.

Sliver from comber and
carding machine are
passed through series of
rollers which draw the
sliver and render the
fiber more parallel and
blending and mixing
also accomplished.




Head stock gears.
Provide interlock arrangement to head stock
gears such that machine can not be started
without cover and covers can not be lifted
without stopping the machine.
Calendar gears to be guarded properly.
Avoid jam to calendar rollers.

Sliver is converted into roving in this process,
sliver through two sets of rollers into a thick
soft roving and also impart strength to it by
twisting before the roving is wounded on the
bobbins.
A) Gears.

There are large numbers gears which needs
fencing on these machine
 Lifter rack and pinion should be well guarded
so that access to the nip is prevented both
when rack lifts and fall.
B) Flyers
 Injury by hitting the flyer at the time of
removing fluff and cleaning work.
 Inter locking to be provided at the rotating
zone of flyers.

Roving converted into yarn in this process,




Accident while piecing broken ends, operators
usually hold the bobbin at its bottom end
between their left hand fingers to stop it.
Chances of accidents due to sharp edges on
bobbin come in contact with fingers causes
accident.
1) Provide finger caps
2) Educate workers to hold the running
bobbins
3) Provide stopping mechanism such as breaks
for individual spindles.


Falling of bobbins from creel tops: - While
creeling average Indian workers may not reach
to the bobbin holder easily and they tstep on
the railing which expose them to the serious
hazards.
Accidents at the time of handling of Knife.

To remove fluff or waste yarn on rollers operators do
use knife. And improper use of knife result into
serious cut injury to fingers.




Sharp edges of damaged cans
Cutting of bale hoop iron band by chisel and
hammer may results into injury, proper bale
opener should be used.
Maximum material is handled in the boxes and
on the trolley so remove jams on the wheels of
the trolley on regular intervals to avoid falling
of trolley and material boxes to be kept in
proper manner.
Wheels of trolleys provided with breaks in
order to blocked them at the time of loading
and unloading.


Over loading of trolleys , boxes and treys to be
avoided.
material to be stored in proper and allocated
position.






Nails from bales
Hoop iron strip
Ring travelers
Bobbins on the floor may create hazard and
person may fall
Damaged floor may fall trolleys and cans at the
time of material shifting
Cans trolleys kept haphazardly on the floor so
chances of striking against these objects.






Maintain good housekeeping
Regular maintenance of electrical equipments
and periodic checkup is necessary
Risk of overheating of bearings can reduced by
providing efficient lubrication.
Day to day monitoring and maintenance of all
moving parts
Smoking to be prohibited
Electrical equipments must comply Indian
Standard and maintained in safe working
condition






Metal detection and diversion system at blow
room
CO2 Flooding system at beaters and carding
section
Provision fire doors to maintain sepretion of
two departments
Fire extinguishers
Fire hydrant system
Smoke detection and alarm system





Noise
Cotton dust
Exposure to chemicals
Exposure to UV rays
Working in Humid atmosphere




Pre employment and periodical mediacl
checkup
Colour blindness checkup
Noise induced hearing loss
Lung function test
Ear plug
 Nose mask
 Safety shoes
 Goggles for specific jobs
 Hand gloves
Etc









Safety policy
Recruitment of safety officer
Safety committee
Accident reporting investigation and analysis
system
Safety audit , inspection and followup for
action taken.
Identification of unsafe acts and conditions
Safety training and education
Safety campaign etc…..
Thank you