Posts Tagged ‘imperial sugar’

Imperial Sugar Marks Third Anniversary of Combustible Dust Tragedy

Thursday, February 10th, 2011

Monday marked the third anniversary of the Imperial Sugar combustible dust explosion. According to the company’s website, ImpCourtesy of ISCerial marked the day with a somber memerial ceremony where family members, friends and co-workers placed flowers and candles at memorial markers in Legacy Park located on the grounds of the plant. The focal point of the park is a beautiful bronze sculpture of 14 doves taking flight from upturned hands that Imperial Sugar commissioned to pay tribute to those employees who lost their lives.

Three years after the explosion, Imperial Sugar has completed rebuilding the Port Wentworth refinery, which has become an exemplary model for safety in the industry. The new facility incorporates state-of-the-art technologies – including a modern packaging facility equipped with dustless loading devices, antistatic floors and firewalls, among other safety features. Read the full story here.

You may also want to check out some of our past blog posts related to the Imperial Sugar tragedy.

Imperial Sugar Rises from the Combustible Dust Ashes: http://www.nilfiskcfmblog.com/2010/10/imperial-sugar-company-rebuilds/

Combustible Dust Ground Zero: The Real Story: http://www.nilfiskcfmblog.com/2010/08/combustible-dust-ground-zero-the-real-story/

Imperial Sugar Company Rises from the Combustible Dust Ashes

Friday, October 8th, 2010

Nearly 3 years after the combustible dust accident heard ’round the world, Imperial Sugar Company has literally rose from the ashes; turning a company associated with tragedy into a company leading the way on safety. The below post from their website (also featured in Food Safety Magazine) details the state-of-the-art transformations the company has recently completed, including dustless loading spouts  to eliminate exposed sugar dust in the shipping processes for bulk trucks and railcars– the first system of its kind in the sugar industry.  

Transformation in the Face of Crisis

Food Safety Magazine

Finding opportunity amidst tragedy takes courage.

Following a 2008 industrial accident at Imperial Sugar Company’s Port Wentworth, GA refinery, Imperial was presented with its most daunting hurdles to date. The company faced extensive rebuilding efforts after the incident destroyed the plant’s packaging area and damaged its three storage silos. As a result, 12% of Imperial Sugar’s Port Wentworth refinery was rendered inoperable until rebuilding efforts were completed.

Tom Wilson, technical services manager, listens carefully during a customer audit. 

As the company and the surrounding community began to heal and rebuild, the sugar industry leader took bold action to transform a series of challenges into the creation of a state-of-the-art facility that is reshaping industry best practices.
This article discusses how the company emerged from the crisis as an industry change agent.

Rebuilding Efforts
When envisioning the reconstructed Port Wentworth facility, food safety, quality and sanitation played key roles in Imperial Sugar’s transformative design-build efforts.

Alterations to the original layout of the plant were made to create more efficiency and establish separate production, packing and shipping facilities to keep each step of the refining process isolated. Additionally, the construction of the facility’s floors and walls were modified to improve product sanitation. Floors were sloped for easy drainage, allowing all surfaces in the facility to be washed easily. The company also constructed a viewing corridor that overlooks the plant’s interior space and allows personnel to observe operations without physically being in the production area and potentially exposing the product to contaminants. The improved layout of the plant, coupled with state-of-the-art equipment, would contribute to a well-organized, clean and safe environment for both employees and its products.

To complement the renovated facility, Imperial Sugar also installed the latest in manufacturing equipment, creating a system that provides the safest operations in the industry today. Dense phase conveyance systems help prevent the breakdown of sugar crystals as they are transported down the production and packaging lines, helping to reduce the occurrence of combustible dust.

To ensure the integrity and safety if its products, the company implemented a rigorous detection system made up of several high-performance components. Magnetics, Inc.’s Ox system, which is composed of rare-earth magnets, was put in place throughout the packaging area to help protect the product from infiltration of foreign metals. Additionally, X-ray detectors that identify both metal and glass fragments were installed, and traditional metal detectors were put in place on smaller-scale production lines. Combined, the three-tiered approach to foreign object identification results in the most comprehensive system available today, providing Imperial’s customers with the peace of mind that comes with the highest level of food safety.

Steps were also taken to protect food products during the packing and shipping phases, in which millions of pounds of sugar are loaded into packages of all sizes. Dustless loading spouts were installed to eliminate exposed sugar dust in the shipping processes for bulk trucks and railcars, creating the first system of its kind in the sugar industry. While passing through magnets, metal detectors and hummer screens, the product remains completely sealed from the silo to the truck or rail car.

Training
Concurrent with the rebuilding process, Imperial Sugar took the opportunity to provide its employees with vital training to equip them with the very latest in operational and food safety techniques.

The company implemented a robust training program, which resulted in the certification of 10 Safe Quality Food (SQF) practitioners and 10 associates who are Hazard Analysis and Critical Control Points (HACCP) certified. Conducting its training program via an interactive computer-based system, Imperial Sugar customized training modules to fit the plant’s unique processes. Featuring language and terms used in everyday operations at Port Wentworth, the training program instructed employees in several categories of health and safety, including protection against food contamination and emergency preparedness.

Additionally, the Port Wentworth plant has achieved a SQF Level 2 certification, which recognizes the refinery’s compliance with international and domestic food safety regulations. To garner this distinction, the company completed a food safety risk assessment of its products and process using the HACCP method and created an action plan to eliminate, prevent or reduce food safety hazards. Imperial Sugar is currently working to achieve an SQF Level 3 designation for Port Wentworth in the near term.

“Investing in our associates to equip them with the best safety training available was just an essential as rebuilding Port Wentworth’s physical facilities,” said Wilson. “Our unique training program provides our team with the latest best practices in food safety that will help them operate our new state-of-the-art facility.”

Reaching Out
With the vast knowledge of food safety best practices gained during the rebuilding, Imperial decided that partnership and collaboration would be required to truly affect industry-wide change. Imperial felt an obligation to do everything possible to heighten awareness of the risks of combustible dust throughout the food industry. As a result, the company invited peers, customers and partners to visit Port Wentworth to witness first-hand the progress the plant had made. During these visits, the company discussed the impact of exposed combustible dust and shared best practices to ensure that others in the industry were aware of the latest techniques available to mitigate risks associated with the issue.

Additionally, Imperial Sugar partnered with its customers to discover new ways to improve its existing best practices. The company holds meetings and town halls with its customers to address their questions and share lessons learned. In fact, customer collaboration led to the development of new ways to sequence Port Wentworth’s production cycle and improve sanitation in the facility.

Imperial Sugar has also maintained a proactive and transparent relationship with the regulatory agencies that play a role in monitoring the plant’s rebuilding progress. Company officials in Port Wentworth contacted the Georgia Department of Agriculture, inviting them to the new facility to provide recommendations for the company’s ongoing rebuilding process. The partnership spurred a great deal of collaboration, and following numerous visits to Port Wentworth, the department was able to witness many of their suggestions put into action.

“Through forward-thinking and collaboration with industry peers, valued customers and governmental agencies, we made transformation part of the solution,” said Wilson.

Moving Forward
Today, Imperial Sugar continues to take strides to improve its food safety efforts while restoring the Port Wentworth plant to full production capacity. Through courage and close partnership with its stakeholders, the rebuilding process has yielded a plant that is among the safest and most advanced in the industry. Through innovation, the plant has become a state-of-the-art facility staffed by highly trained operators, solidifying Imperial’s position as an industry change agent and a leader in food safety.

Tom Wilson is the technical service manager at Imperial Sugar’s Port Wentworth, GA bulk sugar refinery. He has been with the company more than 28 years and has been a supervisor at Port Wentworth for 10 years.

Combustible Dust Ground Zero: The Real Story

Thursday, August 5th, 2010

I came across this archived article today and thought it was still worth sharing.  Written 5 months after the Imperial Sugar Factory tragedy, this Savannah newspaper article paints a dreadful picture of the blast heard ’round the world and really puts the incident into perspective. Imperial Sugar was not just an incident that brought combustible dust to the headlines, awaking the regulatory giants; it was a small town disaster, with lives lost, people injured and countless more emotionally scarred forever. 

A Tragedy Born in Dust

From savannahnow.com, Savannah  Morning News

From the second the massive fireball shot into the night sky Feb. 7, the explosion at the Imperial Sugar Co. refinery became much more than a local tragedy in a small company town.

Bright orange flames were visible 20 miles from the Port Wentworth plant. The secondary blast, about 7:20 p.m., was so bright it was easily recorded on a security camera a couple of miles away at the Georgia Ports Authority.

Smoke billowed 2,000 feet into the night air and was so thick, air traffic controllers picked it up on their radar.

At ground level, it was pure terror.

The concussive force knocked employees in adjacent work areas off their feet. As they rushed to respond, little was recognizable.

Walls were blown away.

Floors buckled.

Fire rolled in waves along the ceiling.

“I saw some horrific injuries,” said Tony Holmes, a forklift operator. “People had clothes burning. Their skin was hanging off.”

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Within minutes, the response spread far beyond Port Wentworth and its 3,500 residents.

Firefighters, police officers, emergency medical assistance crews and other responders converged from Savannah-Chatham, Effingham and Bryan counties – and beyond.

Initial reports indicated as many as 100 people might have been killed. The plant employed 352 people, plus 120 contract workers.

Eight died in the initial blast. Five more succumbed to their burns. Three of the 20 patients treated at the Joseph M. Still Burn Center in Augusta remain hospitalized there today.

More than five months after that horrific night, Port Wentworth Fire Chief Greg Long still has to push back the images and the sounds of disaster whenever he drives along the plant’s winding entry.

“I still get the same feeling every time I drive down Oxnard Drive,” he said. “I still get that eerie feeling, and the hairs stand up on the back of my neck.

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Because of disaster response planning, emergency department personnel quickly mobilized at St. Joseph’s and Candler hospitals as well as at Memorial University Medical Center.

Gurneys lined the hallways or stretched into parking lots as doctors, nurses and other medical workers waited for the burned and injured to arrive.

They came in waves – some in ambulances driven by police officers so the paramedics could focus on stabilizing the patients as they were transported.

Memorial treated the majority, handling more than 30 burn victims the first night. Ten were flown or taken by ambulance to the burn center in Augusta.

Patty Fletcher, a registered nurse at Memorial, later would write to the Savannah Morning News that she was “in awe” of the well-coordinated response.

“Within minutes, the disaster plan was put in motion,” Fletcher wrote. “Staff, from some of the top administrators who had been at an event and arrived in tuxedos to environmental services who were at home eating dinner, started appearing from everywhere to help.”

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Help came in so many other ways.

Neighbors rushed to churches, opening sanctuaries for those who needed to pray or needed solace.

In Chatham County and beyond, blood donors by the thousands rolled up their sleeves and held out their arms to help supply burn victims with massive amounts of blood that they would require daily.

“There is a moment in every community’s life that defines its character,” explained the Rev. Sam Self, pastor of First Baptist Church. “We reached a moment where there was such a unity. We had strangers walking up asking, ‘What can I do?’ ”

Gerald Schantz, owner of Gerald’s Diner, organized a barbecue fundraiser for burn victims’ families. In a single afternoon, he raised $22,000.

The United Way of the Coastal Empire assumed the largest fundraising role. By the end of March, the United Way had raised more than $1 million.

A fundraiser today featuring former Harlem Globetrotters standout Meadowlark Lemon and other teammates will benefit the United Way fund.

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Most of the money raised will help support the burn victims and their families.

For them, recovery will mean months, if not years, of painful skin grafts, physical therapy and the constant risk of infection.

From the first days, the family members and friends making daily trips to Augusta reached out to each other.

“I think you see kind of a community forming in the waiting room,” said Glen Burnsed, who was visiting his injured brother-in-law. “I don’t know if camaraderie is the word, but there’s a lot of helping each other out and kind of sharing each other’s stories on how their loved ones are doing.”

Burnsed’s brother-in-law, Kelly Fields, later became the first burn victim to die of his injuries.

Walter Byron Maxwell and Troy Bacon left the burn center two months to the day after the explosion, and they motivated each other in their rehabilitation sessions at Memorial.

They do what they can to show their thanks to the community, sometimes attending blood drives so donors can see how their efforts help.

Want to read more? Savannah News has an entire section of their website dedicated to the Imperial Sugar Explosion: http://savannahnow.com/news/explosion