Are Contaminants Hurting Your Bottom Line?

Contamination has always been a problem within the bulk transportation industry. We can define a contaminant as any object, or substance that renders something impure. In practical terms, it can be described as any substance that is foreign and is not a component of the primary product or material. It can also be an object that is an unintended contact with the primary product or material.

Contaminants can have a negative impact on any type of bulk load, but often have overwhelming consequences when they come into play with food products or supplements intended for human or animal consumption. There are many types of contaminants that can ruin food products that are being transported in bulk. Examples of typical contaminants are fungi, residual heel from previous loads, corrosion, delaminating liners, vermin, and foreign objects such as: tools, phones, lights, pens, etc.

Tank maintenance can play a big role in minimizing potential contamination problems. It is imperative to maintain hygienic conditions in a tank between loads. A tank wash operation is a basic, common sense maintenance that is critical to reducing the risk of contamination. Unfortunately, the reality is the opportunity for contamination can still exist even if a tanker has gone through a tank wash process.

There have been many instances where a fully loaded tanker was contaminated following a proper tank wash procedure:

  • In one case, a rail tanker had gone through an internal tank wash process and had not yet been loaded. A bird flew into the open manway at some point following the wash. The bird was not noticed, and the tanker was filled with a liquid consumable product and it was delivered to a customer at a manufacturing plant. The liquid was used as an ingredient for the manufacture of a snack food and was used for a time before the contaminant was discovered. The resultant discovery created a major disruption to the plant manufacturing process, employee downtime, expensive sanitation procedures, wasted bulk product and transportation costs. Liability for this event went well into the hundreds of thousands of dollars and damaged the reputation and brand of the company that delivered the contaminated product.
  • In another instance, a tank was put through a wash process, but because of a system malfunction, a pocket of the old product remained in the tank. The tank was next filled with a dis-similar product. This led to a cross contamination event that resulted in a mass product recall and many individuals were sickened.
  • There was one occurrence where workmen were repairing a tank interior and accidentally left lithium battery powered utility lights in the tank. The tank was washed but the lights remained in the tank, and it was used to transport a food product. Fortunately, the seals held on the lights and there were no significant negative consequences. This may not have been the case if the lithium batteries were exposed to the liquid food product and it found its way into a pet, livestock or consumer food product.

The one preventative measure that can catch these contamination events and stop them from occurring is to perform a cursory visual inspection of the internal tank conditions just before loading product. This can be problematic as tanks are confined spaces and are inherently dangerous to enter. OSHA has mandated safety procedures to help ensure the well-being of anyone that must break the plane of a confined space environment. A proper and safe confined space entry, requires training, manpower, equipment and administrative oversight. This means that a quick visual inspection can add complexity, cost, and an additional safety concern into the process. 

Zistos has created a video inspection system that can be inserted into a confined space, such as a tanker, to look for these potential contaminants with no entry required. The tanker inspection system, HDTI-5AR-TIP6-3.5Z, can provide a high-resolution image of conditions inside of the tank, viewable by an individual who remains outside of the confined space-envelope.

The ZistosHD tanker inspection system consists of a telescoping pole with a camera on the base. We insert the pole and camera assembly into the tank via the manway. A swivel assembly on the pole spans the manway opening and allows the camera to be manipulated by the user so it can view any area of the interior. The system generates a wireless HD video signal that can be viewed by the inspector, or others, on a body-worn, hands-free, tablet display. It can also be wirelessly transmitted to an existing network and viewed on a supervisor’s computer. The self-illuminating camera also features a 30X optical zoom that can magnify the smallest of suspicious indicators of potential contaminants.

The inspector can scrutinize the interior to make a final decision, just prior to load, that conditions are acceptable and there are no obvious sources of contamination. Inclusion of this video inspection tool in quality control procedures can go a long way in minimizing the potential for many sources of expensive and devastating contamination events. As the old saying goes, “An ounce of prevention is worth a pound of cure”!

Zistos Applies New Technology To Help Reduce Confined Space Entry Accidents

The Occupational Safety and Health Administration (OSHA) introduced the first regulation that protected personnel who work in confined spaces in 1993. Since then, we have come a long way in keeping confined space workers safe but until the number of fatalities from confined space accidents is at zero, there is still room for improvement.

According to a NIOSH study out of the 100 deaths investigated, the main reasons workers entered a confined space were to perform their work functions of routine maintenance, repairs and inspections. Most maintenance/repair operations start by visually inspecting conditions. We design the ZistosHD Tanker Inspection system to reduce the need to enter a confined space, such as a tanker truck, hopper, vault, or rail tanker. It accomplishes this by allowing an individual to make a visual assessment of the interior of the space without the need to enter. The ability to inspect these locations without the need to enter the confined space makes this phase of the process safer and more efficient.

The system (Part #: HDTI-5AR-TIP6-3.5Z), has a self-illuminating color camera head that features a 30X optical zoom. The camera head is attached to a telescopic pole which sits on the man-way and extends down into the confined space and can wirelessly send the video images onto a 5-inch, (optional 10-inch), tablet display. The inspection system can transmit video to off-site personnel and viewed remotely in real-time. In addition, it can capture the images on an SD memory card as still images (jpg), or motion video in 1080P resolution (mp4). The captured images can be stored on a computer for future reference or included in maintenance inspection reports.

OSHA specifies in regulations 1926.1209(e), that if an individual enters into a confined space, (the entrant), that there must be an individual who remains outside of the space, (the attendant), and is specifically tasked with ensuring that the entrant is not in duress. It is the responsibility of the attendant to maintain continuous communication with the entrant.  There is no OSHA mandated procedure on HOW to communicate with the entrant, just that it must be continuous and provided by the employer. Every company has its own method for communication between the entrant and attendant, and it can be as simple as knocking on the side of the tank and listening for a response, but there is no set rule. Camera technology can play a role to increase safety here as well. If following the visual inspection of the confined space it is determined necessary to enter, then the same video inspection system can assist. The OSHA mandated attendant can utilize it to visually monitor the status of the entrant from outside of the space via the video image.

In addition to the video based visual assessment of the entrant, the system also has listen/talk-back capabilities. This facilitates audible communication between the entrant and attendant, and both video and audio can be recorded. Providing a means for the outside attendant to visually confirm the well-being of the entrant and verbally communicate with them makes going into a confined space safer.

Stay safe by using the ZistosHD Tanker Inspection System to inspect the entire interior of a confined space from outside the space. If a confined space entry is unavoidable, keep safe by using this same system as an entrant monitor with live video and two-way audio communication.

Visit us at the NTTC Conference 2019

New Wireless Video ZistosHD Tanker Inspection System

The wireless ZistosHD Tanker Inspection System enables a safe visual inspection of the interior of a tanker trailer or rail tanker for hygienic conditions, foreign objects, residual heel, cracks and corrosion.

This uniquely configured video pole camera system is inserted into the tanker hatch. Two horizontal stabilizer rods span the hatch of the manway allowing the pole camera to stay situated without the need for the operator to support its weight.

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SafeAirLADDER for Safe Confined Space Entry (patent pending)

Keep safe by using redundant secondary atmospheric tests, which will help ensure a safe entry, when an entry is necessary.

Designed to perform a secondary test, as well as monitor and report environmental conditions — prior to an individual making a confined space entry, the SafeAirLADDER integrates gas metering electronics and alarm annunciation onto a ladder that is used to facilitate entry into a space.

The gas metering sensor is mounted to the base of the ladder and is designed to be inserted into a confined space — such as a tanker truck, rail tanker, processing tank, etc. The top of the ladder mounts onto the manway and has an integrated alarm console.

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NTTC’s 71st Annual Conference & Exhibits – Floor Plan 2019

New Technology Increases Safety for Confined Space Entry

Stay Safe by using remote visual inspection equipment and inspect from outside the space.

Keep safe by using redundant secondary atmospheric tests to ensure a safe entry, when an entry is necessary.

Tanker Inspection System

The Tanker Inspection System enables an individual to make a safe visual assessment of interior conditions, in dangerous and often inaccessible areas using detailed video images.

All areas of a tanker trailer or rail tanker can be safely viewed without the need for inspectors to make a confined space entry. The use of remote video inspection systems can play a role in reducing, and in some cases, eliminating the need for a worker to enter into a confined space, while conducting repair and/or maintenance operations.

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SafeAirLADDER

This ladder system was designed to keep confined space entrants safe by performing a redundant secondary atmospheric test. The SafeAirLADDER will monitor and report environmental conditions prior to an individual making a confined space entry to both the on-location individual and off-location supervisory staff. This intelligent ladder integrates gas metering electronics and alarm annunciation that is used to facilitate entry into a space.

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For more information or a free product demonstration, please don’t hesitate to reach out by phone: (631) 434-1370, email: info@zistos.com or website: www.zistos.com.  We look forward to hearing from you.

ASSE 2018 Tradeshow

Join us at ASSE 2018

Come visit us at ASSE 2018, Booth #434 for a look at some of our NEW confined space safety products. The show is being held at the Henry B. Gonzalez Convention Center located at 900 E Market Street in San Antonio, Texas. Once you arrive at our booth, you will have the opportunity to demo our SafeAir LadderTM and Confined Space Inspection Camera System.

Confined Space Inspection System 

The best way to avoid hazards and the related expense of a confined space entry is to avoid the entry in the first place. The Confined Space Inspection System is designed just for this purpose. Instead of sending a person into the confined space, the system sits on top of the manway and the camera is lowered inside. The range of motion and 40x optical zoom functionality of the system allows for a thorough inspection of the entire interior. The system also includes our WalkAbout DVR which permits video and still images to be recorded.

SafeAir Ladder SystemTM (Patent Pending)

If you must enter a confined space use our SafeAir LadderTM to ensure a safe entry. The SafeAir LadderTM is designed to perform a secondary test as well as monitor and report environmental conditions inside of a confined space prior to an individual making an entry.

A gas metering sensor is mounted to the base of the ladder and is designed to be inserted into a confined space. The top of the ladder mounts onto the manway and has an integrated alarm console, which remains outside the space. The console offers a visual (Red LED – Hazardous Environment, Yellow LED – indeterminate state or malfunction, Green LED – Environment Safe) and audible indication of atmospheric conditions as communicated from the metering sensor at the base of the ladder. When activated and inserted into a confined space the ladder can alert a worker prior to entry, (and management), that the atmosphere inside of the space is or is not suitable to sustain human life.

For more information or a free product demonstration, please don’t hesitate to reach out by phone: (631) 434-1370, email: info@zistos.com or website: www.zistos.com.  We look forward to hearing from you.