Addressing Explosive Risks in Flour and Sugar Mills With Aegex Technologies

When Flour and Sugar Turn Deadly

We may think of them as harmless kitchen ingredients, but flour and sugar are dangerous to the processing industry. When in dust form, these products are highly combustible materials that can explode in the presence of oxygen and an ignition source. An OSHA industry report reveals the U.S. alone has witnessed over 500 incidents of flour and dust explosions in the past 35 years, resulting in over 180 fatalities and severe injuries.

Integrating intrinsically safe solutions like those provided by Aegex Technologies is an effective way for industry to mitigate explosive risks in hazardous environments like sugar and flour mills. In this blog, we will take a historical journey through instances of flour and sugar mill explosions, narrating the events and consequences. We will also highlight the role of Aegex digital tools in mitigating future explosions.

The Chain of Events: How Sugar and Flour Mills Turn Deadly

Over time, sugar and flour factories build up vast layers of fine powder on walls, floors, machinery, and instruments. Normal operations can stir the air, causing the powder to hang everywhere and disperse throughout the factory. When the hanging dust combines with oxygen, it becomes highly combustible to explode with the slightest ignition. 

Industry data reveals it only takes 1 or 2 grams of dust per cubic foot of air to ignite the mixture. Generally, sugar and flour mills pose several ignition sources that range from static electricity and sparks that can occur from friction and rubbing pulleys. When ignited, the dust heats up quickly, stirring the air and getting more powder in the air to light up. The reaction spreads outward from its place of origin so fast, resulting in explosive flames that flash across the entire factory, leading to massive fires, injuries, and death.

Tracing the History of Flour and Sugar Explosions

Dust explosions have a history extending back to the 18th century, with the first documented incident occurring in Turin, Italy, on December 14, 1785. The explosion occurred at Mr. Giacomelli's Bakery Warehouse when flour dust generated during normal handling operations encountered an ignition source from a lamp mounted to enhance visibility.

The resulting explosion injured two employees working in the warehouse and damaged property worth millions of dollars. Ever since then, tragic dust explosion events continue to plague the world, leading to more severe consequences. Here are some of the most notable flour and sugar explosions to date.

1878: The Great Mill Explosion

On May 2, 1878, the Washburn 'A' Mill, in Minneapolis, Minnesota, arguably the largest flour mill in the U.S. at the time, exploded when flour dust inside ignited. The explosion killed eighteen people and injured multiple others. The tragic incident triggered massive reforms in the industry, focusing on ventilation systems and other precautionary devices. 

1975: Davenport, Iowa Flour Mill Explosion

In 1975, an explosion ripped through the Davenport River flour mill, killing two workers and injuring seven others. The official cause of the incident was a grain powder fire. This explosion, alongside several others in the decade, led to massive changes in the industry safety systems, including the requirement for lubrication schedules for equipment and confinement systems to control an explosion in hazardous environments.

2008: The Imperial Sugar Refinery Incident 

Perhaps one of the most memorable food processing explosions in the U.S. to date is that of the Imperial Sugar Refinery. On February 7, 2008, a massive explosion and fire occurred at Imperial Sugar refinery located in Northwest Savannah, Georgia. The incident resulted in fourteen deaths, thirty-eight severe injuries, and massive property damage. An investigation revealed the explosion was fueled by a colossal accumulation of combustible sugar dust hanging throughout the packaging plant. 

2010: Chester Flour Mill Silo Explosion

In April 2010, the ConAgra Silo in Chester, Illinois exploded into a fireball, severely injuring three workers that were clearing a clogged leg vessel in a smoldered silo. The explosion occurred when one of the workers unclogged the leg, exposing it to oxygen that interacted with airborne dust. The ensuing explosion blew massive amounts of concrete from the top of the silo and caused a tremor that shook homes for miles around.

2021: Derst Baking Company Explosion

On September 14, 2021, two team members at Derst Baking Company in Savannah, Georgia suffered injuries from an explosion in the flour mixing room. The Savannah Fire Department investigation report reveals that several electrical components within the sifting room were exposed at the time of the explosion, acting as an ignition source.

How Aegex Technologies Can Help the Industry Mitigate Explosion Risks

There are myriad factors contributing to the risk of flour and dust explosions. Top among them are inadequate ventilation, improper maintenance, poor housekeeping, and equipment that generates heat, static electricity, or explosion. 

In environments such as flour and sugar processing facilities, where combustible dust particles can pose a serious explosion risk, implementing intrinsically safe technology is crucial to ensure safety and prevent potential disasters. 

Aegex Technologies is the leading provider of intrinsically safe solutions designed to eliminate the risk of explosions in Zone 1 environments. Here's how Aegex's digital tools can help the industry mitigate these risks:

• Prevention of sparks or heat: Aegex's intrinsically safe tablets, such as the Aegex100M and other mobile devices, are certified to be safe for use in Zone 1 hazardous environments. These devices are engineered to prevent the generation of sparks or heat that could ignite flammable substances. Workers can use these specialized devices to access information, communicate, and monitor processes without posing an ignition risk.
• Real-time monitoring and communication: Real-time detection and monitoring of dust and flour particles are pivotal in averting explosion risks within the flour and sugar milling environments. Workers can communicate seamlessly using these devices while staying connected to supervisors, enabling quick responses to potential hazards.
• Documentation and compliance: Aegex's digital tools come equipped with software solutions that aid documentation, compliance reporting, and regulatory adherence. This feature helps maintain records to ensure proper safety protocols and to simplify maintenance audits.

Aegex Technologies' Solutions Can Eliminate the Risks of Deadly Explosions

Flour and sugar industries are often labeled as Zone 1 environments due to the potential presence of combustible dust particles in the processing facilities. Over the years, far too many have died in the ensuing explosions and fires that occur in these facilities. Incorporating Aegex's intrinsically safe solutions can be an effective explosion mitigation strategy that ensures a safer working environment for employees. Contact us today to schedule a free demo.