Safety Excellence: Leveraging SUPERGAS LPG for Foam Extrusion Applications

Foam Extrusion

A case study of a customer who trusted and partnered with SUPERGAS for their LPG needs for consistent quality, safety compliance, and optimal production.

Abstract

This case study explores the transition of a customer from using refinery-grade LPG, which led to quality and safety challenges, to adopting SUPERGAS's Straight Run Grade LPG. Noticing safety discrepancies in the client's manifold system and LPG handling, SUPERGAS recommended an installation revamp according to IS 6044 standards. Post-installation, SUPERGAS not only ensured compliance with safety norms but also provided ongoing safety training and audits. This intervention allowed the customer to significantly improve production quality and workplace safety, emphasizing the importance of quality fuel and rigorous safety practices in industrial operations.

LPG for Foam Extrusion Process

Foam extrusion creates cellular polymers by introducing a gas or foaming agent into molten polymer material in an extruder. LPG is used as the foaming agent due to the desirable properties it imparts to the final extruded foam product such as improved cell structure. LPG is injected into the polymer melt, facilitating the creation of the foam’s cellular structure. Furthermore, LPG contributes to the overall quality and uniformity of the extruded foam.

Operational and Technical Impact Study

Before Switching to SUPERGAS	After Switching to SUPERGAS
The platform height was only 700 mm, and the customer was using a crane to unload LPG cylinders which is unsafe.	The platform height was changed from 700 mm to 1100 mm from the ground level as per requirement for safe loading/unloading of cylinders.
Manifold near the factory valve and open window	Manifold with TRV & EFCV installed by SUPERGAS.
Foreign materials in the installation and only one earthing was provided.	Removal of foreign material inside/outside the LPG yard and addition of one more earthing pit.
No Safety distance as per IS guidelines. No copper jumpers and no ventilation.	Installation redesign as IS 6044 guidelines
Violation of other statutory guidelines like lack of thermal relief valves, flow check valves, safety sign board and inadequate fire extinguishers.	SUPERGAS installed fences and cabling in the LPG yard, provided safety boards and fire extinguishers as per IS guidelines.
Multiple unconnected cylinders, which is a violation of statutory rules.	Unconnected cylinders removed from the LPG yard.
The former supplier overlooked safe LPG cylinder installation, handling, and storage	The LPG yard area was redesigned and extended as per the required cylinder manifold installation for better accessibility

Benefits Observed by the Customer

With technical clearance achieved, SUPERGAS commenced supplying SR Grade LPG, complemented by comprehensive safety training for operational and cylinder handling processes.

Furthermore, regular safety training and audits by SUPERGAS have fortified the customer’s confidence in maintaining a production environment free from safety concerns.

The customer now enjoys a secure LPG yard, enhanced end-product quality, diminished accident fears, minimal gas residuals, and consistent gas supply, marking a significant turnaround in operational efficiency and safety.