Inspection Detail

Inspection: 122113871 - Malden Mills Industries

Inspection Information - Office: Boston North Area Office

Investigation Summary

The employer manufacturers various types of textile products for upholstery and clothing. One production process for an upholstery product is known as flocking. During this process, small chemically-treated nylon fibers are applied to a fabric backing using an electrical field. Three of the company's five flock lines are located on the first through third floors and were in operation. A sudden explosion/deflagration occurred on the first floor, originating at the beginning of the production lines where some employees were cleaning. The explosion/deflagration moved throughout the entire first floor of the building with great force, leaving only small incidental fires. Employees #1 through #13 were injured. Employees located closest to the explosion suffered multiple burns. Employees further away sustained less severe burns. Some injured employees were located on the second floor directly above the explosion point. They sustained minor injuries, smoke inhalation, bruise and contusions. Some of the employees who helped with a search and rescue were treated for smoke inhalation. The explosion was caused by an electrical spark which ignited a combustible nylon fiber dust cloud in the hopper room at the beginning of a production line. The hopper room is where the nylon fibers are applied to the cloth backing.

Keywords: BURN, DUST, WORK RULES, FIRE, EXPLOSION, SPARK, COMBUSTIBLE DUST, SMOKE INHALATION, CONTUSION