"The Dustlight was well received by the employees because the traffic light logic makes it clear at a glance how high the dust exposure is. Figures alone are difficult to grasp, but the color indicators, especially red, make it immediately clear when protective measures are necessary."
- Olaf Obermann, Production Manager at Beka-Refractories
Background
Beck u. Kaltheuner Feuerfeste Erzeugnisse GmbH & Co. KG is a leading manufacturer of refractory products and material mixtures used in hot areas. Its product range includes a variety of concrete types, aggregates and components, which are manufactured according to individual customer requirements. The contact to Dustlight came about through the ACHEMA trade fair 2024 in Frankfurt
The raw materials are delivered in powder form and mixed, packaged and delivered at the plant according to the material requirements. In addition to the production of powder mixtures, Beka-Feuerfest has developed a second mainstay in the production of ramming and casting components, which are also manufactured according to individual customer requirements. Considerable amounts of dust are generated in the mixing and foundry where powder products are processed. To ensure the safety of employees, Beka-Refractories relies on continuous monitoring of dust exposure at the workplaces.
The challenge
Continuous monitoring of dust exposure with Dustlight was introduced to determine the actual exposure at individual workstations in production. Despite regular measurements in cooperation with the employers' liability insurance association, it is important to provide employees with a reliable assessment of their dust exposure.
Particularly in the mixing and foundry, where most dust is generated, extraction systems do not guarantee complete elimination. In addition, FFP3 masks are mandatory in many workplaces, which further increases the need for accurate occupational safety measurements.
Solution
Beka-Feuerfest uses the Dustlight to continuously monitor dust exposure. The portable device is worn by employees directly on their belts and passed around the various work areas. It measures the dust concentration in real time and uses a traffic light system (green, orange, red) to indicate when the exposure reaches critical levels.
The visual representation is particularly helpful: the color allows employees to recognize immediately when the exposure becomes dangerous over a longer period of time and protective measures, such as wearing a mask, are absolutely necessary.
Beka-Refractories is planning to build a new production facility to optimize production processes. While this plant is not specifically designed to reduce dust, the Dustlight will be used to monitor whether the changes in production are reducing dust levels.
Results
The introduction of the Dustlight was very well received by the employees. It not only creates transparency about the actual dust exposure, but also makes it easier to understand the need for protective measures. The simple color system makes it clear when a critical level of exposure has been reached and helps employees to work more safely. The device has provided valuable insights, particularly in the mixing and foundry areas, where dust levels are often in the orange or red range.
Close cooperation with the IT department enables a comprehensive evaluation of the collected data. This long-term analysis is crucial for identifying trends and developing targeted measures to improve working conditions. The data is collected and analyzed over several months in order to make well-founded decisions to optimize production processes.
Summary
The Dustlight has proven to be a valuable tool for monitoring and controlling dust pollution in production at Beck and Kaltheuner. It not only helps to protect employees, but also offers a long-term solution for improving production processes. Continuous monitoring and the simple display of data by the color system help to increase safety in the workplace and implement important measures in good time.
Further information as well as video and photo material can be found on the Beka-Feuerfest website and on YouTube.
Here you can find all our products at a glance.
