KONG Air Quality Assessment

Overview

The KONG dog toy factory, located in Golden, CO, tasked the Golden Retrievers with identifying the sources of odor and haze on the factory floor and developing a solution to create a more comfortable work environment. Using slightly different formulas, toys of varying color, size, shape and durability are created. The process that the factory uses to produce rubber dog toys releases fumes as the molded parts are removed from the molding machines and cool down. The toys off-gas both visible and invisible fumes during the cycle and curing process, which is important to maintain to preserve the integrity of the finished product. In addition, factory workers manually trim and count the finished toys. Air quality testing performed by an independent laboratory concluded that there were no health or safety concerns associated with the levels of fumes present at KONG, so workplace comfort for the machine operators is the main focus of the project.

The challenge of this project was to find the major source(s) of the odor and fumes. While visible off-gassing occurs in large quantities when the freshly molded toys are released from the machines, toys that are cooling down sit in intermediate bins and large storage bins located at every workstation. These parts continue to off-gas for hours after they are formed while they are still warm. By testing the levels of volatile organic compounds (VOCs) at numerous locations, the major source was found to be these intermediate holding bins that sit open to the ambient air and contain parts that are still hot. Our project summarizes our findings during testing and includes a few recommendations for better capture of the fumes in the factory.

After initial observations, we wanted to better capture the visible fumes and contain the toys while they were hot. Our initial designs were focused on containing the fumes and funneling them into the existing ventilation system. We proposed intermediate bins that could be placed under the snorkel and surrounded by plexiglass panels to prevent the fumes from being blown around the factory. We also designed intermediate bins that had a small opening to insert finished parts with a vacuum hose to vent all fumes into the ventilation system. To capture steam and gas coming from the initial release from the molds, we proposed modifying the ducting over the back of the machine. A flow meter was used to test the abilities of the ventilation system to capture air from the factory. The circular openings of the snorkel and vent over the back of the machines have sufficient flow, but are the incorrect shape for optimum fume capture. 

The ventilation system itself was also identified as a potential issue. The flow meter was used to measure the drop in air flow as the pre filters become dirty over time. Bag filters and carbon adsorption filters within the system are a possible source of concern as well since they have not been changed since their installation over a year ago. The decision was made to test the factory air for VOCs and particulate matter to identify the main sources of odor. Addressing the areas of the factory that produce the majority of the fumes will contribute the most to increased comfort for the factory workers. In order to accomplish our goal, the team conducted VOC testing at several locations in the factory at varying times throughout normal workdays and over the weekend when the machines were not in use. The results of these tests drove some of our design iterations. We focused more on the cooling parts and those left open to the ambient factory air than on the fumes released during mold opening.

The client needs drove the design iterations to the final design. It was imperative that the solution was not an obstruction to the workers and that it would not change their workflow or process. The client also expressed that there should be no interference with the molding or the cooling process. There was a budget of $125,000 to fully implement the team’s solution if it was found to be satisfactory and necessary. For our final solutions, we focused on containing the fumes released by the toys in the intermediate bins and gaylords.

The team’s recommended design solution is to implement the use of bins and gaylords with lids that can seal most of the fumes inside. To do this, the intermediate bins would be replaced entirely with clear plastic bins that have a latchable opening. In the top of the box would be a small grommet that allows for single toys to be inserted, while also helping to keep the box relatively sealed. The solution for the gaylords would not require a new container, but instead an attachable lid would just be added. This lid would be very similar to that of the bin previously mentioned, but would be entirely detachable for unobstructed access to the entire gaylord contents. This lid could be attached by either a magnet system or a slide lock. By implementing these new container options, it would keep most of the fumes released by the toys inside the container. Although there would be significant release of the fumes when opened, as well as steady leaking of small amounts, the solution would be much more effective than the current process.