CLAYPOOL, Ind. — Like its counterparts in 53 countries, Louis Dreyfus Commodities’ Claypool plant takes safety seriously. The towering complex, the world’s largest fully-integrated soybean processing and biodiesel plant, has been in operation for five years and has had its share of accidents. 

Each incident has been investigated, documented and reviewed to improve operations, Kurt Anderson, SH & E (safety, health and environment) manager at Claypool, told employees, contractors and suppliers attending the company’s third annual global safety day last week.

“Most of our slips, trips and falls can be attributed to icy conditions in the lot,” he said, “but the root cause is often failure of employees to follow procedures.”

“Safety is everyone’s responsibility,” this year’s slogan, was hammered home repeatedly throughout the session. Taking that a step further, a film presented by Marie Chery, LD’s human resource director for North America, focused on representative employees echoing one another by saying, “Safety is my responsibility.”

Estimating that 90 percent of accidents are based on poor decisions, Anderson noted that Louis Dreyfus is investing $70 million in 2012 to improve safety globally. “If you’re not doing it right, the company isn’t doing it right,” he said.

Because a Claypool employee derailed a freight engine by incorrectly handling the remote control, programs are now in place to license anyone working with the rail line. And because an employee slipped and fell from a step ladder propped against a building, the importance of knowing the difference between a step ladder and an extension ladder are stressed, with training on the use of each.

“Employees are our major assets,” Anderson said. “And management listens to them. So far this year, 505 suggestions have been made with many of them resulting in changes.” Anderson and plant manager Jeremy Mullins honored Steve Clements, Dale Gerrard and Brian Raymer, members of the management staff, for high scores on a recent safety test.

One of the most serious incidents occurring at the Claypool operation was not accidental. An employee had a heart attack while work on the megatech machine where beans come through two stories above the eight-story preparation building. It was a difficult time for everyone. A contractor had a crane on site; but because it was not licensed to transport humans, it could not be utilized. A two-hour rescue process ensued in which the man was safely lowered to the ground and transported by helicopter to an area hospital. The man lived and is doing fine.

However, since there is always a possibility another such incident could occur, Warsaw and Clay Township fire departments were on hand to perform a simulated rescue. “This won’t take as long as it did the last time,” one of the responders said as team members went to the top of what employees refer to as the penthouse – the tallest point in the plant. True to his word, in short order a dummy victim was lowered to the main roof and then guided down by firefighters holding guide ropes.

Other demonstrations included fire extinguisher training and a grain dust explosion demonstration.

Following lunch served by Our Father’s House, Warsaw, Chery honored 2011 safety winners and joined Anderson in recognizing contractors.