Health & Fitness for Textile Workers: Part 2 – The Weaving Mill

Following our detailed discussion on the health and fitness considerations for spinning mill workers, we now move to the weaving mill. This department transforms yarn into fabric, a process rich with its own unique set of demands and potential health challenges.

The weaving shed is a dynamic environment, often characterized by the rhythmic, powerful thud of looms. While perhaps less associated with fine dust than spinning, weaving presents significant issues related to noise, repetitive movements, and visual demands. Understanding these specific factors is key to tailoring your health and fitness approach.

I. Understanding the Environment: Specific Health Risks for Weaving Mill Workers

Workers in weaving mills operate a vast array of looms, from traditional shuttle looms to modern rapier, air-jet, and water-jet looms. Each type, while efficient, contributes to particular occupational hazards.

A. Noise-Induced Hearing Loss (NIHL): The Dominant Hazard

• Extreme Noise Levels: Weaving sheds are among the noisiest environments in the textile industry. The continuous operation of multiple looms generates sound levels that routinely exceed safe limits (often well above 90 dB(A)), particularly from shuttle movements, picking mechanisms, and air jets.
• Mechanism of Damage: Prolonged and unprotected exposure to these high noise levels causes irreversible damage to the delicate hair cells in the cochlea (inner ear), leading to permanent hearing loss.
• Effects:
  • Gradual Hearing Loss: Often occurs slowly, making it difficult for workers to notice until significant damage has occurred.
  • Tinnitus: Persistent ringing, buzzing, or hissing sounds in the ears, which can be constant and highly distressing.
  • Communication Difficulties: Struggling to hear conversations, especially in noisy environments, leading to social isolation and reduced quality of life.

B. Musculoskeletal Disorders (MSDs): Repetition, Posture, and Force

Weaving tasks involve significant repetitive movements and often sustained, awkward postures.

• Repetitive Strain Injuries (RSIs):
  • Upper Limbs (Hands, Wrists, Forearms, Shoulders): Attending to warp and weft breaks, knotting threads, replacing bobbins/packages, and operating loom controls require fine motor skills and highly repetitive hand and arm motions. This increases the risk of:
    • Carpal Tunnel Syndrome: Compression of the median nerve in the wrist.
    • Tendinitis: Inflammation of tendons, especially in the wrist, elbow (“tennis elbow” or “golfer’s elbow”), and shoulder (rotator cuff).
    • De Quervain’s Tenosynovitis: Pain and swelling at the base of the thumb and wrist.
  • Neck and Shoulders: Prolonged periods of looking down at the fabric or warp beams, or reaching overhead to adjust machinery, can lead to chronic neck and shoulder pain, stiffness, and tension headaches.
• Lower Back Pain: Prolonged standing on hard surfaces, bending to inspect lower parts of the loom, or occasionally pushing/pulling heavy beam trolleys can strain the lower back.
• Lower Limbs: Continuous standing can lead to foot pain, leg fatigue, and contribute to conditions like varicose veins.

C. Respiratory Health: Dust and Microfibers

While typically less dusty than spinning, weaving mills still present respiratory challenges:

• Fiber Dust: Fine dust particles from yarn (cotton, synthetic, blends) can be aerosolized during the weaving process.
• Sizing Dust: When yarn is “sized” (coated with starches or synthetic polymers to improve strength for weaving), this sizing material can become airborne dust, potentially causing irritation or respiratory symptoms in sensitive individuals.
• Humidification: Weaving sheds often maintain high humidity to reduce static electricity and improve yarn workability, which can sometimes contribute to mold growth if not properly managed, potentially impacting respiratory health.

D. Eye Strain and Fatigue:

• Visual Acuity: Weavers constantly focus on fine threads, identify breaks, and visually inspect fabric for defects. This intense visual demand, often under artificial lighting, can lead to:
  • Eye Strain: Headaches, blurred vision, dry eyes, and general ocular discomfort.
  • Fatigue: Reduced concentration and increased error rates towards the end of a shift.
• Flying Particles: Though less common than spinning, individual fiber fragments or small machine debris can pose an eye injury risk if protective eyewear is not consistently used.

E. Stress and Fatigue:

• Production Pressures: The fast pace of loom operation and strict production targets can contribute to significant work-related stress.
• Constant Vigilance: The need to continuously monitor looms for breaks or defects requires high levels of concentration, leading to mental fatigue.
• Shift Work: Like many mill departments, shift work can disrupt natural sleep cycles, contributing to chronic fatigue and impacting overall health.

II. Targeted Health & Fitness Strategies for Weaving Mill Workers

Protecting yourself in the weaving shed requires a dedicated and proactive approach.

A. Hearing Conservation: Absolute Priority

1. Consistent Use of Hearing Protection: This is non-negotiable. Always wear earplugs or earmuffs provided by the mill. Ensure they are correctly fitted and used for 100% of the time you are in noisy areas. Even brief, unprotected exposure can contribute to damage.
2. Regular Audiometric Testing: Participate in routine hearing tests. Early detection of changes allows for intervention and prevents further loss.
3. Awareness: Understand that hearing damage is irreversible. Educate yourself and your colleagues on the importance of hearing protection.

B. Ergonomics & Movement for Musculoskeletal Health:

Combatting RSIs and back pain requires conscious movement and posture.

1. Micro-Breaks & Dynamic Stretching:
   • Take frequent, short breaks (e.g., 1-2 minutes every hour) to step away from the loom and perform targeted stretches.
   • Upper Body: Perform gentle wrist rotations, finger flexions/extensions, shoulder shrugs and rolls, and neck tilts.
   • Lower Back: Gentle standing backbends, side bends, and pelvic tilts.
   • Legs: Calf stretches and heel/toe raises.
2. Posture Awareness:
   • Standing: Maintain an upright posture with shoulders relaxed and core gently engaged. Avoid hunching over the loom.
   • Reaching: Try to minimize excessive reaching. If possible, adjust your position relative to the loom.
   • Material Handling: When moving beam trolleys or other heavy items, push with your legs, keep your back straight, and avoid twisting.
3. Supportive Footwear: Wear comfortable, well-cushioned, and supportive safety shoes to absorb shock from prolonged standing and walking on hard concrete floors.

C. Respiratory & Eye Care:

1. Dust Protection: If dust is noticeable, ensure you use the appropriate respirator or mask provided, especially when cleaning or maintaining looms. Support good mill ventilation practices.
2. Protective Eyewear: Always wear safety glasses or goggles, particularly when working with fast-moving parts, warp/weft breaks, or during maintenance, to protect against flying fibers or debris.
3. Eye Exercises: Every 20 minutes, look away from your work for 20 seconds at something 20 feet away (the 20-20-20 rule) to reduce eye strain. Blink frequently.

D. Holistic Well-being: Beyond the Mill Floor:

1. Consistent Hydration: Keep a water bottle readily accessible and drink water regularly throughout your shift, especially in warm environments.
2. Nutrient-Rich Diet: Fuel your body with balanced meals and healthy snacks that provide sustained energy.
3. Quality Sleep: Prioritize 7-9 hours of restful sleep. If you work shifts, establish a strict sleep routine to minimize disruption to your circadian rhythm.
4. Stress Management: Engage in activities outside of work that help you de-stress and relax, whether it’s exercise, spending time with family, or pursuing hobbies.

Conclusion

Working in a weaving mill demands resilience and vigilance. By proactively addressing the risks of noise, repetitive strain, and maintaining overall well-being, you can ensure a long, healthy, and productive career. Your commitment to your health not only benefits you but contributes to a safer and more efficient weaving environment for everyone.

Join us for the next lecture, where we will explore the unique health and fitness challenges and solutions for those in the Dyeing and Finishing Departments!