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In this November 2008 photo, Cameron Glass worker Kim Ball adjusts a machine that forms molten, 900-degree glass into clear wine bottles. Roger Werth / Daily News file

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Hot liquid spill shuts down Cameron Glass

Tuesday, January 6, 2009 12:13 AM PST

By Leila Summers

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KALAMA — The new $80 million Cameron Glass wine bottle factory in Kalama is shut down indefinitely after a molten glass leak early Sunday morning sent firefighters scrambling to prevent the superhot liquid from causing a partial collapse of the facility.

Firefighters discovered a hole at the bottom of the 470-ton electric melter around 12:30 a.m. Glass as hot as 2,500 degrees Fahrenheit was falling onto steel support beams and decking below, said Capt. Terry Sinkler of Cowlitz Fire District 5 in Kalama.

“Our main concern was keeping that support structure cool ... and cooling down what was coming out,” Sinkler said.

Nearly 40 firefighters worked for over 16 hours — from 12:30 a.m. to 4 p.m. — to cool the glass and minimize structural damage, Sinkler said.

Eventually, the molten, bright orange and red glass that “kind of looks like lava coming out” cooled enough to plug the hole itself, he said.

No injuries were reported. Cost damages weren’t available Monday.

Cameron Glass spokeswoman Lori Lecker said it’s still unclear how the leak will affect workers.

“We’re evaluating our entire labor situation and will be making decisions on temporary layoffs and ongoing maintenance and repair staffing levels in the coming days,” she said. “Regardless, we have every intention of making sure that everyone who is eligible for unemployment benefits will get those.”

The plant was expected to have 80 workers at full production.

Most of the glass leakage was contained in the basement of the facility. It’s still unclear what caused the leak, Lecker said.

“Given the temperature of molten glass, it will be several days before it cools enough so that repair work and investigative proceedings can begin. We are closely monitoring the situation and will provide updates on the repair process and cause of the failure as they become available,” Lecker said.

It’s too soon to say how far this will postpone the process of going to commercial production, she said. The plant was operating in the commissioning phase of production, which is essentially pre-production, Lecker added.

The $80 million facility was built by JH Kelly of Longview and handed over to Cameron glass in November.

Unnown01 wrote on Jan 6, 2009 1:24 AM:

" Wow 2 major incidents in 4 months glad I didn't put an app. In down there "

Beer&Skittles wrote on Jan 6, 2009 8:29 AM:

" What a flippin' mess! Cheesh... "

Kalama Dude wrote on Jan 6, 2009 8:40 AM:

" Seriously, a major safety injury and now this? I feel bad for those who have to wait out this places clearly poorly managed operation. How many months are they behind schedule now; at least 3 and probably that many more to come. Good luck to all. "

country gal wrote on Jan 6, 2009 8:41 AM:

" This is a new factory and already a leak? "

Lucky7 wrote on Jan 6, 2009 8:59 AM:

" Here's the posibilities:
1) Poor engineering
2) Faulty Construction
3) Improper operation
Or #4 and my personal bet: The 470-ton electric melter is an imported piece of junk from China! "

swan wrote on Jan 6, 2009 9:10 AM:

" beats a nuclear meltdown "

Lucky7 wrote on Jan 6, 2009 9:56 AM:

" Seriously I'd like to know who built the melter that obviously failed for one reason or another! I once bought a $14K imported machine from China for my busniess because the equal from a U.S. manufacturer was $26K, and the sales rep did a good sell job on me. Now 11 years later the Chinese equipment has long since been replaced by the U.S. machine becuase it was a piece of junk that never did what it was supposed to do, was problematic from the start and we could never get decent factory technical support. Learned an expensive lesson that I hope to never repeat. "

klb65 wrote on Jan 6, 2009 11:04 AM:

" Any start up has issues that is why they use this as a time to find any issues with equipment and correct them. Anytime hazadous material is involved, it is better it come to light in the pre production phase than after the production begins. No one was hurt, thankfully and the company will fix the issue, discover what caused it and move forward. Be grateful for the jobs that will supply income for at least 80 families and stop all the negativity already! "

American First wrote on Jan 6, 2009 2:55 PM:

" klb65 is right on, all you experts out there aren't even giving them a chance it's ridiculous. Kalama Dude, poorly managed? How do know this? Maybe you should offer your superior management skills and show them how it's done rather then then making pointless statements which are more then likely out of ignorance. And what exactly is a "major safety" injury? You sound like it's just to unsafe to work, so lets shut it all down. Get back to reality, please. I'm grateful for the having a new company in our local area, the opportunities it provides, and wish them complete success... "

Kalama Dude wrote on Jan 6, 2009 4:23 PM:

" I have tried to follow up to to my first message regarding the safety issues that won't go away in the eyes of the state, but it wasn't posted. I did offer my services thank you very much, but alas they were unwanted. Fine enough by me all along. I know of the safety issues so your ignornance comment actually would more likely apply to you American First. Unless you are one of the few managers at this plant you clearly know less than probably me. Thanks though "

snow shark wrote on Jan 6, 2009 5:45 PM:

" I worked with the manager of the plant for years. I call tell you that he is a honest and safety first person. The poster of negative rants about the "management" doesn't know the whole story.

It is nice to solve all the worlds problems here on this website.

Please get your facts straight. "

all about the hamiltons wrote on Jan 6, 2009 6:21 PM:

" They wouldn't put as much money into the place as they have to hire poor managers. This must be an equipment issue. If that is the case, hopefully the manufacture will do the right thing and make it right. I'm sure the company will fix it regardless. They're not going to get this far and walk away. They know business and saw the opportunity, so let's pray that all goes well and wish the company and their families our best. Good Luck Cameron Familyh Glass... we're all pulling for you! You are a shining light in this poor economy. "

Roudyruss wrote on Jan 6, 2009 6:31 PM:

" How could poor managment put a hole in the bottom of a melter? I would think that either it was manufacured or installed incorrectly. "

atj375 wrote on Jan 6, 2009 9:08 PM:

" I am a CFG employee, and the plant and operation there of will prevail because of the management and the people that work there. "

Kalama Dad wrote on Jan 6, 2009 10:28 PM:

" I am very proud to be a Cameron Glass employee, and cant say enough about our High class management and and my co-workers. This is by far the best place I have ever worked at. Our melter problem does not have anything to with management or saftey. It is a brand new plant and the largest of its kind...things are going to break down. "

American First wrote on Jan 6, 2009 11:15 PM:

" In the eyes of the state is that the best you can do Kalama Dude? You know whats in the eyes of the state, what a pathetic statement. If your services were offered but unwanted, the hiring practices at this business are clearly sound. There is some validity to my ignorance of this company's safety issues (if any), but to make negative comments about a company new to our area, (or old for that matter), which seems to be suffering some growing pains while trying to get a new plant running is just inappropriate. This company is investing in our local economy, creating jobs and paying taxes. I choose to be thankful & appreciative for this investment, rather then kick it when it stumbles, and I hope the state looks at it the same way offering help rather then the usual hurt. By the way I don't work there, but never applied or offered my services either, but maybe someday. Thanks for choosing Cowlitz County Cameron Glass... "

grams wrote on Jan 6, 2009 11:16 PM:

" atj375-- Well said. The flip side of this story is that no one was injured. I am sure that there must be waurentees and some business insurance to buffer this incident and I am sure that none of the local construction companies etc will be found at fault here. J H Kelly is a fine consruction company with very careful and experienced employees. Better this happens now rather than after start up and failure to fulfill contractual agreements for the product made hre. Thumbs up Cameron Glass. "

Joe Shmo wrote on Jan 7, 2009 7:34 AM:

" Obama will fix it all soon. "

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