Safety Issues and Resolutions inModern Bakeries

Tenchi Gao SmithAuburn University

5:40pm Sunday, May 31, 2015

Current Situation

• Bakery Business: Growing at 5% per Year• Safety Awareness: Lacking

OSHA Citations9 out of 10 most frequently cited OSHA violations relate to bakery industry:

• Fall protection• Hazard communication• Respiratory protection• Electrical and wiring methods• Powered industrial trucks• Ladders• Lockout/tagout• Electrical and general requirements • Machine guarding

Types of Bakeries

• Wholesale bakeries– Larger scale – Large and heavy machining and automation– Supply grocery stores and retail bakery stores

• Retail bakeries – Bake as they sell to individual customers

Baking Processes

1. Mixing: industrial mixer2. Flour cooling: cooling of the dough to a

desired temperature. 3. Forming/cutting 4. Baking5. Decorating and Packaging6. Storage

Hazards

• Slips, Trips and Falls• Combustible Dust• Electrical Safety• Machine Guarding/Cuts/Burns• Confined Space• Ergonomic Hazards• Respiratory Problems and Allergies• Housekeeping

Slip, Trip & Fall

• 15% of all accidental deaths• Second to motor vehicles as cause of fatalities

Bakery Slip Trip Fall Injury

• 2005 Injury• 34-year-old worker killed when fell into a 7-ft-

deep fermentation tank • At wholesale bakery• Worker was cleaning the lid and outer portion

of the top of the tank with a cleaning pad• Fell when the pad apparently fell to the

bottom of the tank

Combustible Dust

• 1st documented combustible dust explosion in history • December 14, 1785 • Mr. Giacomelli's Bakery on at Turin, Italy

• 2006• 119 lives and injured 718 people in 25 years

• 2009• Worst combustible dust explosion • Imperial Sugar Factory, Port Wentworth, GA• 14 fatalities

Imperial Sugar Plant Explosion, 2009

Combustion Conditions

• Mixture of enough oxygen• Certain density of combustible dust• Ignition source

• Ex. Large quantity of – Flour– Sugar

Ergonomic Hazards• Heavy loading • Frequent lifting• Awkward posture: twisting• Vibration: tools• Inadequate lighting• Prolonged standing• inappropriate workstation set-ups and heights

• High Musculoskeletal Disorder (MSD) Risks at Hand, Wrist, Shoulder and Low Back

Recommendations

• Current Bakery Standards• Five Hierarchies of Hazard Control– Elimination– Substitution– Engineering controls– Administrative controls– Personal Protective Equipment (PPE)

Current Standards

• OSHA 29 CFR 1910.263– design, installation, operation and maintenance of

machinery and equipment used within a bakery• ANSI Z50.1 & ANSI Z50.2-2013 Safety

Standards – design, construction, installation, safe operation,

and maintenance of bakery machinery and equipment

Hazard Control Hierarchies

• Elimination• Substitution • Engineering Controls• Administrative Controls• Personal Protective Equipment (PPE)

Elimination

• Eliminating the hazard from root– Modify • Job design• Equipment• Tools

– Effective measure

Substitution

• If cannot be eliminated• Substitute with ex.– Less corrosive cleaning supplies

Engineering Control

3 Principles1. Design facility, equipment, or process to

remove the hazard2. Enclose hazard: – Prevent exposure

3. Establish barriers or local ventilation: – Reduce exposure to hazard

Administrative Control

• Task rotation• Regular rest breaks• Periodic inspection• Adequate training

Personal Protective Equipment (PPE)

• Quick• Cost Effective

Personal Protective Equipment (PPE)

• Respirators – Inhalable flour dust

• Protective clothing, such as aprons and gloves • Soft rubber mats: – Prolonged standing

• Hand-lifts, trolleys, and rolling carts:– Moving heavy objects High-temperature silicone

oven mitts and handle holders are to be used when handling hot objects.

Personal Protective Equipment (PPE)

• Industrial non-slip floor surfaces: –Prevent slip, trip, and fall injuries

• Hearing protection • Eye protection: –Corrosive materials

Tenchi Gao Smithtzg0014@auburn.edu