Brewery Hazards and Methods for Reducing Risk Presented by Andrew - - PowerPoint PPT Presentation

Brewery Hazards and Methods for Reducing Risk

Presented by Andrew Dagnan, CHMM GOSH Conference March 11, 2015

DISCLAIMER

• This is just a basic overview of brewery hazards and methods to

reduce risk and/or to ensure regulatory compliance.

• While every effort has been made to assure the information

provided herein is complete and accurate, it is not intended to take the place of published rules, statutes, regulations or your responsibility concerning the use of proper procedures. The contents of these tools may not be relied upon as a substitute for your responsibility to incorporate the most current text or information.

• The Master Brewer’s Association of the Americas (MBAA) does not

assume any responsibility for omissions, errors, misprinting or ambiguity contained within this publication and shall not be held liable in any degree for any loss, or injury, caused by such

• missions, errors, misprinting, or ambiguity in presentation.
• If legal advice or other expert assistance is required, the services of

a competent professional person should be sought.

Agenda

• Importance of Safety
• Hazards overview and control methods
• Proactive Risk Reduction

– Safety Committees – Job Hazard Analysis (JHA) Overview – Near Miss reporting

Why focus on safety?

• Many hazards present in breweries

– Similar to other hazardous manufacturing

• Reuters Data from OSHA Records 2009 -

2012

– At least 4 deaths in US craft brewery – 2 deaths at large breweries that brew 10x more beer – Nearly 4x more safety violations at craft breweries – Safety oversight at smaller companies worse than statistics show

• Injuries may not be reported

Risk Reduction Compliance Business Impacts

Why focus on safety?

• Occupational Health and Safety

Administration (OSHA)

– Federal & State OSHA

• General Duty Clause

– Must provide a safe and healthy place of employment

• Example regulations:

– Hazard Communication, Confined Spaces, Hazardous Energy Control, PPE, Fall Protection, Powered Industrial Trucks

Risk Reduction Compliance Business Impacts

Why focus on safety?

Risk Reduction Compliance Business Impacts

• Save money!

– Reduce financial impact of injuries and illnesses – Reduced insurance and workers comp. costs

• Equipment down time
• Product loss
• Brand equity
• More effective/efficient work practices &

procedures

• Sustainability

Brewery Hazards

Chemicals Ergonomics Walking and Working Surfaces Falls Confined Spaces Forklifts Machinery / Moving Parts Electrical Thermal Pressure CO2 And More!

Ergonomic Hazards

Repetitive motions Lifting: malt bags, moving hoses Awkward postures Leaning / reaching / bending Forceful grips

Source: www.lni.wa.gov:

Ergonomic Hazards (cont.)

• National Institute of Occupational Safety and Health

(NIOSH) study: Ergonomic and Safety Climate Evaluation at a Brewery – Colorado (2011)

• Some conclusions from the study:

– Employees at increased risk for upper extremity (shoulder and wrist) Work-related Musculoskeletal Disorders (WMSDs) – Employees exposed to combination of ergonomic risk factors – Survey indicated that 50% of employees felt safety training received was not adequate and safety procedures in place don’t work

Ergonomic Hazards – Controls

• Reduce / Eliminate lifts

– Automate processes – Keg robots – Hoists / lifts – Conveyors – Bulk (silos, super sacks)

• Two-person lifts
• Training on proper lifting
• Employee stretching program

Walking and Working Surfaces - Hazards

Wet / slippery floors Trip hazards (e.g., hoses) Tight spaces Improperly stacked items Tools and other items left out Uneven surfaces

Ergonomic Hazards – General Controls

• Redesign tools / areas within appropriate heights

– Above knees, below shoulders

• Height adjustable tools / tables
• Training
• Rotate employees
• Encourage micro breaks
• Encourage employees to report injuries and near

misses

Walking and Working Surfaces – General Requirements

• Keep workplaces clean, orderly, and sanitary
• Keep floors as clean and dry as possible
• Keep aisles clear and free of obstructions that

could create a hazard

• Ensure aisles are wide enough where

mechanical handling equipment is used

Walking and Working Surfaces – Controls

• Marking aisle ways
• Implement general housekeeping procedures

– Keep aisles, stairs, and platforms free of clutter – Store materials properly – Store items on shelves safely and securely

• Cleanup spills immediately
• Monthly walk-throughs looking for hazards
• Non-slip surface coating on floors

Fall Protection – General Requirements

• Generally…fall protection required when working at

heights above 4 ft.

• Elevated work platforms

– Handrails with a midrail – 4” toeboard – Guard openings with a swing gate

• Stairways

– Usable width of ≥22 in. with slip-resistant treads – Angled between 30 - 50 degrees – Railings on open sides of exposed stairways, if ≥ 4 steps

Fall Protection – Prevention

Fall Protection – Prevention

Confined Spaces

• Confined Space:

– Large enough to bodily enter and perform work – Limited means of entry or exit – Not designed for continuous human

• ccupancy
• Permit Required Confined Space

– “Permit Space” – Confined space with hazards

Confined Spaces (cont.)

• Permit Space: confined space which meets

any of the following:

– It has or has the potential to contain a hazardous atmosphere – It has a material that could engulf the entrant – It has an internal configuration which could trap

• r asphyxiate

– It has any other recognized serious safety or health hazard(s) that can inhibit an Entrant’s ability to self-rescue

Confined Spaces (cont.)

• In general, it is safe to assume that most

brewhouse tanks are Permit Spaces

– Brewhouse tanks have various hazards including: hot liquids, chemicals, CO2, moving parts, loose grain, etc.

Source: www.soundbrew.com

Confined Spaces – Entry Methods

• “Entry” = any body part crosses plane of opening
• Only enter if absolutely necessary!!

– Create non-restricted access (e.g., add stairs or walkway) – Perform tank inspections from outside space – Clean-in-place (CIP) systems – Add to tanks without entering – Design area for human occupancy

Permit Spaces – Entry Methods

Prevent Entry

• Only enter if

absolutely necessary!!

Alternate Entry

• Method for

entering permit space without an entry permit

• Eliminate or

control hazards before entry

• Reduced

requirements

Permitted Entry

• Permit system with

preplanning, assigned personnel roles, rescue services, etc.

• Most requirements

Powered Industrial Trucks (PITs)

• Mobile, power-propelled truck used to carry,

push, pull, lift, or stack materials

• AKA: forklifts, pallet trucks, rider trucks,

forktrucks, or lift trucks

Source:forklifts.hyundai.eu

PIT Hazards

Instability due to overloading or unstable stacking Instability due to compact design Obstructions or pedestrians in pathway Collisions with other forklifts or pedestrians

Source: www.craftbrewingbusiness.com

PITs – Requirements / Controls

• Written program & documented training
• Daily inspections (each shift if 24-hour facility)
• Various truck requirements including maintenance,

design, ratings, etc.

• Never load a PIT outside of its rated capacity
• Safe Operation

– Use seat belt – Lower load before moving – Be aware of surroundings – Use mirrors – Drive slowly

PITs – Requirements / Controls (cont.)

• Designate areas / aisle ways
• Inspect pallets before moving
• Train all employees on safely working around PITs
• High-visibility vests in PIT areas
• Hazard lights/alarms
• Limit access to PIT areas

Chemical Safety – Common Chemicals

• Caustics: sodium hydroxide, sodium hypochlorite
• Acids: phosphoric, nitric, iodophor, and peracetic acid
• Gases: CO2, oxygen, ammonia, ozone
• Flammables: isopropanol, aerosols
• Oils & lubricants
• Refrigerants
• Glues

Source: www.reflexallen.com

Chemical Safety – General Requirements

• Written Hazard Communication

program

• Training
• Storage: Cabinet or containment

pallet

• Separate incompatible chemicals
• Label all chemical containers
• Have MSDS for each chemical

Hazard Communication Changes

• U.S. adopted UN standard for labeling and

communicating chemical information

– Referred to as the “Globally Harmonized System (GHS)”

• MSDSs renamed SDSs (Safety Data Sheets)

– New SDS format will be implemented over next several years

• Updated labeling requirements
• Additional training requirements

Personal Protective Equipment (PPE)

• PPE = last line of defense

– Only use PPE if cannot use engineering or administrative controls

• Documented program and training

– Selection, use, maintenance, limitations, when to change, etc.

• Hazard assessments of tasks
• Provide PPE
• Separate programs for respirators & hearing

protection

Noise – Hearing Protection

• Breweries can be very LOUD!
• Must have a Hearing Conservation Program if

employee noise exposures meet or exceed an 8- hour time weighted average (TWA) of 85 dbA

• If hearing protection is needed, follow all

requirements such as the following:

– Control noise levels – Provide hearing protection – Provide annual audiometric testing – Provide training

Respiratory Protection

• May need to use respiratory protection during tasks

such as the following:

– Milling – Cleaning-up grain dust – Pouring diatomaceous earth (DE)

• Complete air monitoring to determine need
• If needed, follow all respiratory protection

requirements including:

– Written program and training – Fit test – Medical evaluation – Cleaning / Maintenance

Head Protection – Bump Caps

• Head injuries (e.g., bumps, minor cuts) common
• Bump caps are an easy way to reduce minor cuts, bumps,

bruises, etc. is to use bump caps

• Some look / feel like a regular baseball cap
• Can get hats with built-in bump cap or hat inserts

Source: www.grainger.com

Lockout / Tagout (LOTO) – Control of Hazardous Energies

• Prevent injury to employees working with

hazardous energies

• Example situations to use LOTO:

– Permit required confined space entry – Remove a guard or bypass a safety device – Perform maintenance on automatic starting equipment

• General Requirements

– Written program with equipment specific procedures – Training – Equipment: ID tags and locks that are uniquely keyed for each individual

Thermal Hazards

• OSHA Requirement

– Cover or guard steam & hot-water pipes within 7 ft. of floor or working platform or within 15 in. of stairways, ramps, or fixed ladders to prevent contact

• Example Controls

– Steam and hot water pipe insulation – Label hot surfaces – Written procedures for employees – Training: Ensure employees familiar with systems – PPE: long sleeves and pants, safety glasses, and gloves

Source: www.labelmaster.com

CO2 Safety

• Ensure adequate ventilation throughout brewhouse

– Even in large rooms, CO2 can accumulate

• Monitors / Alarms

– Area monitors/alarms – Personal O2 / CO2 monitors

• Develop protocols for evacuations, posted at each

monitor

• Train employees on alarms and evacuation procedures
• Ensure monitors are calibrated

Keg Safety

• Brewers Association Performance Guidelines for

Refillable Kegs (2014)

– Never alter or tamper with safety devices – Never tamper with keg valve – Systems connected to kegs should have a pressure regulator and pressure relief valve – Maintain pressure, temperature, volume, and flow settings on wash/fill equipment according to the manufacturer

• Only use kegs from your own brewery
• Inspect kegs, sankey valve, steel ball, and o-ring

Proactive Approach to Reducing Hazards

Safety Meetings / Committees Job Hazard Analysis (JHA) Reporting Near Misses

Safety Meetings / Committees

• Safety meetings or committees required based
• n company size
• Use meetings to identify and eliminate

hazards

– Discuss accidents and near misses, develop recommendations, and assign actions

• Empowers employees to speak-up and share

responsibility in maintaining a safe workplace

• Creates and promotes a safety culture

Job Hazard Analyses (JHA)

• JHA: Technique used to review tasks to

identify hazards before they occur.

• Job: A typical “job” includes numerous “tasks”
• Good for observing and eliminating hazards

and meeting regulatory requirements

• Can also be called a Job Safety Analysis (JSA)

JHA Process

• 1. Prioritize tasks
• 2. Review procedures, manuals, and/or applicable

safety documentation

• 3. Observe work to learn the task
• Take numerous pictures
• 4. Complete JHA documentation
• Develop recommended controls
• 5. Prioritize recommendations
• 6. Assign actions to reduce/eliminate hazards
• 7. Use JHAs for training

JHA Process – Reducing Hazards

• Implement controls based on the following

hierarchy:

PPE Administrative Control Engineering Control Elimination / Substitution

Report Near Misses

• Encourage employees to report EVERYTHING,

no matter how small

– Helps to eliminate/reduce hazards before accidents actually occur

• Helps build a strong safety culture
• Encourage reporting everything, don’t punish

employees for it

How to Learn More

• Brewing Engineering and Plant Operations,

MBAA Practical Handbook for the Specialty Brewer, Volume 3

• Industry safety committees

– MBAA Safety Committee – Brewers Association Safety Committee

• Contact your insurance carrier and/or vendors

How to Learn More (cont.)

• MBAA Brewery Safety Committee
• Website coming soon which will contain:

– Written program examples – Example “toolbox talks” – Q&A section – And more!

Summary

• Breweries have many hazards
• Be proactive!!
• Report, track, and investigate accidents and

near misses

• Documentation / program writing important

for compliance

• Encourage a healthy safety culture