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 omissions, 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 Risk – Similar to other hazardous manufacturing Reduction • Reuters Data from OSHA Records 2009 - 2012 – At least 4 deaths in US craft brewery – 2 deaths at large breweries that brew 10x more Compliance beer – Nearly 4x more safety violations at craft breweries – Safety oversight at smaller companies worse Business than statistics show Impacts • Injuries may not be reported
Why focus on safety? • Occupational Health and Safety Risk Administration (OSHA) Reduction – Federal & State OSHA • General Duty Clause – Must provide a safe and healthy place of Compliance employment • Example regulations: – Hazard Communication, Confined Spaces, Business Hazardous Energy Control, PPE, Fall Impacts Protection, Powered Industrial Trucks
Why focus on safety? • Save money! Risk – Reduce financial impact of injuries and illnesses Reduction – Reduced insurance and workers comp. costs • Equipment down time • Product loss Compliance • Brand equity • More effective/efficient work practices & procedures Business Impacts • Sustainability
Brewery Hazards Walking and Chemicals Ergonomics Working Falls Surfaces Confined Machinery / Forklifts Electrical Spaces Moving Parts 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 occupancy • 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 or 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 Alternate Permitted Prevent Entry Entry Entry • Only enter if • Method for • Permit system with absolutely entering permit preplanning, necessary!! space without an assigned personnel entry permit roles, rescue services, etc. • Eliminate or control hazards • Most requirements before entry • Reduced 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 Source: www.craftbrewingbusiness.com Collisions with other forklifts or pedestrians
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: CO 2 , 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
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