ResH&S 2012 FINAL

Recommendations

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THE FLAVOR AND EXTRACT MANUFACTURERS ASSOCIATIONsystems when possible. When systems mustremain open, local (“spot”) ventilation (e.g. “elephanttrunks”) should be used. Fume hoods arecommonly used in research and developmentlaboratories. Dilution through general roomventilation seldom results in exposure reductionunless extremely high volumes of air are circulated.Material handling – flavor compounding andpacking activitiesSimple flavor compounding activitiessuch as mixing or pouring can result in significantexposures. In most instances, mixing of liquidand dry flavors should be conducted in fullyor partially closed vessels with local ventilation.Opportunities for the generation of airborne particlesand aerosols should be minimized.Proper pouring techniques for liquid anddry flavors can greatly reduce opportunities forexposure. For liquid flavoring substances, techniquescan be adopted that pipe material intomixing vessels so that workers do not have topour. In some instances it is appropriate to pipein liquids below the surface of solutions in vesselsto minimize splashing. This is particularlyimportant for volatile substances.For dry and powdered flavors, pouringshould be conducted in such a way that the generationof airborne particulates is minimized.Simple, proper pouring techniques such as pouringslowly close to the mixing vessel can greatlyminimize airborne particulates. Mixing ingredientsin an order in which dry ingredients areadded last to liquid mixtures also can minimizeparticulate generation. Local exhaust is the mosteffective control for these operations. Systemscan be designed that will allow easy pouring andat the same time control exposures.Packaging activities can result in significantopportunities for exposure, especially whendry flavors are filled into bags, boxes, or drumsunder pressure. Closed systems should be usedwhen possible. But unless there is an unusuallyhigh degree of automation, workers will haveopportunities for exposure as filled containersmust be replaced with empty ones. The use ofpersonal protective equipment may then need tobe considered to minimize exposure.Material storageFlavoring substances that are volatileshould be stored in cooled storage areas. Substancessuch as acetaldehyde are often stored incooled rooms, and are often also used in flavormanufacture in a cooled state. Liquid and dryand powdered flavors should ideally be storedin store-rooms with their own air handler thathas minimum recirculation. In some instances,flavor facilities have negative air flow in storageareas to reduce opportunities for exposure.Cleaning of vessels and work areasCleaning of process vessels that containedliquid flavors or viscous mixtures, orwork areas with spilled material, especially withsteam or heated water, may create opportunitiesfor exposure to flavoring substances. Similarly,cleaning vessels or areas used to manufacture ormix powdered flavors with compressed air mayalso result in airborne particulates.It is important that cleaning activities beconducted in a manner that does not result in significantair concentrations of flavors and othermaterials present in the vessel. Cleaning areasshould be isolated and contained to prevent thedissemination of airborne flavors. Automatedcleaning processes will greatly reduce opportu-9
RESPIRATORY HEALTH AND SAFETY IN THE FLAVOR MANUFACTURING WORKPLACEnities for exposure. In some instances, the mosteffective way to protect workers responsible forcleaning activities will be to use respirators.It is also important that adequate care beexercised if workers are to enter or partially enterequipment in order to clean it. In addition toconcerns about possible respiratory exposures,in some instances, cleaning activities involvingvessel entry may be subject to the requirementsof OSHA’s confined space regulations (29 CFR1910.146).Personal respiratory protectionThe implementation of appropriate processand engineering controls is preferable tosimply providing employees with personal respiratoryprotection. However, respirators dohave a role in many respiratory health and safetyprograms. Critical to their success is the selectionof the proper respirator for the conditionspresent in a given facility, the proper fit of thatrespirator to the person using it, and the trainingin its use, maintenance, and storage. OSHA alsorequires that employees wearing most types ofrespirators undergo medical clearance prior totheir use.In terms of specific duty requirementsrelevant to protection against respiratory hazards,OSHA regulations require that personalprotective equipment must be provided to employeeswhenever necessary to address chemicalor other hazards which are “capable of causinginjury or impairment in the function of anypart of the body through absorption, inhalationor physical contact.” Under OSHA’s RespiratoryProtection Standard, the “primary objectiveshall be to prevent atmospheric contamination.”Where, however, that is not feasible through engineeringand process controls, respirators shallbe used. The regulations contain a range of requirements,including the proper selection ofrespirators, standard procedures for use, trainingof employees, respirator maintenance, andother safety measures. The standard and relevantbackground information were publishedin the Federal Register notice announcing thestandard (63 Fed. Reg. 1152. 8 January 1998).Important resources on the subjects ofexposure assessment and control include:■■ Diacetyl exposures in the flavor manufacturingindustry (Martyny et al., 2008).■■ Evaluation of a local exhaust ventilationsystem for controlling exposures during liquidflavor production (Dunn et al., 2008).■■ Occupational Exposure to Flavoring Substances:Health Effects and Hazard Control(OSHA, 2010).■■ OSHA National Emphasis Program forFacilities that Manufacture Food FlavoringsContaining Diacetyl (OSHA, 2011).■■ OSHA National Emphasis Program forMicrowave Popcorn Processing Plants (OSHA,2011).■■ Draft Criteria Document - OccupationalExposure to Diacetyl and 2,3-Pentanedione(NIOSH, 2011).■■ Occupational lung disease risk and exposureto butter-flavoring chemicals after implementationof controls at a microwave popcornplant (Kanwal et al., 2011).Medical surveillanceMedical surveillance is a key componentof an effective respiratory health and safety programin the flavor industry. This is especiallythe case when it is difficult to identify a specificcausative agent for an observed effect and when10
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ResH&S 2012 FINAL

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