ResH&S 2012 FINAL

RESPIRATORY HEALTH AND SAFETY IN THE FLAVOR MANUFACTURING WORKPLACErely on workers manipulating large quantities offlavors and other materials by hand during theformulation and packing processes. Because ofthis great variability, “one size fits all” solutionsto material handling strategies and engineeringcontrols is inappropriate. However, a number ofbasic principles can greatly reduce opportunitiesfor hazardous exposures.Product substitutionAwareness that specific substances arehazardous often results in the application of asimple industrial hygiene strategy – productsubstitution. Product substitution may be employedwhen it is known that a substance is hazardousand can be replaced with one that isn’t.The unique nature of the flavor imparted by certainsubstances, many of which are naturally occurringconstituents of food, makes it difficult toidentify substitutes that are effective.In 2010 OSHA published a “WorkerAlert” on diacetyl and substitutes noting that“some diacetyl substitutes may also cause harm.”The Alert stated, “Diacetyl substitutes that havenot been proven to be safe include diacetyltrimer, 2,3-hexanedione, 2,3-heptanedione, and2,3-pentanedione.” In January, 2011, NIOSHrequested information on flavoring substancesthat may be used as substitutes for diacetyl (76Fed. Reg. 1434. 10 January 2011). FEMA providedinformation to NIOSH on six flavoringsubstances that it was aware of that may serveas substitutes for diacetyl:■■ Four alpha-diketone substances: 2,3-pentanedione,2,3-hexanedione, 3,4-hexanedione,and 2,3-heptanedione.■■ Two other related substances: acetoin anddiacetyl trimer.NIOSH published results from environmentalmonitoring at a microwave popcorn productionplant focusing on the possible presenceof “diacetyl substitutes” (Boylstein, 2012).Heating of flavorsHeating of flavors is of particular concernwith regard to potential hazardous exposures.Heating will increase volatility andgreatly increase air concentrations of flavoringsubstances. Mixing of heated flavors should beconducted in closed vessels with local ventilation.Workers should not open heated vessels toconduct visual inspections in such a way as tocreate an opportunity for exposure. In instanceswhen workers must work near open vesselsthat are heated and cannot be closed or do nothave local ventilation, their exposures should bepromptly evaluated by environmental sampling.If exposures are elevated then the proper personalprotective equipment should be employed.Facility structure and organizationOpportunities for exposure can be greatlydecreased by segregating functions that involvethe handling of flavors from functions that donot. For example, a flavor compounding, packing,or shipping area should not share space witha sales office. Flavor production areas shouldbe separate from non-production areas and theyshould not share the same air handler.VentilationFlavoring substances and mixtures,whether liquid or dry, must be handled in sucha way as to minimize the creation of airborneaerosols or particulate matter. This means thatmixing, blending, and other physical manipulationactivities should be performed in closed8