How Are Food Manufacturing Workers Protected From Chemical Exposure?

Workplace Safety | Chemical Compliance

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Food processing and manufacturing facilities must be kept clean and sanitary to protect food safety and prevent foodborne illness. Chemical soaps, detergents, sanitizers and disinfectants are routinely used to help keep food free of unwanted microorganisms and other contaminants. These chemicals are vital to the safety and success of any food production process, but they can also be hazardous. Employees who use them or work around them need to understand their hazards and know how to protect themselves.

What Chemicals Are Used in Food Processing/Manufacturing

In general, soaps and detergents are the least hazardous to workers, and disinfectants are the most hazardous:

• To clean, sanitize or disinfect surfaces, chemicals must be able to kill microorganisms such as bacteria, viruses, and fungi
• Most sanitizing and disinfecting chemicals you find in food production can kill microorganisms because they are corrosive
• Different corrosives can damage different materials, including metals and a variety of organic compounds, but almost all are capable of irritating, damaging or even destroying living tissue on contact
• This makes them great for killing microorganisms, but unfortunately it means they can also be harmful for people who must handle them
• Corrosive chemicals can irritate or damage most types of body tissue
• If corrosive chemicals get onto your skin they can cause itching, swelling, rashes, and chemical burns
• If they get into your eyes they can cause irritation or even serious eye damage
• If you breathe them in, corrosive chemicals can irritate the sensitive tissues in your nose, throat and lungs, and can cause breathing problems or trigger asthma
• If accidentally swallowed they can cause damage to the mouth, throat, stomach and intestines
• In addition to being corrosive, some of these chemicals are also toxic and can make you very sick

If you are exposed to a corrosive chemical, the reaction you have will depend on several factors:

• How you are exposed to the chemical. If some bleach spills on your skin it might only cause some minor skin irritation, but if you inhale bleach fumes it could cause serious breathing problems.
• The dose, or the amount of the chemical that enters your body
• The concentration of the chemical
• Your age, size, gender, and overall health can all impact the way you react to a chemical exposure

Chemical container labels are a great way to tell at a glance what kind of hazards a chemical may present. The Occupational Safety and Health Administration, or OSHA, requires that chemical manufacturers use the Globally Harmonized System of Classification and Labeling of Chemicals, or GHS, on labels for hazardous industrial chemicals. GHS labels require one or more of nine possible pictograms, which will allow workers to quickly identify the types of chemical hazards. The label will also require a signal word, which is a single word that indicates the relative level of severity of the hazard. These signal words are “DANGER” or “WARNING”, with “DANGER” indicating more immediate or more extreme hazards.

There must also be a hazard statement, which describes the nature of the hazard, and a precautionary statement, which describes recommended measures to minimize adverse effects of exposure to that chemical. A product identifier, which is the chemical identity of the substance, is also required to be on the label. Finally, the supplier’s information, including the name, address, and number, should be on the label. OSHA requires your employer to make sure all hazardous chemicals in your facility have either their original, GHS-compliant manufacturer labels, or equivalent workplace labels.

The GHS uses nine standard pictograms:

• Health Hazards
• Oxidizers
• Irritant
• Corrosives
• Flammables
• Environmental Toxicity
• Acute Toxicity
• Gases Under Pressure
• Explosives

There are some other chemical containers you may see in the workplace. Chemicals which are not considered very hazardous will have much simpler labels without all the warning information. You may also encounter hazardous cleaning chemicals in packaging's that have standard consumer labels instead of industrial GHS labels.

For more detailed information about the hazards of a particular chemical, you can consult the Safety Data Sheet, or SDS. SDSs will contain 16 sections:

• Identification
• Hazard identification
• Composition and information on ingredients
• First-aid measures
• Fire-fighting measures
• Accidental release measures
• Handling and storage
• Exposure controls and PPE
• Physical and chemical properties
• Stability and reactivity
• Toxicological information
• Ecological information
• Disposal considerations
• Transport information
• Regulatory information
• Other information

Your employer is required to make sure there is an SDS available for each hazardous chemical in the workplace. The SDSs must be readily accessible, in a location known to employees.

Before handling any chemical product for the first time:

• Read the label, SDS and any company process sheets, wall charts or other information about the chemical and how to use it
• Be sure you have ready access to the SDS while using the chemical, in case you need to refer to it during an emergency
• Only handle chemicals when you have the proper ventilation and protective equipment, as indicated on the SDS
• Only use chemicals for their intended purpose, and only use them as directed on the label or process sheet
• When you are done using chemicals, make sure to follow all procedures for disposing of used chemicals and empty containers
• Ensure that all waste containers are properly marked, and always keep waste chemicals separate from unused chemicals
• Be sure that you know and follow any other required procedures
• Observe careful hygiene practices when handling chemicals

Always know and wear the appropriate personal protective equipment, or PPE, for the chemicals you are using:

• Always wear gloves which can protect your skin from that chemical
• Check the SDS to know what types of glove materials work best
• Gloves for cleaning, sanitizing and disinfecting procedures should cover your forearms, not stop at your wrist
• Aprons or coveralls should be worn to keep chemicals off your clothes
• Eye protection such as chemical splash goggles are also strongly recommended, especially if there is a risk of spraying or splashing chemicals
• Waterproof, slip-resistant footwear is also recommended anywhere liquids may be present on the floor
• In some rare instances, it may be necessary for you to wear respiratory protection (If you are required to wear respiratory protection, you will need additional training over how to wear it properly, and will need to undergo a medical evaluation and fit test)

Take care when dispensing chemicals from a container; spills or accidental mixing can be hazardous:

• Only dispense from one container at a time
• Put the cap back on the container and wipe the outside clean before opening another container
• Dispense as little as possible, trying to only take what you need right now
• Avoid spills and reduce the amount of dust, mist, vapor or fumes that leave the container and get into the air
• Open the container slowly, avoid shaking or squeezing it, and follow any other instructions on the container
• Be sure that the container you are pouring into is stable and large enough
• Never squeeze a container or use pressurized air to push out the contents unless the procedure specifically calls for it
• Never use your mouth to siphon liquid out of a container
• Be sure any container you put the chemical into, and any scoops, funnels or other tools that you use to move the chemical, are made of appropriate materials that won’t be damaged by the chemical

Never mix chemicals together unless specifically directed to do so by a supervisor or process sheet.

Many sanitizing and disinfecting chemicals will come to your facility in highly-concentrated forms, and you will need to dilute them with water in order to make a usable solution:

• When diluting, always add the chemical to the water, not the other way around, and add it slowly
• If you need to dilute a powder or granulated solid, mix a small amount of water with the solid to make a slurry, then add that to the rest of the water

Before placing any chemical into storage, inspect the incoming container to ensure that it is undamaged and properly labeled:

• Never accept delivery of defective or unlabeled containers
• In general, you should always store chemicals separately from other materials, especially food ingredients, and away from processing and handling areas
• You should also keep incompatible chemicals separate from each other
• Keep liquids separate from solids, keep acids separate from bases, and keep flammable chemicals away from combustible materials and ignition sources
• Always store chemicals in appropriate containers as recommended by the manufacturer
• Make sure that chemicals are always properly labeled and that labels are undamaged, facing forward and easy to read
• Keep all containers tightly closed except when the contents are being used
• Protect containers against banging or other physical damage during storage and handling
• Store containers at a convenient height for safe lifting and handling, below eye level if possible
• Always keep storage areas clean, organized, and free of trash and clutter
• Clean up any spills promptly, following the procedures outlined in your facility policies
• If chemical containers become swollen, notify your supervisor immediately
  

Storage areas should be well lit, well ventilated, and dry. Temperatures should be carefully maintained according to the manufacturer’s recommendations:

• Chemicals for cleaning, disinfecting and sanitizing should be kept away from direct sunlight, leaky pipes, steam pipes, boilers, and any other sources of heat or water
• Walls, floors and shelving should be resistant to corrosion and should not react with the chemicals being stored
• Liquids should be stored with proper spill containment, and floors where liquids are stored should not allow liquids to penetrate
• Appropriate PPE and supplies for handling the chemicals should be kept in the store room or easily accessible nearby
• Firefighting equipment and supplies for cleaning up spills should be available in the storage areas
• Storage areas should be labeled with proper warning signs, and only trained and authorized personnel should be allowed inside

Chemical spills, even small ones, can present serious hazards including damage to equipment, health hazards for exposed workers, and in some cases even fire and explosion hazards:

• Always respond to spills promptly, and carefully follow your facility policies and any instructions on the chemical’s SDS
• Do your best to control the scene and prevent people from walking through the area
• Spill cleanup kits with the materials you need should be readily available
• You should receive training over how to respond to spills and how to properly use spill kits
• Liquids should be absorbed by a disposable material that can hold the liquid and won’t react with the chemical
• All waste created by the spill – including the chemical itself, any absorbents used, and broken containers – should be placed into approved, marked, leak-proof containers and disposed of according to facility policy
• Always report any spill incidents to your supervisor as soon as possible

This blog is part of a food manufacturing safety series. For more topics, visit the blogs below:

Listeria Control in Food ManufacturingFloor and Drain Cleaning in Food ManufacturingForeign Material Control in Food ManufacturingCleaning and Sanitizing in Food ManufacturingSalmonella Control in Food ManufacturingCurrent Good Manufacturing Practices in Food ProductionHow do Food Manufacturers Use Hazard Analysis and Critical Control Point (HACCP) Plans to Protect Consumers?12 Ways Food Manufacturers Protect Consumers Who Suffer From Food AllergiesFood DefenseProper Hand Hygiene and Handwashing in Food Manufacturing

Effective chemical control is an essential part of maintaining a safe workplace. It helps minimize the risk of employee injury due to improper use of chemicals and helps limit potential product contamination.

Hazard Analysis Critical Control Point (HAACP), and other food and feed systems, require chemical control programs. Address each of the following topics in your chemical program to meet the requirements outlined in OSHA’s Hazard Communication standard (HCS) and industry standards (29 C.F.R. § ..)

Establish a safety team for chemical purchase approval

Establish a food safety team to manage essential pre-requisite programs, such as chemical control. Designate one or more members to serve as a chemical approval team to evaluate chemical purchase requests and give purchase approval.

The chemical approval team should:

• Review chemical purchase requests to authorize the intended use and location of use
• Verify that requested chemicals are safe for food and feed operations and contact surfaces
• Check if a similar chemical is already available in the facility. If so, decide whether both are necessary or if the former chemical can be eliminated.

Keep chemical labels and Safety Data Sheets for reference. The labels contain important usage information and the Safety Data Sheets detail specific chemical hazards.

Develop a master list of approved chemicals

Develop a master list of all approved chemicals that identifies the name, manufacturer, intended use, locations of use and departments authorized for use. Divide the list into categories, such as boiler and water treatment, pesticides, herbicides, laboratory, janitorial, sanitation and maintenance. This list serves as a reference for departments to learn which chemicals are approved for regular purchase.

Receiving and storage of chemicals

When accepting a chemical shipment, receiving personnel should verify that each chemical is on the master list of approved chemicals and update chemical inventory logs to reflect the current quantity and lot numbers.

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Chemicals should never be left unattended. It could lead to mishandling or misuse by personnel who are not trained to use chemicals safely. Receiving personnel should keep chemicals in designated storage areas and notify the appropriate department of the arrival. Move unapproved chemicals to a controlled storage area until the chemical approval team determines to accept or return it.

Controlled storage areas for chemicals

Controlled storage areas restrict chemical access to authorized personnel using electronic keypads or badges, padlocks or key locks. Some companies incorporate security cameras to keep digital records of personnel entering and exiting these areas.

It is essential that authorized personnel maintain control of chemical containers during usage and that chemicals are returned to the controlled storage area upon completion of the task. It is also beneficial to maintain a list of the chemicals stored in each controlled storage area.

The setting and type of chemical influence what kind of controlled storage area is suitable. Chemical cages or designated rooms may be needed to store pesticides or chemicals for maintenance, sanitation or boiler and water treatment, while controlled access closets are often appropriate for storing janitorial chemicals. Laboratory chemicals should be stored in controlled access cabinets in the laboratory itself and, in some circumstances, it may be best to secure the entire laboratory. Some storage areas may require spill containment equipment, ventilation and personal protective equipment (PPE.)

It may be necessary to separate certain chemicals within controlled storage areas. For instance, separation may be required to prevent non-compatible chemicals from generating dangerous gases that could cause serious respiratory injury. Sometimes separation is necessary to isolate specific chemicals from a particular ingredient, packaging, work-in-progress or finished product. It also helps avoid cross-contamination (for example, food grade and non-food grade lubricants should be stored separately; sanitizers and general cleaning chemicals should be stored separately.)

Labelling chemical containers

The original chemical container labels detail appropriate handling and usage requirements. When transferring chemicals to secondary containers, it is imperative that the secondary containers be labeled properly to comply with the Globally Harmonized System of Classification and Labeling of Chemicals (GHS) and OSHA Hazard Communication standard (HCS) (29 C.F.R. § ..)

The label must indicate the chemical name and the hazards present. There are many ways to communicate this information, such as color-coding or attaching laminated or engraved identification tags. Select a system that will work for each location.

Secondary containers must comply with labeling requirements if any of the following occurs:

• The employee who made the transfer does not use all of the chemical during the work shift
• The employee who made the transfer leaves the work area
• The employee who made the transfer is no longer in possession of the container and it is moved to another work area

Labels on secondary containers are not required if the employee who made the transfer uses all of the contents during the work shift.

Chemical inventory logs and usage records

It is important to keep accurate documentation of chemical inventory and usage records, in fact, many third-party audit programs require these records. 

Update the chemical inventory log with the new inventory quantity upon receiving a new shipment of chemicals. If you are adding chemicals to a bulk storage container, record the total amount of chemical in the container. If the chemical arrives in individual containers, it may be more efficient to track containers (for example, 14 cartridges of food grade grease) or in the quantity of chemical present (for example, 10 gallons.)

Usage records track the amount of chemical used and where it is used. You can use electronic dispensing systems to track specific usage amounts of chemicals stored in bulk containers. Many companies find electronic dispensing systems advantageous because they can record the quantity of chemicals remaining, reduce chemical overuse by only dispensing predetermined amounts at designated times and control chemical access by requiring a password, user ID or electronic access card.

It may not be possible to track specific usage amounts of chemicals packaged in containers such as aerosol cans or grease cartridges. In these instances, the inventory log should be updated as containers are taken from the controlled storage area.

Chemical concentration verification

Sometimes chemicals are in a concentrated form and need to be diluted or mixed. Refer to the chemical label for the required concentration, diluting method and mixing instructions.

Concentration checks may be necessary to ensure the appropriate concentration has been mixed. For example, some cleaning chemicals and sanitizers require specific concentrations for usage. When used at the proper concentration, they may not require a potable rinse from equipment surfaces. However, if they are used at a higher concentration, equipment surfaces require rinsing.

Consult with the chemical supplier regarding the best method of verifying chemical concentrations. Concentration checks may be conducted via titration, test strips, chemical meters, etc. If metering systems are used, calibration of these devices should be conducted on a pre-determined schedule.

Proper disposal method for chemicals

Chemical container disposal protocols should be implemented and chemical label instructions should be followed for appropriate procedures. For example, some pesticide labels state that the container needs to be punctured and triple-rinsed before disposing. Chemical containers should never be reused for other purposes within the operation.

Chemical spill containment procedures

Chemical spills may occur in the storage area or during usage. According to OSHA’s HCS, the Safety Data Sheet must detail accidental release measures, such as personal precautions, PPE, emergency procedures, methods and materials for containment and clean up (29 C.F.R. § ..)

Spill containment devices and materials should be present in chemical storage areas and authorized personnel should know how to use them. Appropriate disposal considerations should also be followed.

Chemical spills and clean-up procedures should be documented on a company-approved form for recordkeeping. See OSHA’s HCS for further information on spill containment.

Chemicals and contractors

Contractors often use chemicals while completing their tasks. Assign authorized personnel to oversee contractors to help ensure that your chemical control program is followed. This may include obtaining chemical approval and Safety Data Sheets, updating chemical inventory and usage records, maintaining controlled storage areas while on-site and performing proper chemical applications.

Training for chemical usage, storage and application

Authorized personnel should be trained in chemical usage, including proper storage, application and documentation (such as, inventory logs and Safety Data Sheets.) They must understand the health hazards of the chemicals they utilize and be trained to use PPE and perform first aid (29 C.F.R. § ..)

It is important that all personnel understand that mishandling chemicals creates a risk to themselves and the food or feed being produced. In addition, all personnel should receive general chemical training and education on company protocols, (for example, controlled storage access requirements, prohibited use of unapproved chemicals and personnel authorization for chemical usage.) All personnel should be instructed to report suspicious activity, unsecured areas or missing chemical quantities. If a color-coding program is utilized, all personnel should be aware of color designation and usage.

Implementing and maintaining a fully developed chemical control program

Implement and maintain a fully developed chemical control program. It is a vital component of food and feed pre-requisite programs by helping increase employee, customer and product safety. Conduct periodic inspections to help ensure compliance with industry and regulatory agency standards.

Contact your Nationwide risk management consultant to learn how our team of food safety experts can help you create a safer workplace.

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