Safe Cleaning and Sanitisation in the Meat Industry

Developed fororganisations in the

Australian MeatProcessing Industry

2010Published by Teys Bros on behalf of the Australian Meat Industry.

1 Background Purpose Scope Target Participants Objectives of the Training Definitions Relevant Legislation/Standards Training Methodologies Assessment Methods and Key Competencies

2 Introduction: Cleaning in the Meat Industry

3 The Cleaning Process Step 1. Dry Clean Step 2. Wash Down / Flush Step 3. Foaming and Scrubbing Step 4. Post Foaming Rinse Step 5. Sanitation Step 6. Dry - Post-Sanitising Step 7. Pre-Operational Inspection

4 Monitoring

5 Corrective & Preventative Action - Product contact and non-contact surfaces

6 Systematic Hazard Management Hierarchy of Controls

7 Hazardous Energies in the Meat Industry

9 Assessing and Controlling the Risks Machinery Moving Machinery Entanglement Laceration and Amputation Hazards Isolation & Lock out Tags/Signage Electrical Hazards Chemical Hazards Thermal Hazards Slips Trips & Falls Radiation Biological Hazards Manual Handling Personal Hygiene: - Infestation, Infection & Disease

Table of Contents

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Training Guidance Note:The following is provided for information only, to assist organisations conducting work in the Australian Meat Processing Industry to develop their own safety training programs for personnel working in meat processing workplaces (or on such facilities or equipment).

This information is based on training developed in a large ”Export Beef“ Meat Processing Facility, but can be generalised to other meat processing workplaces which share similar hazards, environments, equipment and production requirements.

The document is not a training program in its own right: it is intended to assist Employers to develop their own training and Hazard Management programs, based on their own particular operations, work processes, working environments and equipment. In accordance with requirements of the relevant State or Territory OH&S jurisdiction, Employers will need to assess their own work practices and identify their own range of hazards, assess their own risks and then develop and implement their own range of Control measures.

Teys Bros, its principals, affiliates, directors, author(s) or any other person involved in the preparation and distribution of this publication expressly disclaim all and any contractual, tortuous or other form of liability to any person (using this publication) in respect of the publication any consequences arising from its use by any person in reliance upon the whole or any part of the contents of this publication.

The information contained in this guide was obtained from sources believed to be reliable. Teys Bros, its principals, affiliates, director(s) or other persons as above, do not accept responsibility for such information and state the publication is of a general nature. Whilst every care has been taken in its preparation no person should act specifically on the basis of the material condition herein without considering and taking professional advice.

Safe CleaNING aNd SaNITISaTIoN IN The MeaT INduSTry

alternative NoteThis training guide provides general information about the obligations of contractors and employers under the occupational health and safety and workers compensation laws. The guide gives some suggestions for complying with these obligations, especially as they apply in the meat industry work situations. However, this guide is not intended to represent a comprehensive statement of the law as it applies to particular problems or to individuals or as a substitute for legal advice. Full details of legal obligations and responsibilities are set out in the occupational health and safety and workers compensation legislation referred to in the publications list. If you refer to the legislation you should take care to ensure that you use the most up-to-date version. You should seek legal advice if you need assistance on the application of the law to your situation.

1.1 PurposeThe purpose of this document is to assist meat processing workplaces to ensure that all relevant personnel can effectively control the OH&S hazards and risks associated with the cleaning, sanitation and pre-operational inspections of meat production areas.

1.2 ScopeThe following training guide has been developed to assist employers to develop training programs, to induct and train meat workers and other personnel in Australian Meat Processing facilities, in the common OH&S potential hazards and injuries encountered during:- Cleaning Sanitation and Pre-Operational Inspection of meat

processing workplaces.

1.3 Target ParticipantsEmployees (meat workers, cleaners and maintenance workers) and contract (service) personnel associated with the design, installation, commissioning, operation, maintenance, cleaning and repair of meat processing works.

1.4 objectives of the TrainingTo ensure all relevant personnel are aware of the common OH&S hazards associated with meat processing and have a sound understanding of the controls to be applied during cleaning, sanitation and pre-operational inspection of the workplace.

1.5 definitionsAA GuidelinesApproved Arrangement Guidelines.

AQIS Australian Quarantine Inspection Service.

Clean Clean to touch and free from extraneous visible matter and objectionable odour.Approved Chemical Chemical approved by the employer for use in a particular work process, in the Meat Processing Industry.

MSDS (or ”SDS“)Material Safety Data Sheet: summarising chemical attributes, common uses, hazards, risks and essential workplace safety and emergency management requirements.

Primary Areas Areas that require routine daily cleaning after processing.

Sanitise –Applying heat and/or chemicals to a surface to reduce the bacterial load to a level that does not compromise food safety and does not permit transfer of infectious disease.

Secondary Areas Supplementary areas which are cleaned less frequently.

Verification Observation and assessment of product, processes, records or establishment personnel work performance to establish compliance with requirements.

SoilContaminate with meat/tissue, blood, other body fluids, faeces, mud or other unwanted material

Hold Tag A Tag attached to a Meat Product (or its container) to prevent its continued processing, packaging or sale. State or Territory Workplace Health & Safety Acts and Regulations (See Sec 1.6 below)

baCkGrouNd11.6 releVaNT leGISlaTIoN / STaNdardSThe relevant State or Territory Occupational Health & Safety Act and/or Regulations can be found at the following websites:-

Australian Capital Territory• ACT Occupational Health and Safety

Commissioner - A Quick Guide to the ACT’s Health and Safety Laws (PDF, 2.51MB)

• ACT Office of Regulatory Services WorkCover - Codes of Practice under the OH&S Act.

New South Wales• WorkCover NSW• What legislation covers occupational health

and safety? • Codes of practice

Northern Territory• NT WorkSafe• Legislation and regulation• Codes of Practice

Queensland• QLD Workplace Health and Safety• A guide to the Workplace Health & Safety Act 1995 • Industry Codes of Practice

South Australia• SafeWork SA• Occupational Health, Safety and Welfare Act

and Regulations• Codes of Practice

Tasmania• Workplace Standards Tasmania• A Guide to the Workplace Health and Safety

Legislation (PDF, 1.2MB)• Duties of employers and self-employed

persons• Codes of Practice Victoria• WorkSafe Victoria• Acts and regulations• Compliance Codes

Western Australia• WorkSafe Western Australia• OHS Regulations• Codes of Practice

Commonwealth of Australia• Comcare

National Standards and Codes of Practice• Safework Australia• Dept Agriculture, Fisheries and Forestry

(Meat, Meat export)• Australian Quarantine and Inspection Service• AS 4696:2007 Australian Standard for

Hygienic Production and Transportation of Meat for Human Consumption

• AS 4709:2001 Guide to cleaning and sanitising of plant and equipment in the food industry

• SCARM Report No 80: Australian Standard for Hygienic Production and Transportation of Meat and Meat Products for Human Consumption

• ”Safe Working at Heights from Work Platforms in the Meat Industry“ WorkCover NSW.

• ”National Code Of Practice for the Prevention of Musculoskeletal Disorders from Performing Manual Tasks at Work“, Australian Safety & Compensation Council (now ”Safework Australia“)

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1.7 training methodologiesThis document provides a general guideline for key OH&S and hygiene information to be included in Meat Industry training programs.

This training material should be presented to participants during initial Induction and on-the-job training.

Face-to-face training in a conventional classroom setting is the preferred medium for initial induction training of this material, in context with overall ”generic“ OH&S induction to the organisation. Presentation will normally be by way of lectures, with slides, reference to training manuals/course notes, demonstration and group discussion. Part or all of this material could also be presented by video if necessary.

The initial induction should be reinforced during initial training on each work procedure, either in mock-up workstations (in a training room) or on-the-job training, whilst being closely supervised by a suitably competent person with training responsibilities. Each Safe Work Procedure should cross-refer to the relevant part(s) of this training material and should be drawn to the workers’ attention.

Thereafter the training should be ”refreshed“ with workers periodically (eg: by Supervisors or Trainers), ”in tool-box training“ sessions or other appropriate settings:• particularly if injury/incident trends indicate an

emerging problem with any part of these work procedures;

• if the work processes or equipment or materials changes; and

• every 3-5 years anyway, as a matter of course.

assessment Methods and key CompetenciesOH&S Competency-based Assessment* must be sufficient to demonstrate that the participant can recognise the major hazards in the meat industry and has adequately grasped the essential safety issues (recognition/identification of hazards and the application of control measures) in each Step of the cleaning/sanitation process.(*Note: Food Quality requirements will have additional

competencies to add to those listed in this Guide, for

workers to demonstrate effectiveness of their cleaning/

sanitation practices)

In the ”classroom“ induction, participants must be able to: • Demonstrate a basic awareness of

”Systematic Hazard Management“;• Describe (briefly) the 8 steps of the cleaning/

sanitation process;• List at least 7 major hazards in the meat

industry; and• List at least 7 major Control(s) associated with

the Industry.

Individual Employers may add additional site-specific questions such as ”which chemical is used in this process?“ or ”What concentration do you mix?“ and so on.

Participants should be provided with a quiz-sheet (see example with possible answer in italics, attached as Appendix 1) which can be assessed. Trainers should use their discretion as to whether prompting for answers is required.

During on-the-job training, participants must be able to explain (to the trainer/supervisor) each step of the particular process and articulate the major hazards and control measures to be applied.

During ”tool-box“ training sessions, workers should be able to describe the hazard management process and identify hazards and controls (again, with prompting, if required).

Cleaning and sanitising of a meat production plant is undertaken to ensure that plant and equipment is clean prior to commencement of production and:-• is free from all visible contamination or

oxidation when viewed under good lighting when the surface is dry

• has no discernible objectionable odour• does not feel greasy when rubbed with clean fingers• after being sanitised, is substantially free from

pathogenic or spoilage organisms.

Surrounds are to be maintained to ensure that the grounds, structures equipment and the plant hygiene practices prevent product contamination. Adequate cleaning of the plant is also an essential part of pest control.

CleaNING IN The MeaT INduSTry2

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STeP 1: Worker SafTeyDe-energise, lock and tag out all plant that is not required to be operational and remove any further potential hazards prior to commencing the cleaning process. The priority for cleaning needs to be worker safety first.

STeP 2: dry CleaN The Dry Clean process commences once production has finished and involves the removing of all solid waste (i.e. packaging, meat trimmings, fat, bones, etc.). Generally equipment such as scrapers, shovels, brooms and bins are used to remove the bulk wastage and help prevent the blocking of drains.An inspection needs to be carried out to ensure this step has been performed adequately prior to commencing step 2.

STeP 3: WaSh doWN / fluShThe Wash Down / Flush process is the washing down of production areas with water to remove any waste material and protein build-up. This includes washing down all equipment including food contact surfaces, floors, platforms, mesh grids, walls, tables, benches, handrails, conveying equipment and meat processing tools and machinery. It is recommended to use ambient temp water to prevent cooking proteins to surfaces. This reduces the amount of protein which the detergent has to remove. An inspection needs to be carried out to ensure this step has been performed adequately prior to commencing step 3.

STeP 4: foaMING aNd SCrubbINGThe Foaming and Scrubbing process is the foaming of all contact surfaces and required fixtures with approved chemical mixed at the correct ratio, allowing for the required contact time. During this time, designated cleaners scrub all contact surfaces and required fixtures. Foaming detergent is applied to loosen and aid the removal of protein build up. Generally the scrubbing is carried out with a Chlorinated alkali and a scouring pad. An inspection needs to be carried out to ensure this step has been performed adequately prior to commencing step 4.

STeP 5: PoST foaMING rINSeThe Post-foaming rinse process is rinsing of all foamed equipment with hot water to flush away detergent, and any protein left on surfaces. An inspection needs to be carried out to ensure this step has been performed adequately prior to commencing step 5. Note: Any water pooling should be removed prior to sanitation.

STeP 6: SaNITaTIoNThe Sanitation process involves spraying or wetting of all surfaces with a Quat based sanitiser, paying particular attention to food contact surfaces. After allowing for the required contact time, it is recommended that surfaces be air dried. Surfaces may need to be rinsed after sanitisation depending on specific requirements.

STeP 7: dry - PoST-SaNITISINGAll water pooling and condensation is removed at this step.

STeP 8: Pre-oPeraTIoNal INSPeCTIoNA final (or pre-operational) inspection takes place here to ensure all defects are rectified.

The CleaNING ProCeSS3The cleaning process in production can be broken down into eight stages: A nominated person (i.e. Quality Assurance

Officer) conducts daily pre operational hygiene inspections prior to commencement of work to verify quality of work performed and ensure that the plant and equipment is of an acceptable standard for commencement of production. Corrective action is taken immediately where required to rectify any deficiencies.

Prior to the commencement of production and after the cleaners have finished and the area is ready for production, the nominated person will inspect the area and report and record any deficiencies.

If the area/room is unsatisfactory, the nominated person takes the necessary action to ensure that production is not allowed to commence.

The nominated person (i.e. Department Manager) is notified immediately.

A cleaner generally accompanies the nominated person and will wash with a Chlorinated Alkali, rinse and re-sanitise any areas required to be re-cleaned.

The nominated person is then responsible for verifying that the spot cleaning has been effective.

If an item of equipment is unsatisfactory the nominated person holds the item until it has been re-cleaned and re -inspected.

MoNITorING4

CorreCTIVe & PreVeNTaTIVe aCTIoN - ProduCT CoNTaCT aNd NoN-CoNTaCT SurfaCeS5

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This document provides a general guideline for key OH&S and hygiene information to be included in Meat Industry training programs.

Australian state and Territory (and Federal) OH&S laws require the application of risk management principles to ensure the health and safety of people at a workplace:-

• All Hazards associated with a workplace (including any arising from plant or substance used at the workplace or specific operations being carried out) must be identified, based on experience, recorded data and other information;

• Risk Assessments must be carried out (based on the consequences and likelihood of harm to workers and others) on the identified hazards, to ascertain whether control measures are necessary (and to assign priorities for action);

• Control measures must be implemented (where appropriate) to eliminate or, where this is not practical, control the associated risk arising from the hazards (refer to the hierarchy of controls, below);

• Employers should monitor the control measures (and revise them periodically, where necessary) to ensure that they are working correctly to control the risk and that no other risk have been created.

hIerarChy of CoNTrolSEmployers should select a combination of controls, in the following ”hierarchy“ (listed in descending order of preference/effectiveness), in order to reduce residual risk to acceptable levels:-

1 Elimination: Where practicable, hazards are to be eliminated. However where this is not possible, choose one or more of the following, to minimise the risk to the lowest practicable level.

2 Substitution: Substituting the equipment, substances or procedure giving rise to the risk with a process of lesser risk (eg: supply cleaning chemicals in smaller containers to reduce Manual Handling risks).

3 Isolation/ Engineering: Isolate the hazard from the person potentially put at risk (eg: by using machine guarding) or minimising the risk by engineering methods (eg: use mechanical lifting devices).

4 Administration: Minimising the risk by administrative methods (eg: close supervision, safe work Permits, training, licensing, instruction and information).

5 Personal Protective Equipment: Minimising the risk using personal protective equipment.

Note: A combination of the above measures is required to be taken to minimise the risk to the lowest level reasonably practical if no single measure is sufficient for that purpose.

• Thermal Energy refers to both heat (ambient weather, steam lines, hot water, operating plant such as heat knives, etc) and cold (immersion in cold water, work in cold-rooms, etc.);

• Gravitational Energy refers to the potential of falling from heights or objects falling (or being dropped) onto workers below, as well as slips, trips and falls in general (eg at floor level);

• Kinetic Energy and Inertia refers to the energy transferred when striking a stationary object (eg: piece of Plant) or being struck by a moving object (forklift);

• Radiation can be either • Non-ionising (sunlight, welder’s flash,

ultra-violet sterilisers) or • Ionising radiation (which may be

present in minute amounts in smoke detectors, metering devices, etc.);

• Biological ”energy“ refers to potential health effects caused by:-

• Toxic effect, infection or disease, such as from Zoonoses (Q-Fever) or vermin (rat bites, faecal contamination, etc.)

• Human energy, such as Manual Handling, which may cause traumatic injuries (eg: back injury) or cumulative micro-trauma (over-use injuries).

SySTeMaTIC hazard MaNaGeMeNT6

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Energy, in all of its forms, has the capacity to cause injury and damage to equipment, infrastructure and the environment - the potential in most cases is such that the degree of injury and damage can be devastating. It is critical that due respect and the greatest regard is paid to the control of all types of energy, in all of the activities that are performed on site.

The tasks being performed and the environment in which they are being performed must be analysed by each Employer, to identify where these forms of energy may endanger workers (or others).

Site specific Standard Operating Procedures (SOP`s) need to address each of the forms of energy commonly and generally experienced within the meat industry, and establish a rational and organised method in which to identify, assess, safely control, safely maintain control and finally re-energise to normal operational status.

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There are a number of sources of energy associated with cleaning in the meat industry, which are potentially hazardous:-

• Mechanical Energy associated with moving or operating plant or equipment:-

• Kinetic Energy describes the force which can be exerted by the moving mass (eg: production line, moving saw)

• Potential(or ”stored“) Energy describes the force which may be stored (eg: residual Electrical energy stored in a condenser; Pneumatic tools or Hydraulic equipment) which might be inadvertently released (eg: accidental operation of a cutter or press);

• Sound Energy (Noise);

• Electrical Energy in plant, equipment, lighting, other power circuits;

• Chemical Energy in potentially hazardous chemicals which may be toxic, a skin irritant, an asphyxiant (suffocating) or even flammable or explosive;

• Thermal Energy refers to both heat (ambient weather, steam lines, hot water, operating plant such as heat knives, etc) and cold (immersion in cold water, work in cold-rooms, etc.);

• Gravitational Energy refers to the potential of falling from heights or objects falling (or being dropped) onto workers below, as well as slips, trips and falls in general (eg at floor level);

• Kinetic Energy and Inertia refers to the energy transferred when striking a stationary object (eg: piece of Plant) or being struck by a moving object (forklift);

• Radiation can be either • Non-ionising (sunlight, welder’s flash,

ultra-violet sterilisers) or • Ionising radiation (which may be present

in minute amounts in smoke detectors, metering devices, etc.);

• Biological ”energy“ refers to potential health effects caused by:-

• Toxic effect, infection or disease, such as from Zoonoses (Q-Fever) or vermin (rat bites, faecal contamination, etc.)

• Human energy, such as Manual Handling, which may cause traumatic injuries (eg: back injury) or cumulative micro-trauma (over-use injuries).

Energy, in all of its forms, has the capacity to cause injury and damage to equipment, infrastructure and the environment - the potential in most cases is such that the degree of injury and damage can be devastating. It is critical that due respect and the greatest regard is paid to the control of all types of energy, in all of the activities that are performed on site.

The tasks being performed and the environment in which they are being performed must be analysed by each Employer, to identify where these forms of energy may endanger workers (or others).

Site specific Standard Operating Procedures (SOPs) need to address each of the forms of energy commonly and generally experienced within the meat industry, and establish a rational and organised method in which to identify, assess, safely control, safely maintain control and finally re-energise to normal operational status.

The following hazards were considered to represent the more common (or more serious) risks in the Meat Industry and the more common control measures identified for inclusion in your OH&S Induction and Training Programs.

This is not an exhaustive list and does not negate the need to conduct your own comprehensive hazard identification and risk assessment in your workplace. The hierarchy of control must be followed when implementing any controls and it should be noted that many risks may require the use of more than one control measure.

aSSeSSING aNd CoNTrollING The rISkS 8

hazardouS eNerGIeS IN The MeaT INduSTry7 8.1 machinery

a) Machine HazardsA Simple transfer of mechanical energy can cause injury by direct impact, pinching, trapping and crushing.

Alternatively, potential energy can be released in the form of steam, compressed gases, or air, water, hydraulic or release of mechanical systems (eg; spring-loaded devices) if uncontrolled release occurs. Resultant injuries can be from attached devices being activated (laceration, amputation, crushing, etc.) or by direct action of the released steam, gas or liquid (i.e.: burns, lacerations or even embolism, such as when compressed air passes through the skin, into veins or arteries, causing blood clotting, stroke, etc). Finally, operating machinery can produce harmful levels of noise which, over time, can cause Noise-induced hearing loss to exposed workers.

b) Machine Control MeasuresEnsure all plant and equipment is adequately guarded and complies with AS 4024.1-2006 Safety of Machinery

b1) EliminationMachinery is to be de-activated and purged of any stored forms of energy before cleaning or maintenance work commences. Some existing industry practices include lowering raised platforms or conveyors to a ”safe“ position, steam or hydraulic pressure released to prevent accidental activation of parts or unplanned release of pressurised fluids and cutting edges removed or closed over or otherwise guarded.

b2) SubstitutionPlant, equipment and substances are to be substituted to a process of lesser risk (eg: supply cleaning chemicals in smaller containers to reduce Manual Handling risks).

b3) Isolation/GuardingMachine guarding or barriers/fencing are to be fitted in place to protect workers from laceration/entrapment in cutting edges or nip points, drive belts or wheels, flywheels, conveyors, cogs, chains and sprockets, drive-shafts, arms, spindles, etc.).

Guarding material (i.e. mesh) is to be of suitable gauge and sufficiently distant from the machinery to prevent body parts (i.e. fingers or arms) from reaching through to the blade/nip point. Fixed Guarding should be permanently fixed or, where necessary, fixed with latches/screws requiring special keys or tools to prevent unauthorised removal.

Where access is required for maintenance or cleaning, Interlock devices are to be in place to prevent activation of the machine when the guard is removed. Presence-sensors may be used to de-activate machines when triggered by a person entering the hazard area.

Lock out systems are to be installed on all energised plant so that all forms of energy can be de-energised and securely locked and tagged out.

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Example of engineered inspection and flush access points that restrict human access during the cleaning process.

b4) Administrative ControlsGiven that personnel could re-start de-activated machines whilst others are still working in/on them or before guarding has been replaced, additional administrative controls will also be required to reduce this residual risk.

Staff Training, formalised start-up checklists and procedures for Lock-out/Tag-out systems (see (f) and (g), below), Permits-to-Work and sign-off, supervisor checks for loose hair/clothing, (etc) are examples of such controls.

b5) Personal Protective Equipment (PPE)Personnel may need to be provided with additional PPE to protect from mechanical injuries (hearing protection, goggles, helmets) in addition to their usual PPE (non-slip footwear, overalls, gloves etc.).

c) Moving MachineryHowever, throughout the meat industry there are many direct food contact surfaces, where, at times during the cleaning process, it may be necessary to have some processing equipment (i.e. conveying equipment) operational to effectively clean and sanitise equipment.

Alternative controls need to be implemented to eliminate or minimise associated risk.

During certain stages of the cleaning process it may be necessary for certain machinery such as food contact conveyors to operate during the wash down/rinsing processes to ensure adequate cleaning of these systems. These pictures are examples of how associated risk may be minimised.

Unsafe working distance

Safe working distance from moving conveyor

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Example of safety interlock guarding over moving conveying section

Examples of safety interlock guarding installed on conveyor

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e) Laceration and Amputation HazardsLaceration and Amputation injuries can occur during the cleaning process, due to contact with sharp edges on plant, knives, powered knives, saws and cutting blades.

Controls:• Round off sharp edges on equipment.• Remove all knives and blades from production

areas prior to cleaning.• Lock and tag out all remaining cutting

equipment, i.e. hock cutters, saws, etc.• Install blade storage racks / brackets.• Ensure operators are appropriately trained

and understand lock out & tag out procedures.

Blades removed from machinery prior to performing cleaning duties

8.1 machineryd) Risk of EntanglementEntanglement type injuries can occur for a number of reasons during the cleaning process, including entanglement and entrapment with machinery and plant, particularly conveying systems.

Controls:• Lock and Tag out of moving machinery

including conveyor systems• Safe distance maintained when hosing

moving conveying systems (Refer to the ”Moving Machinery“ section)

• Ensure clothing is secure• Ensure operators are appropriately trained and

understand lock out and tag out procedures• Ensure operators are appropriately trained

and understand their task requirements and potential hazards associated with it

• Ensure machinery complies with AS4024.1-2006 Safety of Machinery

Personal safety locks fitted incorrectly and without personal danger tags

Moving machinery tagged out & locked out prior to cleaning

Correctly fitting a personal safety tag & lock

Personal safety tags & locks applied correctly to isolation point

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f) Isolation & Lock Out of Moving MachineryProduction equipment in the meat industry is used to process meat and includes moving machinery, saws and cutters. No persons should attempt to put any body part, for any reason inside moving machinery. All plant items are required to be isolated, locked out and tagged out prior to the removal of any guards or prior to performing any task on moving machinery.

In cases where plant items need to be running to be cleaned, such as conveying equipment, then pressure hose cleaning or extension cleaning tools should be used. These systems should be locked out if these options are not adequate. Only trained operators will clean specified work areas. Never remove guarding, interlocks or safety lines unless machinery is isolated and locked out.

8.1 machineryg) Tags / SignagePersonal Danger Tag: is red and black on a white background and is used for tagging electrical and non-electrical equipment. It is attached to the means of isolation to prevent unauthorised or inadvertent operation of equipment being repaired or installed. Personal danger tags are a prime safety requirement and should be recognised as such.

Caution (”Do Not Operate This Equipment“) Tag: is black on a yellow background and is used for the tagging of electrical and non-electrical equipment. They are used to identify faulty or unsafe equipment or machinery placed out of service thereby preventing damage to plant and equipment or injury to persons.

Lock-Out: a system where a safety device is used too physically isolate the main energy source from a piece of plant or equipment (eg. padlocks and chains) to make it inoperable.

Safety Lock: is a lock that is used for the locking out of electrical and non-electrical equipment. The lock can be either single or used with multi-locks devices known as ”lock-out scissors.“

Information Tag: is blue with black ruled lines. They are used for the provision of information about the equipment they are attached to.

Authorised Person: ”An authorised person is defined as a person who is designated by the employer who must personally fully investigate the removal of any personal danger tag by other than the signatory to ensure that no person will be endangered by its removal.“

Competent Person: is a suitably qualified trades person who assesses that the equipment is safe to operate.

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8.4 Thermal hazards (temperature & chemical)Extremes of temperature are commonly encountered throughout the meat processing industry.

Hot lubricants, hot work, hot mechanical components all have the capacity for serious injury. Extremes of cold produced by refrigeration, and rapidly expanding gases, for example, also have significant potential to result in serious injuries and damage.

In many cases the extremes of high temperature (in particular) are associated with the additional hazards of pressure energy - radiators, accumulators, etc. The combination of these two energy forms, sets the scene for extremely serious outcomes.

Burn injuries can occur for a number of reasons during the cleaning process, including contact with high temperature plant and water, contact with chemicals, possible ”freeze-burns“ and friction type burns.

Controls:• Ensure sterilisers are turned off and drained

prior to cleaning• Allow for any high temperature plant or

equipment to cool prior to cleaning• Limit the temperature of the water used

for cleaning and restrict access to high temperature water by installing a removable lever

• Co-ordinated hosing methods and adopt a top to bottom method of working (i.e starting hosing high then moving hose down to low points). All team members hosing in same direction, no cross hosing

• Install chemical dispensing units to minimise direct contact with neat (undiluted) chemical

• Ensure adequate PPE is available, personnel have been trained in its use and it is being used correctly

• Ensure emergency shower/eye wash stations are installed and Material Safety Data Sheets (MSDS) are made available

• Provide training to workers in chemical handling and use

• Ensure hot water hoses are rated to withstand high temperatures and pressures

• Adopt the use of the ‘trigger’ type nozzles to ensure the cease of water flow in the event of uncontrolled movement of the hose.

High-temperature hot water pipes with shifters removed to prevent unauthorised use

The use of a chemical dispensing unit

8.2 eleCTrICal hazardSThese can range from low-voltage apparatus, such as batteries, to medium voltages powering lighting and small hand tools, to the high voltages powering large equipment (and, indeed the very high voltages in transmission Mains and transformer stations supplying larger workplaces).

Uncontrolled electrical energy can result in electrocution, arcs, flashes, over-heating and fire.

Controls:• Ensure electrical outlets within all areas

comply with AS3000: 2007- Wiring Rules;• Ensure no unauthorised entry to switchboards

and switchboard rooms;• Prevent ingress of water to electrical

equipment - procedures should prohibit the direct hosing down of electrical outlets, isolation points or emergency stop buttons as pressurised water may penetrate switches and cause damage to electrical circuits and/or machines;

• Provide training and supervision to workers to ensure that electrical outlets are not directly hosed.

8.3 CheMICal hazardSChemical energy exists in all of the various chemicals that are used on site, or that are part of the production or maintenance process. Examples include fuels, degreasers, solvents, gases, acids and explosives.

Uncontrolled releases of chemical energy may result in fires, explosions, pollution, corrosion, tissue damage from contact, lung damage from inhalation or other internal damage from ingestion; depending on the nature and amount of the chemical in question.

Further, chemicals can exclude oxygen from confined spaces, or contaminate inadequately ventilated atmospheres.

Controls:Employers must obtain Material Safety Data Sheets on every chemical used in their operations. These provide detailed information about the nature of the chemical, its hazard status, its safe use, toxicity, flammability (etc.) and first aid and spill clean-up information, including appropriate safety Controls, PPE (etc.).

• The principal Control measure is to eliminate all hazardous chemicals or substitute them with less hazardous substances or diluted forms or reduced quantities of the chemical.

• Where this is not possible, administrative controls, such as restricting access, documented procedures and supervision are required.

• Workers must be trained in the safe use of the chemicals, including transport, storage and decanting/dilution procedures (and clean-up of spills).

• MSDSs must be made generally available to workers (and OH&S and First Aid staff, Wardens, etc) and are usually located around the site at the HAZMAT box (emergency Manifest Box), Maintenance Store, Safety Office, First Aid Office and the Chemical store.

• Finally, reliance on PPE is essential as a last resort protection of workers from exposure via skin contact, inhalation or exposure to fumes, accidental ingestion and contact with mucous membranes.

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8.5 Slips, Trips and falls

a) Working at HeightsKinetic energy in the form of the energy inherent in moving objects is experienced frequently on site. The energy levels inherent in moving conveyors, moving and rotating equipment are addressed in 8.1 (above).

However, the kinetic energy of a moving worker bumping into objects or tripping and falling must not be ignored. In addition, things that can fall, roll or slide whether they be people, tools, equipment, meat product or by-product or the structures themselves, have stored gravitational energy, which can again result in injury or damage. Multi-level processing lines (such as in abattoirs) may provide potential risks for falling from heights or having objects fall onto personnel below.

Controls:Refer to the ”Working Across Borders (NSW, Qld, Vic) publication by WorkCover NSW, titled ”Safe Working at Heights from Work Platforms in the Meat Industry.“

b) Slip & Trip HazardsSlip and trip type injuries can occur for a number of reasons during the cleaning process, including poor or relaxed housekeeping practices, slippery or uneven surfaces, elevated walkways or stairs and poor grip on workers boots.

Controls:• Regular housekeeping monitoring.• Regular inspection programs to ensure

non-slip and even surfaces.• Monitoring and replacement of boots as

required.• Stack/ remove buckets & tubs when not in use• Provide storage areas for hoses and cleaning tools.• Provide appropriate lighting for areas of work• Highlight potential trip hazards eg. steps, by

making them identifiable.

Example of poor housekeeping

Example of poor non-slip surface

Example of poor boot tread

Good housekeeping

Good non-slip surface

Good boot tread

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8.6 radIaTIoN

Radioactivity use normally involves a few specifically qualified persons in the Meat Industry and thus will not be addressed in this document. Radioactive sources in smoke detectors present negligible risk (apart from compliance with safe disposal requirements).

However, other forms of non-ionising radiation may occur in some workplaces and need to be considered as potentially hazardous. Whilst solar radiation (UV light and glare) is not usually an issue inside meat processing facilities, introduced UV light can still be a problem.

Controls:Documented Welding procedures should ensure that safeguards are in place to prevent other persons (eg: cleaners) being affected by ”welders flash“ whilst welding operations are under way in any workplace (including re-scheduling work, erecting screens, notifying adjacent workers and diverting traffic and pedestrians around the area, etc).

Ultraviolet sterilisation does present potential hazards to workers, and device-specific (and site-specific) control measures need to be developed by employers who use these devices.

8.7 bIoloGICal hazardS

a) Manual HandlingDespite considerable advances in automation, Manual Handling still constitutes a major cause of injury in the Meat Industry.

”Manual Handling“ refers to any activity which involves a person:-• Lifting, Lowering• Carrying• Pushing, Pulling• Twisting• Holding or restraining any person, animal or

object.

Resultant injuries may be sudden (traumatic) sprains and strains (of joints, ligaments, tendons and muscles) or an accumulation of micro-trauma (overuse injuries, such as tennis elbow, carpel tunnel syndrome, etc). Other injuries (burns, lacerations etc) can also result from dropping items whilst manual handling.

Controls:Due to the wide variety of contributing factors, effects and possible Control measures, Employers are urged to refer to the ”National Standard for Manual Tasks“ and a ”National Code of Practice for the Prevention of Musculoskeletal Disorders from performing Manual tasks at Work“ (both available from the ”Safe Work Australia“ website at www.safeworkaustralia.gov.au) to identify such hazards, assess the risks and develop and implement controls.

A potential manual handling hazard during the cleaning process may be movement of industrial type hoses, options such as mobile hose real trolleys may minimise the manual handling risk.

b) Personal Hygiene Meat Workers must comply with an extensive range of control measures (hand-washing, rubber boots, protective hairnets, etc) to prevent contamination of both food contact surfaces and the meat product itself.

Other biological Hazards: • Infection & Disease, such as brucellosis, Q-fever,

or other Zoonoses;• Infestation by parasites (eg: hydatids, tapeworms)

or other vermin (fleas, ticks, rodents); or• Skin disorders from exposure to fluids, cleaning

chemicals.• Panicking animals

The medium for transfer of diseases or parasites can include:• Direct skin contact;• Lacerations/punctures from cutting blades or

animal bones;• Inhalation of dust, body fluids, etc;• Splash in the eye; and• Accidental ingestion (eg. contaminated hands

touching food).

In addition, there is the simple physical risk of being struck by hooves, horns or being knocked over in the pens, yards or on the killing line.

Controls:National animal disease screening programs already reduce the likelihood of exposure to many diseases (brucellosis, foot & mouth disease, equine influenza, bird ‘flu).

Each employer’s animal inspection procedures should identify any diseased or infested animals entering their facility, enabling them to be rejected for processing or alternative controls to be implemented.

Whilst PPE (gloves, waterproof apparel, boots, safety goggles, masks, etc) provide considerable ”last resort“ protection, and hand washing and showering procedures reduce contamination further, many employers require workers to be vaccinated against Q-fever and/or tetanus.

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oh&S aNd The CleaNING ProCeSSSaMPle QuIz1 describe “Systematic hazard Management”:-

Sample answer:Identify the HazardsAssess the RisksImplement Control Measures Monitor and Review

2 In a few words, describe how the following key steps of the cleaning process are conducted:-

Step 2. Dry CleanSample answer: Removal of solid waste using scrapers, shovels, brooms and bins.

Step 3. Wash Down / FlushSample answer: Wash down production areas with cold water.

Step 4. Foaming and ScrubbingSample answer: Foaming of all contact surfaces and fixtures with chemical mixed at the correct ratio, for the required contact time and scrubbing with a Chlorinated alkali and a scouring pad.

Step 5. Post Foaming RinseSample answer: Rinsing off foamed equipment with hot water to remove detergent and any protein left on surfaces and remove any water pooling.

Step 6. SanitationSample answer: Spraying all surfaces with a Quat-based sanitiser (allowing for the required contact time) and air drying.

Step 7. Dry - Post-SanitisingSample answer: Remove pooled water and condensation.

Step 8. Pre-Operational InspectionSample answer: Check for any defects, rectify.

3 list at least 7 major hazards to be aware of in the Meat industry:-

Sample answer:

Hygiene, infection, disease Manual handlingSlips/trips/fall Machinery activationBlades/cutters Heat/ColdChemicals Fall from heightElectricity Overuse injury

4 list at least 7 Control measures which should be in place for Cleaning & Sanitising:-

Sample answer:Gloves, masks, goggles Use proper cleaning toolSafety boots with non-slip soles Isolate and de-energise machinesTraining on hazards Lock-out, Tag-out machinesHandrails/guardrails Non-slip surfacesHousekeeping Pack away tubs, hoses (etc)Signage No loose clothingQ-Fever vaccination Hand-washing

(*Note: Employers should add additional questions relating to other essential OH&S competencies

and Food Quality Control requirements in their workplaces.)

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