working in a bakery and the dust controls you should know!

Oh you work in a Bakery how is that Dust Problem and what are the Controls

Exposure Control Plan for Flour Dust in Bakeries When you think Floor Dust and Risks do you think about, personal breathing zone (PBZ) and general area (GA) monitoring for inhalable flour dust, α-amylase and wheat, a questionnaire, and blood tests for IgE specific to flour dust, wheat, α-amylase, and common aeroallergens. The geometric mean PBZ and GA inhalable flour dust concentrations for the lower-exposure group was 0.235 mg/m(3), and for the higher-exposure group was 3.01 mg/m(3). Employees in the higher-exposure group had significantly higher prevalences of work-related wheezing, runny nose, stuffy nose, and frequent sneezing than the lower-exposure group. The prevalence of IgE specific to wheat was significantly higher among employees who ever had a job in the higher-exposure group or in production at another bakery at both the ≥ 0.10 kU/L and the ≥ 0.35 kU/L cutoffs, and to flour dust and α-amylase at the ≥ 0.10 kU/L cutoff, compared to the lower-exposure group.

Your Company information

Name:

Address:

ContactInformation:

PurposeWe have a duty to protect our workers from exposure to airborne flour dust during the manufacture of baked goods.

We know that a combination of control measures will be required to achieve this objective. We commit to being diligent in our efforts to select the most effective control technologies available. We also commit to ensuring that the best practices, as described in this exposure control plan (ECP), are followed at our worksite.

ResponsibilitiesThe employer is responsible for the following: Identifying and assessing work processes that might lead to worker exposure to airborne

flour dust.

Date: Exposure Control Plan for Flour Dust in Bakeries P bar Y Safety 1

Ensuring that the materials (for example, tools, equipment, and personal protective equipment [PPE]) and other resources (for example, worker training) required to fully implement and maintain this ECP are readily available where and when they are required.

Ensuring that all required tools, equipment, and PPE are used as required by the ECP. Ensuring that supervisors and workers are educated and trained to an acceptable level

of competency. Maintaining records of worker training, respirator fit-test results, and workplace

inspections. Conducting a periodic review (at least annually) of the effectiveness of the ECP. This

includes a review of available control technologies to ensure these are selected and used when practical.

Supervisors are responsible for the following: Ensuring that workers have received adequate instruction on the hazards associated

with exposure to flour dust. Selecting and implementing the appropriate control measures. Ensuring that workers using respirators have been properly fit-tested and that the results

are recorded. Directing the work in a manner that ensures the risk to workers is minimized and

adequately controlled.

Workers are responsible for the following: Attending educational sessions provided by the employer. Using the assigned protective equipment in an effective and safe manner. Following established work procedures as directed by the supervisor. Reporting any unsafe conditions or acts to the supervisor. Reporting exposure incidents to the supervisor.

Risk identification and assessmentWorkers exposed to flour dust are at risk of health effects such as occupational asthma, respiratory sensitization, and allergy to flour dust. Flour is an organic dust that may be made from a number of different grains, including wheat, rye, millet, barley, oats, and corn. Flour contains allergens that are both naturally occurring and additives.

Activities such as mixing, pouring, and weighing flour create airborne flour dust, which workers may inhale. Symptoms of exposure include cough, wheeze, shortness of breath, and inflammation or swelling of the sinuses. Workers exposed to flour dust may develop an allergy or sensitization after repeated exposures. Once sensitization occurs, exposure to even a small amount of flour dust can trigger an asthma attack or an allergic reaction.

The association between exposure to flour dust and the development of occupational asthma or other respiratory symptoms is well documented in the scientific literature. Health effects due to flour dust inhalation have resulted in occupational disease claims in B.C.

Workers in bakery, flour manufacturing, and food processing settings may be at risk of developing adverse health effects as a result of exposure to flour dust.

Health hazardsFlour contains naturally occurring chemicals that can induce allergy, respiratory sensitization, and, at increasing exposures, occupational asthma (baker's asthma). One of the most potent allergens in flour is alpha-amylase.


Alpha-amylase is an enzyme that occurs naturally, in small amounts, in wheat flour. It is also added as a dough improver to break up large starch molecules and speed up the activity of the yeast.

Exposure limitIn B.C., the eight-hour occupational exposure limit (OEL) for flour dust is 0.5 milligrams per cubic metre (mg/m3) of air. This would be the equivalent of a very small pinch of flour, smaller than a fingernail, being inhaled during a single work shift. Flour dust is also a sensitizer, and exposures must be kept as low as readily achievable (ALARA).

Exposure controlThe Occupational Health and Safety Regulation requires employers to select controls based on the following hierarchy:1. Substitution (use flour types with fewer allergens; for example, fungal amylases)2. Engineering controls (for example, mixer covers, local exhaust ventilation)3. Administrative controls (for example, using oil instead of flour in pans and on dough

brake tables, and cleaning with HEPA vacuums and wet mops rather than dry sweeping)4. Personal protective equipment (for example, respirators)

Acceptable control methods for exposure to flour dust during the manufacture of baked goodsThe work methods that appear in the following table are acceptable, provided the controls listed are used.

Administrative controls will be the main methods of eliminating or reducing the risk to workers of exposure to flour dust.


Acceptable control methods

Work activity Controls/procedures Personal protective equipment

Comments

Weighing ingredients

Use containers or bins to store flour. Do not scoop flour from open bags.

Move the flour containers or bins close to the weighing area before use.

Use proper weighing boats with spouts — not buckets or tubs. Measure flour carefully into the boat — do not pour from a distance. Close containers or bins after use. Add ingredients to the mixer after weighing — do not leave them

stacked on the table.

Wear a half-face N95 disposable respirator when weighing out very fine flour or large volumes of ingredients.

Consider weighing ingredients in a filtered powder weighing cabinet. This additional control can be used if other controls or procedures don’t reduce dust levels.

Filling flour containers or bins

Make certain other workers are not nearby. Remove any visible flour dust from the surface of the bag using a

HEPA vacuum. Cut the bag open carefully — do not tear it open. Pour flour slowly into the bin while folding up the bag from the base.

Let the contents slide from the bag. Do not dump the flour and shake the bag until it is empty.

Dispose of the empty bag immediately into a covered disposal bin.

Wear a half-face N95 disposable respirator when filling multiple bins or emptying more than one bag at a time.

Mixing Ensure that the mixer is fitted with a solid cover that closes over the bowl. Mixer covers typically have a small hatch through which additional ingredients can be added.

Add wet ingredients to the mixer first. Don’t pour dry ingredients into the mixing bowl from a height. If dry ingredients are added from a bag, place the top of the bag

into the mixing bowl and cut it open using a knife. Pour flour slowly into the mixer while folding up the bag from the base. The contents should slide from the bag. Do not dump the flour and shake the bag until it is empty. Dispose of the empty bag immediately into a covered disposal bin.

Close the mixer's cover before turning on the mixer. Start the mixer on LOW speed, and increase the speed once all the

ingredients are moistened. Add ingredients through the small hatch in the cover. Don’t open

the cover until the ingredients have been thoroughly mixed.

Wear a half-face N95 disposable respirator when mixing dry ingredients.

Work activity Controls/procedures Personal protective CommentsDate: Exposure Control Plan for Flour Dust in Bakeries P bar Y Safety 4

equipmentPreparing dough Where possible, use oil [insert name/type of oil here] on the brake

(dough sheeter) table rather than flour. When oil can’t be used, use a silicone/Teflon baking mat [insert mat

type here]. Use non-stick sprays [insert name/type of spray here] on baking

pans instead of flour. If flour must be used, sprinkle small amounts onto the table using a

shaker — don’t “throw” the flour. Avoid spreading the flour by hand.

Cleaning up Do not use compressed air for cleaning. Do not dry sweep equipment, tabletops, or floors. Use a HEPA vacuum to remove flour dust from surfaces. Use a wet mop to clean floors. Do not let dust accumulate. Clean up spills immediately. Place waste in covered waste bins. Take HEPA vacuums outside before changing bags or filters.

Wear a half-face N95 disposable respirator when emptying the HEPA vacuum or changing the filter.


Respirators Each worker will be fit-tested if a respirator is required. The worker must be clean-shaven where the respirator seals with the face. Used respirators will be discarded at the end of each shift. When the worker notices a resistance to breathing, the respirator must be replaced. Respirators will be used in accordance with the respirator program.

Safe work planning Work from the Acceptable Control Methods table included in this exposure control plan. Inspect all equipment and tools to make sure they are in good working order. Use and maintain all tools and equipment as specified by the manufacturer.

Cleanup Cleanup must be performed in accordance with the Acceptable Control Methods table

included in this exposure control plan.

Worker training for flour dust exposure Training will be performed by the employer or the employer’s designate. Records of attendance, dates of training, and training material will be documented and

retained. Additional training or reference material on exposure to flour dust will be made available

to workers upon request. Training topics will include the following:

o Health hazards of and symptoms of exposure to flour dusto Engineering controls and safe work practices used to protect workerso The importance of proper equipment control and maintenanceo The respirator program and proper use of respiratorso The details of the exposure control plan

Health surveillance Workers will report any symptoms of exposure to the employer and OH&S or OSHAC for

tracking and investigation.

Annual review This exposure control plan will be reviewed at least annually and updated as necessary

by the employer, in consultation with the joint health and safety committee or the worker health and safety representative.


Sample Respirator Program for Flour Dust Exposure

Purpose[Company name] has determined that our workers in the bakery department are potentially exposed to a breathing hazard (flour dust) during routine operations.

The purpose of this program is to ensure that respirators used by our workers provide effective protection against airborne contaminants in our workplace(s).

Note that before considering respirators as a way to control exposure, the employer is required to first consider engineering or administrative controls to eliminate or minimize the risk of exposure. Examples of such controls include ventilation, enclosing the process, substituting less hazardous products, and other effective means.

ResponsibilitiesEmployerThe employer is responsible for: Implementing a written respirator program and designating a respirator

program administrator Ensuring that the worksite is evaluated for breathing hazards Eliminating or minimizing all breathing hazards Providing and maintaining respirators needed for any airborne hazard present

at the worksite, and ensuring that workers use the equipment when required Providing supervisors with the education and training necessary to ensure that

workers use respirators safely Providing workers with the education, training, and supervision necessary for

safe use of respirators Ensuring that all illnesses or injuries resulting from breathing hazards and

requiring medical aid are reported and recorded Requiring a medical assessment if there is a concern about a worker’s ability to

wear a respiratorProgram administratorThe program administrator [insert name] is responsible for: Assessing the type and amount of exposure Selecting the appropriate respirators Implementing training and instruction programs Administering the overall program, including the maintenance of records Reviewing the program on an annual basisSupervisorsSupervisors are responsible for ensuring that: Workers are aware of breathing hazards on the worksite(s) Respirators are available when required Workers use respirators correctly as required Workers are clean-shaven Workers are aware of any equipment or clothing that may interfere with


respirator use Workers are aware of potential issues that may develop during respirator use,

such as discomfort, skin irritation, or breathing difficulty The program administrator is notified of concerns or conditions that might

affect workers’ respiratory protectionWorkersWorkers are responsible for: Understanding and following safe work procedures Using their respirators as instructed Understanding the limitations of their respirators and following the

manufacturers’ instructions Inspecting their respirators before use Immediately reporting any equipment problems to their supervisors

Respirator selectionThe selection of a respirator must be appropriate to the contaminant, its concentration, and the level of protection provided by the respirator (i.e., the protection factor and maximum use concentration).

Only respirators bearing NIOSH/MSHA (U.S. Mine Safety and Health Administration) approval or other respirators acceptable to OH&S or OSHAC will be provided to workers.

The following respirators are available to workers and are to be worn for the work activities listed below.

Work activity Contaminants Type of respiratorWeighing large volumes of flour

Flour dust Half-face N95 single-use

Filling containers/bins with flour


Mixing dry ingredients Flour dust Half-face N95 single-use

Emptying the HEPA vacuum or changing the filter


Always read the instruction manual prior to use and be certain the correct filter is selected.

Respirator fittingTo fit properly and provide protection, respirators that are designed to fit the face must have an effective seal.

Workers using this type of respirator must be clean-shaven in the area where the respirator seals with the face (i.e., no visible stubble). Workers will receive a fit test once a year (see the “Respirator fitting procedures” section).

[insert name] will arrange fit testing and keep records of the results of these tests.


Worker trainingEvery worker who may have to wear a respirator will be trained in the proper use of the respirator. Both the worker and his or her supervisor receive this training. This training includes: A description of the type of contaminant and the amount of exposure A description of the respirator The intended use and limitations of the respirator How to wear and adjust the respirator How to perform a user seal check How a fit test works and the steps to follow How to inspect the respirator

This training is repeated as often as necessary, at least annually, to ensure that workers remain familiar with the proper use of the respirators. A record will be kept of this training.

The training program is evaluated at least annually by [insert name] to determine that it continues to be effective.

Always refer to the respirator instruction manual for information.

Proper use of single-use respiratorsCorrective eyewear or other equipment must not interfere with the seal of the respirator.

No covering can be used which passes between the respirator facepiece and the wearer's face.

Respirators will be inspected before use to make sure the straps and filter material are not damaged. If a worker discovers a fault or defect in a respirator during an inspection, he or she will bring it to the attention of the supervisor, and the respirator will be replaced.

User seal checks will be performed, where applicable, by respirator users each time they put on their respirators.

When wearing respirators, workers experiencing any of the following must leave the contaminated area: Nausea Dizziness Eye irritation Unusual odour or taste Excessive fatigue Difficulty breathing

The program administrator will determine whether or not a worker may be allowed to wear a respirator. Where there is any doubt on the part of the worker or program administrator about the worker’s ability to wear a respirator, the worker is to be examined by a physician. Certain medical conditions, such as lung disease (e.g., asthma or emphysema) or heart disease, may affect the worker's ability to wear a respirator.


Respirator fitting procedures

How to put on your half-face N95 single-use respirator

1. Hold the respirator in your hand with the nosepiece at your fingertips and the straps hanging freely below your hand.

2. Place the bottom edge of the respirator under your chin with the nosepiece up.

3. Position the top strap high at the back of your head and the other strap around your neck below your ears.

4. Using the fingertips of both hands, mold the nosepiece to the shape of your nose by squeezing it gently while moving your fingertips down the sides of the nosepiece.

How to do a seal check

1. Cover the facepiece completely with your hands.2. If there is a valve, block it off by covering it with

the palm of your hand.3. Breathe in and out, taking care not to move the

respirator out of position. If you have a good seal, the facepiece should collapse slightly on your face when you inhale. When you exhale, you should feel no air escaping.

4. If air leaks out around the nosepiece, mold it more closely to your nose. If air leaks out around the edges of the respirator, adjust the position of the straps.

5. If you are unable to get a good seal, DO NOT use the respirator. Inform your supervisor.


Fit testingAfter the respirator has passed the seal check, another test of the seal, called a fit test, must be done and the results recorded.

When fit tests are performed, workers must be clean-shaven. Prescription eyeglasses must not interfere with the seal of the respirator. Ideally, fit tests should be done under operating conditions similar to those that workers would experience at the worksite.

There are two types of fit testing: qualitative and quantitative. In qualitative fit testing, workers with poorly sealing respirators will detect an irritant, an odour, or a taste when exposed to a test agent. In quantitative fit testing, specialized equipment is used to actually measure the amount of the test agent leaking into the facepiece.

Our workplace uses the following qualitative fit testing procedure.

Bitter aerosol taste fit testIn this test, a worker is exposed to a spray containing denatonium benzoate. It has an extremely bitter taste. The worker wears a respirator equipped with any particulate filter and puts on a test enclosure or hood that covers the head and shoulders. The fit tester exposes the worker to the bitter aerosol by spraying the test solution into the enclosure. Because it is a very bitter solution, it can be easily detected by the worker if it leaks through the face seal. If the worker cannot taste the bitter aerosol after the predetermined number of sprays, it means that the respirator fits properly.

A bitter aerosol fit testing kit can be purchased from suppliers of safety equipment. These kits contain pre-mixed solution as well as instructions for administering the fit test.

Workers should not eat, drink (except plain water), smoke, or chew gum for at least 15 minutes before taking the bitter aerosol fit test.

Before conducting the test, make sure the worker being fit tested can detect the bitter taste by performing a threshold screening check. The threshold screening should be done under a test hood, and the worker being tested should not wear a respirator.

Caution: This test agent may affect workers with respiratory sensitivities.

Bitter aerosol threshold screening1. Instruct the worker to breathe through a slightly open mouth with the tongue extended.2. Ask the worker to let you know when a bitter taste can be detected.3. Insert a nebulizer containing the threshold check solution into an opening located at the

front of the test hood. Direct the spray away from the worker’s breathing zone.4. Rapidly squeeze the bulb of the nebulizer 10 times and ask if the worker can taste the

bitter aerosol.5. If the worker cannot taste the bitter aerosol, rapidly squeeze the nebulizer bulb 10 more

times and ask again if the worker can taste it. If the response is still negative, squeeze the nebulizer bulb 10 more times.

6. Once the worker reports tasting the bitter taste, proceed with the fit test. If the worker cannot detect the bitter taste after 30 squeezes, perform a different fit test.

Bitter aerosol fit test procedureA successful seal check must be done before the fit test. The steps of the fit test are as follows:


1. Prepare a solution made of bitter aerosol and salt solution in warm water and pour the solution into a nebulizer.

2. Have the worker put on a test hood while wearing the respirator. The front portion of the hood should be clear of the respirator and provide sufficient room for free head movement.

3. Instruct the worker to breathe through a slightly open mouth with the tongue extended. Ask the worker to let you know if a bitter taste can be detected.

4. Insert the nebulizer filled with prepared solution into the opening in the test hood directly in front of the worker’s nose and mouth. Direct the spray away from the worker’s breathing zone.

5. Firmly squeeze the bulb of the nebulizer containing the test solution either 10, 20, or 30 times, depending on the worker’s sensitivity to the bitter aerosol (as determined by threshold screening).

6. Instruct the worker to perform the following six fit test exercises while the fit test solution is sprayed into the test hood: Normal breathing. Deep breathing. Be certain breaths are deep and regular. Turning head from side to side. Be certain movement is complete. Nodding head up and down. Be certain motions are complete. Alert the test

subject not to bump the respirator on the chest. Have the test subject inhale when his or her head is in the fully up position.

Talking. Slowly and distinctly, count backwards from 100. Normal breathing.Perform each exercise for one minute.

7. Every 30 seconds, replenish the aerosol concentration by squeezing the nebulizer bulb half the number of squeezes used previously (i.e., use 5, 10, or 15 squeezes). Squirt the solution into the test hood.

8. If the worker reports tasting the bitter aerosol, the respirator has failed the fit test. If the worker cannot detect the bitter aerosol, the respirator has passed the fit test.

A bitter solution is sprayed into the test hood for the bitter aerosol fit test.


Respirator selection information formProcess/operation informationWork area location: Bakery

Work area characteristics (open area, confined space, etc.):

Open area

Location of hazardous area relative to safe area:

Work description/operation:

Pouring, weighing, and mixing flour, and preparing baked goods

Anticipated length of time that respirator will be used:

1 hourWorker activity level (light, moderate, or heavy):

Light

Information for each breathing hazardStep 1: Oxygen level (if below 19.5%, air-purifying respirators

cannot be used)20.9%

Steps 1, 2: Air contaminant and concentration Flour dust; 4 mg/m3

Step 3: 8-hour time weighted average (TWA) limit 0.5 mg/m3

Step 4: Immediately dangerous to life or health (IDLH) concentration

Not listedStep 5: Can the contaminant cause eye irritation? NoStep 5: Can the contaminant irritate skin or be absorbed through

the skin?No

Step 6: Respirator under consideration and assigned protection factors

Half-face N95 single-use; PF=10

Step 7: Hazard ratio (minimum protection factor) 8Step 8: Maximum use concentration (MUC) 5Step 9: Air-supplying or air-purifying respirator? APRStep 10: State of contaminant DustStep 11: Adequate warning properties (odour, irritation, etc.)? Not applicable

Recommended approved respirator(s):

Half-face N95 single-use


Recommended approved filter or cartridge:

Other protective equipment required:

Respirator inspection checklistfor single-use air-purifying respirators

Filtering facepieceCheck for: Holes in the filters

Worn-out (torn, no longer elastic) or missing strapsMissing or curled valvesFolds, creases, or distortion in the facepiece


Respirator fit test formName of worker: Date:

Does the worker wear/have:

Eyeglasses Contact lensesDentures Facial hair

If yes to any of the above, discuss how the respirator seal will be affected (workers must be clean-shaven where the respirator seals with the face). Other comments regarding counselling on eyeglasses, dentures, contact lenses and facial hair:

Does the worker have any medical concerns about wearing a respirator?

Yes No

If yes, refer worker for a medical assessment.

Fit test procedureFit testing must be repeated annually to ensure that a proper face seal is maintained.

Check when completed successfully:

Correct positioning of respirator and strap adjustmentUser seal check

Qualitative fit testing using:

Bitter aerosolOther

Qualitative fit testing: PassFail

Quantitative fit testing: PassFail

Respirator(s) fit tested by the workerWhen a worker wears different makes and models of respirators, fit testing must be done on each make and model of respirator and the results recorded. The worker should also wear all other required personal protective equipment, such as hearing and eye protection, while undergoing the test.

Make/model/size

Make/model/size

Make/model/size

Points discussed with the worker


Respirator selectionRespirator limitations

Fit test date: Next fit test date:

Fit tested by:

Comments:


working in a bakery and the dust controls you should know!

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