1. Safety Issues and Resolutions in
Modern Bakeries
Tenchi Gao Smith
Auburn University
5:40pm Sunday, May 31, 2015
Session: - Applied Solutions 4 - Session 5
Date: Sunday, May 31, 2015
Session Time: 5:00 PM - 6:15 PM
Presentation Time: 5:40 PM
Room: Ryman 1
Session Type: Oral

2. Current Situation Bakery Business: Growing at 5% per Year
Safety Awareness: Lacking

3. OSHA Citations
9 out of 10 most frequently cited OSHA violations relate to bakery industry:
Fall protection
Hazard communication
Respiratory protection
Electrical and wiring methods
Powered industrial trucks
Ladders
Lockout/tagout
Electrical and general requirements
Machine guarding

4. Types of Bakeries Retail bakeries Wholesale bakeries Larger scale
Large and heavy machining and automation
Supply grocery stores and retail bakery stores
Retail bakeries
Bake as they sell to individual customers

5. Baking Processes Mixing: industrial mixer
Flour cooling: cooling of the dough to a desired temperature.
Forming/cutting
Baking
Decorating and Packaging
Storage

6. Hazards Slips, Trips and Falls Combustible Dust Electrical Safety
Machine Guarding/Cuts/Burns
Confined Space
Ergonomic Hazards
Respiratory Problems and Allergies
Housekeeping

8. Slip, Trip & Fall 15% of all accidental deaths
Second to motor vehicles as cause of fatalities

9. Bakery Slip Trip Fall Injury
34-year-old worker killed when fell into a 7-ft-deep fermentation tank
At wholesale bakery
Worker was cleaning the lid and outer portion of the top of the tank with a cleaning pad
Fell when the pad apparently fell to the bottom of the tank
(National Institute of Occupational Safety and Health, 2006)

10. Combustible Dust 1st documented combustible dust explosion in history
December 14, 1785
Mr. Giacomelli's Bakery on at Turin, Italy
2006
119 lives and injured 718 people in 25 years
2009
Worst combustible dust explosion
Imperial Sugar Factory, Port Wentworth, GA
14 fatalities
the U.S. Chemical Safety and Hazard Investigation Board (CSB)

11. Imperial Sugar Plant Explosion, 2009

12. Combustion Conditions
Mixture of enough oxygen
Certain density of combustible dust
Ignition source
Ex. Large quantity of
Flour
Sugar

13. Ergonomic Hazards Heavy loading Frequent lifting
Awkward posture: twisting
Vibration: tools
Inadequate lighting
Prolonged standing
inappropriate workstation set-ups and heights
High Musculoskeletal Disorder (MSD) Risks at Hand, Wrist, Shoulder and Low Back

14. Recommendations Current Bakery Standards
Five Hierarchies of Hazard Control
Elimination
Substitution
Engineering controls
Administrative controls
Personal Protective Equipment (PPE)

15. Current Standards OSHA 29 CFR 1910.263
design, installation, operation and maintenance of machinery and equipment used within a bakery
ANSI Z50.1 & ANSI Z Safety Standards
design, construction, installation, safe operation, and maintenance of bakery machinery and equipment

16. Hazard Control Hierarchies
Elimination
Substitution
Engineering Controls
Administrative Controls
Personal Protective Equipment (PPE)

17. Elimination Eliminating the hazard from root Modify Effective measure
Job design
Equipment
Tools
Effective measure

18. Substitution If cannot be eliminated Substitute with ex.
Less corrosive cleaning supplies

19. Engineering Control 3 Principles
Design facility, equipment, or process to remove the hazard
Enclose hazard:
Prevent exposure
Establish barriers or local ventilation:
Reduce exposure to hazard

20. Administrative Control
Task rotation
Regular rest breaks
Periodic inspection
Adequate training

21. Personal Protective Equipment (PPE)
Quick
Cost Effective

22. Personal Protective Equipment (PPE)
Respirators
Inhalable flour dust
Protective clothing, such as aprons and gloves
Soft rubber mats:
Prolonged standing
Hand-lifts, trolleys, and rolling carts:
Moving heavy objects High-temperature silicone oven mitts and handle holders are to be used when handling hot objects.

23. Personal Protective Equipment (PPE)
Industrial non-slip floor surfaces:
Prevent slip, trip, and fall injuries
Hearing protection
Eye protection:
Corrosive materials

24. Tenchi Gao Smith