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HHE Search Results
32 HHE reports were found based on your search terms. Reports are listed in order of year published with the most recently published reports listed first.
Year Published and Title
(2017) Health hazard evaluation report: evaluation of exposures and respiratory health at a coffee processing facility. (Click to open report) In August 2015, the National Institute for Occupational Safety and Health (NIOSH) received a management request for a health hazard evaluation at a coffee processing facility. The request expressed concern about exposure to diacetyl (2,3-butanedione) during coffee roasting, grinding, and flavoring. In February 2016, we conducted a ventilation assessment, an industrial hygiene survey, and a medical survey. The industrial hygiene survey consisted of the collection of air samples and bulk samples o... (Click to show more)In August 2015, the National Institute for Occupational Safety and Health (NIOSH) received a management request for a health hazard evaluation at a coffee processing facility. The request expressed concern about exposure to diacetyl (2,3-butanedione) during coffee roasting, grinding, and flavoring. In February 2016, we conducted a ventilation assessment, an industrial hygiene survey, and a medical survey. The industrial hygiene survey consisted of the collection of air samples and bulk samples of coffee and flavorings for the analysis of diacetyl, 2,3-pentanedione, and 2,3-hexanedione. Continuous monitoring instruments were used to monitor total volatile organic compounds, carbon monoxide, carbon dioxide, temperature, and relative humidity in specific areas and during tasks. The medical survey consisted of breathing tests and a questionnaire covering medical and work histories. Overall, average air levels of diacetyl, 2,3-pentanedione, and 2,3-hexanedione were not elevated. We identified specific work tasks that resulted in higher air concentrations of diacetyl and 2,3-pentanedione than other tasks. Specifically, packaging and flavoring tasks were associated with the highest levels of diacetyl and 2,3-pentanedione. Some employees reported respiratory symptoms or diagnoses and/or had abnormal lung function tests. We recommend using engineering and administrative controls as a precautionary approach to limit employees' exposures and establishing a medical monitoring program.
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(2016) Health hazard evaluation report: evaluation of respiratory and indoor environmental quality concerns at a snack foods facility - Pennsylvania. (Click to open report) In December 2013, the National Institute for Occupational Safety and Health received a confidential health hazard evaluation request from employees at a snack foods manufacturing facility in Pennsylvania. The request listed concerns about respiratory illnesses, headaches, nosebleeds, and cancer related to indoor dampness and potential exposure to mold and mildew, seasonings, and asbestos. We evaluated employee health concerns and potential exposures to mold and mildew, seasonings, flavoring chem... (Click to show more)In December 2013, the National Institute for Occupational Safety and Health received a confidential health hazard evaluation request from employees at a snack foods manufacturing facility in Pennsylvania. The request listed concerns about respiratory illnesses, headaches, nosebleeds, and cancer related to indoor dampness and potential exposure to mold and mildew, seasonings, and asbestos. We evaluated employee health concerns and potential exposures to mold and mildew, seasonings, flavoring chemicals and asbestos among employees at a snack food manufacturing facility. We performed an indoor environmental quality assessment and assessed air levels of seasonings, flavoring chemicals, and dust. We noted water damage from roof and window leaks that promoted dampness and the potential for mold growth in the facility. Our air samples highlighted several areas of the facility with high risk of exposure to irritant seasonings, dust, and flavoring chemicals. We recommend roof and building structure repairs to mitigate further water damage. We also provide several means to reduce potential employee exposure to irritant seasonings, dust, and flavoring chemicals.
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(2014) Health hazard evaluation report: evaluation of health concerns at a pet food manufacturing facility - Missouri. (Click to open report) In September 2012, the National Institute for Occupational Safety and Health received a confidential health hazard evaluation request from employees of a pet food manufacturing plant in Missouri. The requesters expressed concerns about vomiting, seizures, and breathing problems potentially associated with substances used in the manufacture of pet food and dog biscuits and/or possible phosphine exposure, which is a fumigant applied to bulk materials prior to arriving at the facility. They were al... (Click to show more)In September 2012, the National Institute for Occupational Safety and Health received a confidential health hazard evaluation request from employees of a pet food manufacturing plant in Missouri. The requesters expressed concerns about vomiting, seizures, and breathing problems potentially associated with substances used in the manufacture of pet food and dog biscuits and/or possible phosphine exposure, which is a fumigant applied to bulk materials prior to arriving at the facility. They were also concerned about other issues with their livers, lungs, and kidneys. This health hazard evaluation was conducted after a phosphine investigation by the Occupational Safety and Health Administration and in the context of litigation against the company filed by some current and former employees concerning health impacts of employment. In December 2012, we conducted a walk-through site visit at the facility, interviewed employees, and reviewed company records. In February 2013, two interim letters were sent describing the visit, the sampling results of the walk-through survey, and the preliminary recommendations, all of which are included in this final report. The purpose of the survey sampling was to assess potential exposure agents and characterize the process in terms of these agents; it was not designed to assess personal exposures for comparison against regulatory limits. Results from the three tape-lift mold samples indicated no surface mold in the mill room basements. Grain dust was not sampled or tested for mold during the site visit, but it should be examined in any future exposure assessments of this industry. Headspace chemical analysis of bulk materials showed the presence of diacetyl and 2,3-pentanedione in one ingredient used in the production process. Fugitive dust emissions were observed during some process events. We cannot conclude from our preliminary walk-through investigation whether health effects reported by workers were work-related or not. We planned a return medical survey since we were concerned with health symptoms experienced by requesters and interviewed employees; the medical survey was cancelled due to plant closure. Further medical testing of employees who work in this industry and industrial hygiene sampling of exposure agents at similar processing facilities are warranted to resolve health concerns raised about phosphine, flavorings, and/or dust exposures that may occur during the production of pet food and treats.
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(2013) Health hazard evaluation report: an evaluation of respiratory health at a flavoring manufacturing facility - Kentucky. (Click to open report) In October 2011, the National Institute for Occupational Safety and Health received a confidential employee request for a health hazard evaluation at a flavoring manufacturing facility in Kentucky. The request concerned exposure to chemicals including diacetyl, lack of respiratory protection and ventilation, and upper and lower respiratory problems including shortness of breath. Diacetyl is a butter flavoring chemical that can cause lung disease. Prior to visiting the site, we interviewed employ... (Click to show more)In October 2011, the National Institute for Occupational Safety and Health received a confidential employee request for a health hazard evaluation at a flavoring manufacturing facility in Kentucky. The request concerned exposure to chemicals including diacetyl, lack of respiratory protection and ventilation, and upper and lower respiratory problems including shortness of breath. Diacetyl is a butter flavoring chemical that can cause lung disease. Prior to visiting the site, we interviewed employees, the health and safety manager, and the facility's spirometry provider by telephone and reviewed documents provided by the facility. From November 29 to December 1, 2011 we visited the facility. We toured the facility, interviewed managers, and conducted private interviews with employees representing the facility's departments. We conducted air sampling for volatile organic compounds using evacuated canisters and qualitatively assessed local exhaust ventilation. We collected and reviewed reports of spirometry tests. The spirometry testing often was not conducted according to international guidelines, so we could not reliably interpret the tests. From March 12 to 22, 2012, we conducted a medical survey at the facility consisting of an interviewer-administered questionnaire and lung function tests (spirometry and diffusing capacity). We found that the facility used thousands of chemicals, some of which are recognized respiratory toxins and most of which have unknown respiratory toxicity. The facility provided a list of chemicals for which respirator use is required during the preparation of flavor recipes. There were many controls in place to limit employees' exposure to these chemicals. However, we noted some opportunities for exposure to these chemicals, including: lack of labeling of respiratory hazards in some cases, inadequate local exhaust ventilation, early removal of respiratory protection, and disposal of flavoring waste into open containers. We did not detect diacetyl in any air samples. We detected a diacetyl substitute, 2,3-pentanedione, in two air samples taken in the liquid samples room. Among current employees, some symptoms and diagnoses were more common than expected, while spirometric abnormalities were not in excess compared to U.S. adults. Most participants with obstruction did not respond to bronchodilator, meaning they had fixed obstruction. Symptoms, work-related symptoms, lung function abnormalities, and average lung function values differed by work history characteristics. Employees with longer facility tenure, those who worked in production departments, those who spent more time in production areas, and those who used flavoring ingredients tended to have more symptoms, more work-related symptoms, more lung function abnormalities, and lower average lung function values than others. These differences could not be explained by age, smoking status, or employment at another flavoring plant, and persisted in analyses limited only to production employees, suggesting that they are a result of occupational exposures at the facility.
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(2013) Health hazard evaluation report: evaluation of respiratory concerns at a cream cheese manufacturing facility. (Click to open report) In April 2011, the National Institute for Occupational Safety and Health received a confidential employees' request for a health hazard evaluation at a cream cheese manufacturing plant. The employees submitted the request because of respiratory concerns related to exposures during the manufacturing and packaging processes. We visited the plant on two occasions. On our initial site visit, we toured the plant, talked with employees, and collected bulk samples of flavorings and cardboard debris. We... (Click to show more)In April 2011, the National Institute for Occupational Safety and Health received a confidential employees' request for a health hazard evaluation at a cream cheese manufacturing plant. The employees submitted the request because of respiratory concerns related to exposures during the manufacturing and packaging processes. We visited the plant on two occasions. On our initial site visit, we toured the plant, talked with employees, and collected bulk samples of flavorings and cardboard debris. We analyzed the headspace air over each bulk sample we collected during our initial visit and identified the ketone chemical compounds diacetyl, 2,3-pentanedione, and acetoin in the headspace of a liquid dairy flavoring. We identified diacetyl and 2,3-pentanedione in the headspace of a liquid strawberry flavoring and liquid smoke flavoring. We found small amounts of diacetyl in the headspace of a powder cheesecake flavoring, a powder cheese flavoring, a liquid blueberry flavoring, and a liquid kosher strawberry flavoring. We also found a small amount of diacetyl in the headspace of a strawberry puree. On our follow-up industrial hygiene survey visit, we performed area and personal air sampling alongside the production and packaging of various cream cheese products. We identified diacetyl in air samples at levels above the NIOSH proposed recommended exposure limit in several areas (free ingredients room, free cook room, cook room, 703 fill room) and jobs (703 fill operator, free cook, condiment cook, soft cook). We identified 2,3-pentanedione and 2,3-hexanedione in air samples in the free ingredients room during clean-in-place and clean-out-of-place operations. We have provided recommendations to decrease exposures to flavoring chemicals, cardboard dust, and cleaning chemicals. We recommended additional sampling for diacetyl and 2,3-pentanedione during cleaning operations and after the additional of local exhaust systems. We also recommended that employees see a healthcare provider if they develop or have developed persistent or worsening respiratory or other symptoms.
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(2013) Health hazard evaluation report: evaluation of respiratory concerns at a snack food production facility, New York. (Click to open report) In December 2010, the National Institute for Occupational Safety and Health (NIOSH) received a confidential employee request for a health hazard evaluation (HHE) at a snack food production facility in New York. The facility produces potato chips, corn chips, and other savory snack foods. The employees submitted the HHE request because of concerns about exposures to flavoring chemicals, seasonings, and materials encountered during cleaning activities, and concerns about breathing problems and lun... (Click to show more)In December 2010, the National Institute for Occupational Safety and Health (NIOSH) received a confidential employee request for a health hazard evaluation (HHE) at a snack food production facility in New York. The facility produces potato chips, corn chips, and other savory snack foods. The employees submitted the HHE request because of concerns about exposures to flavoring chemicals, seasonings, and materials encountered during cleaning activities, and concerns about breathing problems and lung disease. We initiated the evaluation by interviewing employees, managers, treating physicians, the facility's nurse, and the company's medical consultant by telephone. We also reviewed documents provided to NIOSH prior to the site visit, including material safety data sheets. From May 14-16, 2012, we visited the facility. We toured the facility, interviewed managers, the facility's nurse, the respiratory protection program administrator, and 25 randomly selected employees, and observed sanitation activities. We collected air samples during production and sanitation activities and collected bulk samples of seasonings for analysis of volatile organic compounds. We also collected additional documents, including records pertaining to the respiratory protection program. We found that the facility uses multiple substances that are respiratory irritants and/or allergens and that previous air sampling demonstrated the presence of the butter flavoring chemical diacetyl and diacetyl substitutes. One worker developed an uncommon immune-mediated lung disease, hypersensitivity pneumonitis, during employment that treating physicians concluded was caused by exposures to organic materials at the facility. During our site visit, we noted opportunities for potential respiratory exposure to organic materials from sources including corn and potatoes, seasonings, cardboard, sludge from a clarifying tank, and a catalyst. We detected diacetyl in three air samples at levels that were too low to quantify and found trace amounts of diacetyl in four bulk samples of seasonings. We detected sodium hydroxide in one air sample at a level that was too low to quantify. Until more is known about the safety of diacetyl substitutes, we recommend that seasonings that contain these substitutes be handled as respiratory hazards. We recommend reducing the potential for respiratory exposures to organic materials through a combination of enhanced engineering controls, modified work practices, and mandatory use of respiratory protection. Results of industrial hygiene evaluations should be interpreted with the knowledge that permissible exposure limits for dust or specific chemicals (where they exist) may not be protective for an immune-mediated health outcome. Employees should be encouraged to report new or persistent respiratory symptoms to the facility's nurse. The occurrence of such symptoms in the workforce should prompt consideration of work-related lung disease, re-evaluation of the potential for exposure to respiratory hazards, and lowering of such exposures.
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(2011) Lung function (spirometry) testing in employees at a flavorings manufacturing plant - Indiana. (Click to open report) In March 2008, an International Brotherhood of Teamsters local union requested a health hazard evaluation at a flavoring manufacturing company because of concern about possible lung effects of flavoring exposures, including diacetyl. In May 2008, NIOSH conducted a brief walk-through visit of the company. Subsequently, the company brought litigation to prevent further on-site evaluations. In June 2009, after resolution of the litigation, the company agreed to provide NIOSH with various medical an... (Click to show more)In March 2008, an International Brotherhood of Teamsters local union requested a health hazard evaluation at a flavoring manufacturing company because of concern about possible lung effects of flavoring exposures, including diacetyl. In May 2008, NIOSH conducted a brief walk-through visit of the company. Subsequently, the company brought litigation to prevent further on-site evaluations. In June 2009, after resolution of the litigation, the company agreed to provide NIOSH with various medical and workplace information. All information was received by November 2009. NIOSH staff evaluated spirometry data supplied by the company on production employees tested from 1998 through 2009. The majority of the spirometry tests was performed in the years 2004 and later. We classified spirometry tests for quality and compared the prevalence of abnormalities in acceptable quality tests to national population prevalence, adjusted for the distributions of age, sex, race, smoking, and body mass index in the company's employees. We calculated declines over time in forced expiratory volume in 1 second (FEV1), a lung function measurement made using spirometry, for employees with more than one spirometry test of acceptable quality, since excessive decline in FEV1 can be an early marker of lung disease. Using an approach that adjusts for quality of a spirometry monitoring program, reflected by within-person variation, we compared the declines in lung function to a statistically-determined lower limit of normal decline. After establishing which employees had abnormal declines in lung function, we evaluated work area risk factors for associations with excessive declines in lung function, adjusted for age, smoking, tenure, change in weight, and obesity. Based on our experience in other flavoring plants, we designated a group of areas with higher potential for flavorings exposure as a possible risk factor. These were liquid compounding, process flavors, dry blend, extract and distillation, and spray dry. We compared spirometric findings for employees in these areas with employees who worked in other areas of the plant. We also evaluated environmental monitoring measurements supplied by the company before and after our walk through visit, along with the four measurements conducted during the walk through. The flavorings manufacturing company supplied spirometry data on 112 employees; 75 percent of these employees had more than one test session, with a follow-up range of 0.5 to 11 years. The most recent spirometry measurement for 106 employees with at least one spirometry test of acceptable quality showed that 30/106 (28 percent) employees had restrictive abnormalities, 3/106 had obstructive abnormalities, and 1/106 had both restrictive and obstructive abnormalities. The 28 percent of employees with restrictive abnormalities was 3.8 (95 percent confidence interval 2.6-5.4) times higher than would be expected in a U.S. population with the same demographic characteristics. Among the 30 employees with restrictive abnormalities, 27 percent had longitudinal testing demonstrating abnormal declines in FEV1 over time, indicating that progressive deterioration in lung function had occurred; 17 percent had no history of longitudinal testing, and thus no evaluation for excessive decline over time was possible. In addition to the 34/106 (32 percent) with abnormal restrictive or obstructive spirometry, 5 employees with normal most-recent spirometry values had longitudinal testing demonstrating abnormal declines in FEV1 over time, which, if continued, might result in spirometric abnormality. Thus a total of 39/106 (37 percent) employees among those with company spirometry measurements had evidence of some abnormality, either in classification of most recent spirometry as showing restriction or obstruction; and/or longitudinal spirometry showing excessive decline over time, with most recent spirometry values still within the normal range. Forty-two employees did not have serial data of adequate quality to allow evaluation for abnormal declines. The company's 2009 exposure measurements documented that diacetyl was present in at least one sample in all sampled production areas, the laboratory, and the warehouse. Two of the four NIOSH area measurements detected diacetyl in liquid compounding and packaging areas. These findings supported our designation of a group of areas with higher potential for flavorings exposures, although some areas that were classified as being in the lower potential for exposure group did have exposures of concern. Employees who ever worked in areas with higher potential for flavorings exposure (liquid compounding, process flavors, dry blend, extract and distillation, and spray dry) had 2.8 times greater average annual declines in FEV1 than employees in areas with lower potential for flavorings exposure. In particular, employees who had ever worked in liquid compounding had statistically higher average annual declines in FEV1, compared to the lower potential for exposure group. Employees who currently worked in higher potential for flavorings exposure areas were 7 times more likely to have abnormal declines in FEV1 than employees in other areas, which is consistent with work-related risk for adverse respiratory health outcomes. Additional medical testing is needed to determine whether the abnormal spirometry findings found among workers are due to lung disease. In particular, medical testing is needed to determine the underlying cause of restrictive spirometry. Although obesity is a major cause of restrictive abnormalities in the United States, our comparisons with the U.S. population were adjusted for the proportions of employees who were overweight or obese, as were our analyses of work area risk factors. Thus, restrictive spirometry in this workforce cannot be explained by obesity. Since the excess of spirometric abnormalities is substantial and the distribution of excessive declines in lung function is associated with history of working in areas with higher potential for exposure, there is great cause for concern about occupational lung disease. It is possible that some exposure other than diacetyl may underlie these abnormalities, since the predominant pattern of restrictive abnormalities differs from the pattern of obstructive abnormalities seen among microwave popcorn employees. Also, the flavorings used in this plant are more diverse than are found in microwave popcorn production. However, some diacetyl-exposed individuals in microwave popcorn plants and other settings have had restrictive abnormalities without other apparent cause. Thus, the spectrum of abnormalities caused by diacetyl might include restrictive lung disease. This possibility remains to be fully explored. We recommend further lowering of flavoring exposures, without regard to anticipated exposure limits to diacetyl, since other chemicals may be associated with the adverse respiratory health outcomes documented in the workforce. We reiterate our interim report recommendations for engineering controls, work practices, enhanced respiratory protection, and medical surveillance. Ongoing medical surveillance that uses longitudinal spirometry testing to monitor those with potentially harmful exposures is also recommended, particularly until the cause of the high burden of abnormal spirometry in the workforce is fully understood. The company's contract with its medical provider should provide for aggregate epidemiologic analysis of the medical results, including analysis of medical results by department or job. Aggregate analysis can identify hazards associated with flavoring manufacture and may assist the company in targeting priorities for prevention through exposure control.
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(2009) Findings from industrial hygiene air sampling, ventilation assessment, and a medical survey at a facility that manufactures flavorings, modified dairy products, and bacterial additives, Chr. Hansen, Inc., New Berlin, Wisconsin. (Click to open report) Background: Workers at Chr. Hansen, Inc., in New Berlin, Wisconsin, requested that NIOSH perform a health hazard evaluation to investigate the risk of respiratory and eye problems from exposures to diacetyl, butter flavorings, cheese flavorings, enzymes, colors, bacterial cultures, and cleaning agents. The plant has separate rooms for the production of the following products and product types: 1. Starter distillate, a liquid which contains the flavoring chemical diacetyl, is produced in the star... (Click to show more)Background: Workers at Chr. Hansen, Inc., in New Berlin, Wisconsin, requested that NIOSH perform a health hazard evaluation to investigate the risk of respiratory and eye problems from exposures to diacetyl, butter flavorings, cheese flavorings, enzymes, colors, bacterial cultures, and cleaning agents. The plant has separate rooms for the production of the following products and product types: 1. Starter distillate, a liquid which contains the flavoring chemical diacetyl, is produced in the starter distillate room. 2. CHY-MAXR, a standardized solution of the enzyme chymosin (produced at another plant) is diluted and packaged in the enzymes room; starter distillate is also diluted and packaged in this room. 3. Cheese, dairy, and other flavors and cheese products are produced in the flavors room. 4. Powdered flavors and colors are produced through a spray drying process in the spray dry room. 5. Bacterial blends for use in foods intended for human consumption are produced in the human health room. (Flavorings are not used or produced in this room.) 6. Bacterial blends for use as feed supplements for farm animals are produced in the animal health rooms. (Flavorings are not used or produced in this room.) Exposures related to production of flavorings are of particular concern to NIOSH. Previous NIOSH investigations have identified evidence of a severe disease of the small airways in the lung (bronchiolitis obliterans) among workers exposed to butter flavoring chemicals in microwave popcorn plants and among production workers in flavoring manufacturing plants. Exposures to enzymes and other organic dust are also of concern due to their potential to cause lung disease in some individuals. Workplace exposures to enzymes can cause asthma and other allergic problems. Repeated exposure to organic dusts (materials from living things such as plants, animals, bacteria, or fungi) can cause hypersensitivity pneumonitis, another serious lung disease. Assessment: NIOSH staff visited the plant initially in September 2007 to meet with management and workers, conduct an initial walkthrough of the plant, learn about production processes, and do preliminary air sampling. NIOSH staff returned to the plant in December 2007 to do a detailed ventilation assessment and industrial hygiene air sampling, and to conduct a medical survey which included a questionnaire and lung function testing with spirometry. All current workers in production areas, the QC laboratory, the warehouse, and maintenance were invited to participate in the medical survey. For analyses of the medical survey results by type of potential exposure in the plant, workers were classified as follows: 1. Flavoring workers: Current workers with potential exposure to diacetyl and other flavoring-related chemicals in the starter distillate, enzymes, flavors, or spray dry rooms, the QC laboratory, or in maintenance work. 2. Bacterial products workers: Current workers with potential exposure to bacteria and other organic dusts in the animal health or human health rooms. 3. Warehouse workers. Results: Air sampling showed diacetyl air concentrations in the spray dry, starter distillate, and flavors rooms and in the quality control laboratory that were similar to those measured at some flavoring plants and microwave popcorn plants where some workers have developed severe lung disease likely caused by exposure to diacetyl and possibly other flavoring chemicals. This included both average air concentrations over the work shift and peak air concentrations during specific tasks. The atmospheric pressure in the spray dry and flavors rooms was neutral to positive relative to the warehouse; as a result, movement of air contaminants from those rooms into the warehouse is possible. The Torit local exhaust ventilation unit used during packaging of finished product in the spray dry room allowed some of the captured dust to escape back into the room air. One worker in the flavoring worker group had mild fixed airways obstruction on spirometry testing. Although this finding might be related to flavoring chemical exposures, additional medical tests are required to establish if a particular lung disease is present and the likely cause; information from additional medical evaluation was not available to NIOSH investigators. Among nine current and former workers in flavoring production areas who reported chest symptoms from work exposures, three workers reported chest symptoms from exposure to enzymes; three workers reported chest symptoms from exposure to acids; one worker reported chest symptoms from exposure to diacetyl; and one worker reported chest symptoms from exposure to encapsulated starter distillate. One worker reported eye burning from diacetyl and starter distillate. Air sampling in the animal health large and intermediate packaging rooms showed intermittent peak exposures to dust during ingredient mixing and product packaging activities. For some processes, local exhaust ventilation in these rooms did not adequately control dust exposures. Of ten workers in the animal and human health rooms who participated in the medical survey, five reported post-hire skin problems, four reported chest symptoms from exposures, and three reported work-related eye and nasal symptoms. Two of the four with chest symptoms reported that these occurred with exposure to Biomax and other powders. Spirometry tests in two animal health workers showed restriction, a decreased ability to fully expand the lungs. One of the two workers with restriction also reported weekly episodes of unusual tiredness and fatigue and monthly episodes of fever, chills, or night sweats. These symptoms in an individual with restriction on spirometry can be due to hypersensitivity pneumonitis, a lung disease which occurs in a small percentage of individuals exposed to organic dusts. Additional medical tests are necessary for a physician to establish if an individual has this disease. Conclusions and Recommendations: The levels of diacetyl measured in flavoring production areas at the Chr. Hansen plant may be high enough to put workers at risk of developing severe lung disease. Because flavoring-related lung disease can occur after only several months of exposure and can rapidly progress to severe irreversible disease, uncontrolled exposures should be minimized. Workers in the animal and human health rooms may also be at risk for respiratory symptoms and disease from exposure to organic dust. The Recommendations section of this report contains detailed guidance on what Chr. Hansen mangers should do to decrease exposures in all production rooms, the quality control laboratory, and the warehouse to minimize the potential for workers to develop respiratory and other health effects. The following approaches for prevention are addressed: ventilation improvements, administrative and work practice changes, use of respirators and other personal protective equipment, worker education, and medical monitoring with regularly scheduled spirometry tests.
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(2009) Report on an investigation of buttermilk flavoring exposures and respiratory health at a bakery mix production facility, General Mills, Los Angeles, California. (Click to open report) On July 8, 2008, the National Institute for Occupational Safety and Health (NIOSH) received a confidential Health Hazard Evaluation (HHE) request to perform an investigation of possible health hazards at the General Mills, Inc. bakery mix facility in Los Angeles, California. The requestors described concerns about respiratory health, including bronchiolitis obliterans which is a rare irreversible lung disease found in some workers exposed to diacetyl in flavorings. They noted exposure to hazardo... (Click to show more)On July 8, 2008, the National Institute for Occupational Safety and Health (NIOSH) received a confidential Health Hazard Evaluation (HHE) request to perform an investigation of possible health hazards at the General Mills, Inc. bakery mix facility in Los Angeles, California. The requestors described concerns about respiratory health, including bronchiolitis obliterans which is a rare irreversible lung disease found in some workers exposed to diacetyl in flavorings. They noted exposure to hazardous chemicals, including flavorings containing diacetyl. Prior to their request, the California Division of Occupational Safety and Health (CalOSHA) had visited the facility, performing a limited review under the Flavoring Industry Safety and Health Evaluation Program. NIOSH investigators were aware that a buttermilk flavoring containing 15-20% diacetyl was used at the facility in the past, which had been re-formulated and reported to contain less than 1 percent diacetyl. NIOSH investigators conducted telephone interviews with workers, union representatives, an inspector from CalOSHA familiar with the facility, and company management and safety officials. In September-October 2008, NIOSH staff conducted a medical survey at the plant consisting of an interviewer-administered questionnaire and lung function testing with spirometry before and after bronchodilator administration; they also observed production processes, collected bulk samples of flavorings, and measured concentrations of airborne contaminants in all areas of the facility. In May 2009, NIOSH staff performed additional air sampling to quantitate levels of a diacetyl substitute, 2,3-pentanedione. NIOSH staff conducted spirometry on 24 (59%) of the current employees, including 19 (70%) production workers. None of the workers tested with spirometry had fixed airways obstruction as seen in flavoring-related bronchiolitis obliterans. Participants had higher than expected rates of shortness of breath, physician-diagnosed asthma, and a restrictive pattern on spirometry, compared to U.S. adults. Some participants reported symptoms with a work-related pattern. Analytical results of headspace bulk samples of currently used liquid and powdered flavorings indicated that five of six contained the alpha-diketone substitute compound, 2,3-pentanedione; four contained diacetyl, three contained acetoin, and three contained other alpha-diketones. None of the applicable Material Safety Data Sheets for the evaluated bulk flavorings listed diacetyl or its alpha-diketone substitutes. Only one MSDS listed acetoin. Results of personal and area air samples indicated quantifiable concentrations of 2,3-pentanedione during handling of the re-formulated liquid buttermilk flavoring and during production of a bakery mix that contained the re-formulated flavoring. No diacetyl, acetoin, or other alpha-diketones were above minimum detection limits in workplace air for time-weighted samples. The toxicology of diacetyl substitutes is only now being studied. Because 2,3-pentanedione, 2,3-hexanedione, and 2,3-heptanedione all share the same functional alpha-diketone group as diacetyl, these compounds may also share diacetyl's mechanism of toxicity. Until more is known about 2,3-pentanedione and other alpha-diketone compounds, they should not be assumed to be safe. A "safe" level of diacetyl has not been established, and even low levels of diacetyl are potentially hazardous. Management should continue to limit exposures to flavorings through a combination of engineering controls, work practices, and respiratory protection. Workers should report symptoms to their personal physician and to a designated individual at the workplace.
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(2009) Respiratory symptoms in workers at three commercial kitchens, Aramark, New York, New York. (Click to open report) In February 2008, the UNITE HERE International Union requested Health Hazard Evaluations to evaluate both respiratory health and inhalation exposures of food preparation workers at three New York City food service facilities managed by the Aramark Corporation. This request was triggered by concerns of exposure to artificial butter-flavored cooking oils, containing diacetyl. Exposure to diacetyl is associated with a severe lung disease, called bronchiolitis obliterans. At NIOSH's request, in Febr... (Click to show more)In February 2008, the UNITE HERE International Union requested Health Hazard Evaluations to evaluate both respiratory health and inhalation exposures of food preparation workers at three New York City food service facilities managed by the Aramark Corporation. This request was triggered by concerns of exposure to artificial butter-flavored cooking oils, containing diacetyl. Exposure to diacetyl is associated with a severe lung disease, called bronchiolitis obliterans. At NIOSH's request, in February 2008, the New York City Department of Health and Mental Hygiene collected four bulk samples of current-use cooking oils at the 1 Chase Manhattan Plaza (CMP) Aramark facility. On March 11-12, 2008, we completed a walk-through visit of the three facilities where we performed limited air sampling, evaluated the cooking area ventilation systems, collected bulk samples of current-use cooking oils, and reviewed material safety data sheets (MSDSs) and Occupational Safety and Health Administration (OSHA) 300 logs. We visited the facilities again from March 31 to April 4, 2008 to perform a medical survey consisting of an interviewer-administered questionnaire and spirometry (lung function) testing. We detected low levels of diacetyl in bulk samples of unsalted butter at the 277 Park Avenue (Park) and 1 New York Plaza (NYP) Aramark locations and in two bulk samples of Prep ZT, a butter-flavored cooking oil, from the CMP Aramark location. We did not detect acetoin, a ketone similar to diacetyl also found in many butter-flavored products, in any bulk samples. We did not detect diacetyl or acetoin in any area or personal air samples at the three facilities and have no evidence that workers are currently exposed to diacetyl or acetoin vapors while using these products during cooking or food preparation. We did not detect oxides of nitrogen (NOx) or nitrous dioxide (NO2) at any of the locations. Carbon monoxide (CO) was not detected at the Park and NYP locations, but two separate one-minute readings of 6 and 3 parts per million (ppm) were detected at the CMP location during a cooking operation. These short-term concentrations were well below the OSHA Permissible Exposure Limit (8-hour time-weighted average of 50 ppm) and the NIOSH Recommended Exposure Limit (8-hour time-weighted average of 25 ppm) for CO. Real time monitoring for VOCs at all locations did not detect levels greater than 2 ppm, and real time particle measurements were generally below 1 mg/m3; however, there are no applicable exposure guidelines for these measurements. We observed some employees handling cleaning agents without the proper eye and skin protection recommended in the MSDSs. NIOSH staff interviewed 116 workers (82%) about their health and job histories and obtained interpretable spirometry tests from 104 of these participants. Among the 116 participants, 71 (61%) reported nasal irritation; 54 (47%) eye irritation; and 26 (22%) reported a post-hire skin rash or skin problem. Aramark workers had higher than expected prevalence of wheeze (a symptom of asthma); stuffy, itchy or runny nose; watery, itchy eyes; nasal allergies, including hay fever; and shortness of breath on exertion compared to the U.S. adult population as reported in NHANES III [CDC 1996]. Workers who reported cooking as part of their job were twice as likely to report asthma-like symptoms, shortness of breath following exercise, and cough than those who did not report cooking among their job duties. Additionally, they were three to four times more likely to report work-relatedness of their respiratory symptoms. Participants who reported cleaning as part of their duties were also more likely to report lower respiratory symptoms, specifically, asthma-like symptoms and shortness of breath while walking uphill compared to those whose job duties did not involve cleaning. Workers who reported cleaning hot surfaces were more than three times more likely to report shortness of breath following exercise than those not reporting this exposure. Aramark workers had a higher than expected prevalence of a restrictive pattern on spirometry tests (14%) compared to the U.S. adult population as reported in NHANES III; the prevalence of airways obstruction was not higher when compared to the U.S. adult population [CDC 1996]. We identified five workers (5%) with airways obstruction; of whom two had fixed obstruction which did not appear to be flavoring-related. These two workers started working at their current Aramark facility after artificial butter-flavored products were no longer in use. They, as well as the other three workers with airways obstruction, did not report any professional cooking experience in their current facility or in the food service industry outside of their current facility. Three of the workers reported cleaning experience. One worker with reversible airways obstruction reported no smoking history. The other four workers with airways obstruction reported past or current smoking. No cases of obstruction were observed at the CMP Aramark location where a diacetyl-containing butter-flavored cooking oil was used at the time of the survey. Diacetyl and acetoin were not detected in any personal or area air samples at the three facilities collected by NIOSH at the time of the survey.
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