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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
(2008) Report on fixed obstructive lung disease in workers at a flavoring manufacturing plant, Gold Coast Ingredients, Inc., Commerce, California. (Click to open report) On October 24, 2006, Gold Coast Ingredients, Inc. requested a Health Hazard Evaluation (HHE) from the National Institute for Occupational Safety and Health (NIOSH) to medically screen workers for occupational lung disease at their Commerce, California, flavoring manufacturing plant. The company was participating in a voluntary special emphasis program for the flavor manufacturing industry, called the Flavoring Industry Safety and Health Evaluation Program (FISHEP). On September 6, 2006, Cal/OSHA... (Click to show more)On October 24, 2006, Gold Coast Ingredients, Inc. requested a Health Hazard Evaluation (HHE) from the National Institute for Occupational Safety and Health (NIOSH) to medically screen workers for occupational lung disease at their Commerce, California, flavoring manufacturing plant. The company was participating in a voluntary special emphasis program for the flavor manufacturing industry, called the Flavoring Industry Safety and Health Evaluation Program (FISHEP). On September 6, 2006, Cal/OSHA had previously requested technical assistance (HETA 2006-0361) from NIOSH for an industrial hygiene and engineering control assessment at the same Gold Coast Ingredients plant to characterize work tasks, processes and procedures, and potential occupational exposures. A secondary goal was to develop recommendations for and evaluate the effectiveness of exposure control techniques. Reports and correspondence regarding the industrial hygiene surveys and the engineering control surveys at the plant were sent to the company previously and are summarized in this HHE report. They are also available in their entirety in the appendices of this report. Medical surveys of workers were conducted during October 30-November 1, 2006 and March 13-14, 2007; industrial hygiene surveys during November 14-16, 2006 and July 11-12, 2007; and engineering control surveys during November 14-16, 2006 and July 9-12, 2007. During the initial medical survey among 41 participants, one of 14 (7%) ever-production workers had severe fixed airways obstruction, later confirmed as bronchiolitis obliterans. Post-hire eye irritation was significantly more prevalent in current production workers (11 of 12, 92%) compared to current nonproduction workers (16 of 29, 55%) (p-value=0.03). On repeat spirometry, 1 of 11 (9%) current production workers was found to have developed new obstruction, with a 1-liter drop in the forced expiratory volume in the first second of exhalation (FEV1). Among 15 ever-production workers from both medical surveys, 2 (13%) had fixed airways obstruction. During the initial industrial hygiene survey, mean full-shift TWA diacetyl air concentrations were 0.46 ppm in the liquid production room, 0.34 ppm in the powder production room, and 0.21 ppm in the pre-production corridor for both area and personal samples. The highest task-based diacetyl air concentration (11.04 ppm) was measured when a worker (in a full-facepiece respirator with organic vapor and particulate cartridges) was pouring diacetyl from a bulk container into smaller containers in the pre-production corridor over a 10-minute period. Mean, full-shift TWA acetoin air concentrations were 0.15 ppm in the liquid production room, 0.09 ppm in the powder production room, and 0.07 ppm in the pre-production corridor. The highest task-based acetoin air concentration (1.05 ppm) was measured during mixing and pouring of a butter flavor in the liquid production room by a worker wearing a full-facepiece respirator with combined organic vapor and particulate cartridges; this activity took 61 minutes. Mean, full-shift TWA acetaldehyde air concentrations were 0.14 ppm in the powder production room, 0.07 ppm in the liquid production room, and 0.07 ppm in the pre-production corridor. A task-based acetaldehyde air concentration of 0.19 ppm was measured during pouring and mixing of ingredients for a fruit flavor in the liquid production room; this activity took 53 minutes. During the follow-up industrial hygiene survey, mean full-shift TWA area diacetyl air concentrations were 0.529 ppm in the liquid production room, 0.483 ppm in the powder production room, 0.098 ppm in the pre-production corridor, and 0.041 ppm in the distribution warehouse. The highest single-area 2-hour air concentration of diacetyl (6.33 ppm) was observed in the spray-drying room while a recipe with diacetyl was being encapsulated. Higher task-based diacetyl concentrations (ranging from 4.75 ppm to 17.38 ppm) were measured during some activities: 1) pouring liquid diacetyl; 2) scooping and sifting flavored powder products; 3) packaging flavored powder products; and 4) adding ingredients into flavor formulations. Mean full-shift TWA acetoin air concentrations were 0.20 ppm in the spray-drying room, 0.163 ppm in the powder production room, 0.077 ppm in the pre-production corridor, and 0.067 ppm in the distribution warehouse. The highest task-based acetoin air concentration (2.78 ppm) was measured during packaging of a dairy-flavored powder product in the powder production room over a 33-minute period. Mean full-shift TWA acetaldehyde air concentrations were 0.44 ppm in the spray-drying room, 0.343 ppm in the powder production room, 0.273 ppm in the liquid production room, and 0.029 ppm in the pre-production corridor. The highest task-based acetaldehyde air concentration (4.02 ppm) was measured during packaging of a powdered dairy-flavored product in the powder production room; this activity took 33 minutes. During the initial engineering control survey, NIOSH investigators performed a walkthrough of the plant to review production processes and provided recommendations on the design and implementation of engineering controls. During the follow-up survey, NIOSH investigators evaluated the local exhaust ventilation system (bench-top and booth-type hoods) installed in the liquid production room. When activated, the ventilated bench-top and booth-type hoods had good overall performance; however, NIOSH investigators made recommendations to further improve the performance and operability of the local exhaust ventilation. NIOSH investigators also recommended that management continue to install ventilation and other engineering controls to minimize exposure to hazardous chemicals in the powder production processes. Additionally, we recommended that workers wear full-facepiece respirators (with NIOSH-certified organic vapor and particulate cartridges) at all times when they are in the pre-production corridor, liquid production room, powder production room, spray-drying areas, or distribution warehouse. Workers who enter these areas should also undergo spirometry testing every three months. Workers with abnormal spirometry or a decline in FEV1 greater than 10% should be removed from exposure to flavoring chemicals until medically evaluated for appropriate restrictions.
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(2007) Gold Coast Ingredients, Inc., Commerce, California. Interim report. (Click to open report) On October 24, 2006, Gold Coast Ingredients, Inc. requested a Health Hazard Evaluation (HHE) for medical screening for occupational lung disease at their Commerce, California plant. The company was participating in a voluntary special emphasis program called the Flavoring Industry Safety and Health Evaluation Program (FISHEP). In 2006, this program was initiated by the California Department of Health Services (CDHS) and the California Division of Occupational Safety and Health (Cal/OSHA) to iden... (Click to show more)On October 24, 2006, Gold Coast Ingredients, Inc. requested a Health Hazard Evaluation (HHE) for medical screening for occupational lung disease at their Commerce, California plant. The company was participating in a voluntary special emphasis program called the Flavoring Industry Safety and Health Evaluation Program (FISHEP). In 2006, this program was initiated by the California Department of Health Services (CDHS) and the California Division of Occupational Safety and Health (Cal/OSHA) to identify workers with flavoring-related lung disease such as bronchiolitis obliterans (BO) and institute preventive measures in the California flavoring industry. Under FISHEP, companies must report to CDHS the results of employee medical screening and worksite industrial hygiene assessments, and implement control measures recommended by Cal/OSHA. During the initial walkthrough of the plant, the NIOSH medical officers noted workers in the production areas wearing various respirators including full-face, half-face, and N-95 filtering facepiece respirators. Production workers wore the full-face and half-face respirators with NIOSH-certified organic vapor cartridges but not always with particulate filters. Some 3 production workers were not wearing respirators while co-workers performing the same tasks were wearing respirators. Pouring of liquid ingredients was observed in the corridor (pre-production area) outside of the liquid production area. Management stated its policy was to require respirator use when acetoin, acetaldehyde, diacetyl, acetic acid, and benzaldehyde were used. Management stated that qualitative fit testing was done with isoamyl acetate (banana oil). No quantitative fit testing had been done. During the walkthrough on November 1, 2006, production had ceased for the day. All of the workers performing cleaning activities in the production areas wore half-face or full-face respirators with organic vapor cartridges. Some had particulate filters, as well. During the walkthrough on March 13, 2007, no production activities were occurring. All workers in the production rooms were wearing full-face respirators with organic vapor cartridges, and some had particulate filters. All the current production workers, except for one worker and the production manager, had been quantitatively fit tested for a Survivair Opti-Fit full-face respirator. Mention of company names or products does not constitute endorsement by NIOSH. We found 2 workers with production work history that had fixed airways obstruction. The very severe case was not previously able to wear a respirator and had been transferred to a job with less exposure to flavoring chemicals. Such cases are sentinels of risk to co-workers. The second case evolved during FISHEP participation and demonstrates the importance of: 1) mandatory use of appropriate fit-tested respirators with both organic vapor/acid gas cartridges and particulate filters; and 2) implementation of engineering controls to lower exposure in plants with cases of fixed airways obstruction. This second case had an extreme drop in lung function into the abnormal range within a 4.5 month period of time and without symptoms. In this facility, current production workers did not have an excess of chest symptoms compared to other workers, although the two cases developed during production work. When sick workers transfer to less physically demanding work or leave employment altogether, the remaining workers can look "healthier" in comparison to the rest of the workforce. This effect is common in cross-sectional studies and such findings should not be interpreted as an absence of risk in production workers. In this facility, the sickest employee transferred out of production, and thereby contributed his/her symptoms to a nonproduction employee grouping in Table 1. Considering the results of both spirometry surveys, the two cases of fixed obstruction arising in production employment are consistent with flavoring exposure being associated with risk. Whether restrictive abnormalities are related to flavoring exposures remains unclear. No flavoring-exposed workforce studied to date has had a statistically significant excess of restrictive spirometry. However, individual cases with restriction have occurred in the microwave popcorn industry without explanation or alternate diagnosis (11,12). Longitudinal follow-up may clarify whether cases of restriction are coincidental, a stage of flavoring-related abnormalities, or a less common response to flavoring exposure. Similarly, longitudinal follow-up may establish whether borderline obstruction seen in two workers in production indicates higher risk of progression to fixed airways obstruction of bronchiolitis obliterans syndrome.
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(2007) Report on severe fixed obstructive lung disease in workers at a flavoring manufacturing plant, Carmi Flavor and Fragrance Company, Inc., Commerce, California. (Click to open report) On June 11, 2006, CDHS-OHB and Cal/OSHA made a joint request for NIOSH technical assistance with industrial hygiene assessment and medical screening for occupational lung disease risk at the Carmi Flavor and Fragrance Company plant in Commerce, California. At the time of this request, Cal/OSHA was conducting a compliance investigation at this facility due to the identification in April 2006 of a former worker (and possibly a second worker) with bronchiolitis obliterans. NIOSH investigators were ... (Click to show more)On June 11, 2006, CDHS-OHB and Cal/OSHA made a joint request for NIOSH technical assistance with industrial hygiene assessment and medical screening for occupational lung disease risk at the Carmi Flavor and Fragrance Company plant in Commerce, California. At the time of this request, Cal/OSHA was conducting a compliance investigation at this facility due to the identification in April 2006 of a former worker (and possibly a second worker) with bronchiolitis obliterans. NIOSH investigators were aware of similarly affected workers at five other flavoring plants, and had previously investigated similar lung disease in microwave popcorn workers, identifying inhalation exposure to butter flavoring chemicals as the cause. In July 2006, NIOSH staff conducted a medical survey at the plant consisting of an interviewer-administered questionnaire and lung function testing with spirometry. In August 2006, NIOSH staff conducted industrial hygiene air sampling in all areas of the plant. NIOSH staff conducted follow-up spirometry tests on production and laboratory workers at the plant in November 2006. NIOSH staff conducted spirometry tests on 34 of 36 current workers and administered the questionnaire to 31 of 36 current workers at the plant. One former laboratory worker had the questionnaire and spirometry administered at the plant and two former production workers had the questionnaire and spirometry administered at an off-site location. Workers in all areas of the plant commonly reported symptoms of eye and nasal irritation. Respiratory symptoms were reported more often by production workers who made powdered flavorings and by laboratory workers. Respiratory illness was reported mostly by production workers who ever worked in powdered flavoring production. Respiratory illness was reported infrequently by other workers. Of the16 current workers and two former workers who had a history of working in the production room, four were found to have abnormal spirometry: one had mild restriction and the other three had severe fixed obstruction (FEV1 ranged from 21 to 32 percent of predicted). All three production workers with severe obstruction had made powdered flavorings. The highest area TWA total VOC concentrations were seen in the production room, with concentrations ranging from 10.3 mg/m3 to a high of 38.5 mg/m3. The highest real-time area total VOC concentrations (greater than 100,000 ppb units) were identified in the powdered flavoring production area during production of a butter-flavored baking powder which contained diacetyl, specifically when the production worker was filling boxes with the finished product. Some of the highest peak real-time VOC concentrations observed in the liquid flavoring production area may have resulted from migration of contaminants from the powdered flavoring production area. Full-shift personal and area mean TWA diacetyl air concentrations in the liquid flavoring production area were 0.030 ppm and 0.025 ppm respectively, and in the powdered flavoring production area were 0.223 ppm and 0.249 ppm respectively. Partial-shift personal and area mean TWA diacetyl air concentrations in the powdered flavoring production area during the production of butter-flavored and vanilla-flavored powders were 7.76 ppm and 21.2 ppm respectively. Real-time FTIR sampling in the workers' breathing zones during the production of these butter- and vanilla-flavored powders showed peak diacetyl air concentrations as high as 204 ppm during the packaging of the finished product.
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(2007) Yatsko's Popcorn, Sand Coulee, Montana. (Click to open report) In March 2006, NIOSH received a request for a Health Hazard Evaluation (HHE) from owners of Yatsko's Popcorn, a small popcorn popping plant, located in Sand Coulee, Montana. The company had originally operated out of a smaller building from 1979 to 1999, when the operation was moved to the current location. The occupational exposure concerns cited in this request included flavoring chemicals from popcorn production activities; reported health concerns included breathing problems, shortness of br... (Click to show more)In March 2006, NIOSH received a request for a Health Hazard Evaluation (HHE) from owners of Yatsko's Popcorn, a small popcorn popping plant, located in Sand Coulee, Montana. The company had originally operated out of a smaller building from 1979 to 1999, when the operation was moved to the current location. The occupational exposure concerns cited in this request included flavoring chemicals from popcorn production activities; reported health concerns included breathing problems, shortness of breath, wheezing, tightness in the chest, and skin disorders. This request was based on health concerns following NIOSH investigations of fixed obstructive lung disease consistent with bronchiolitis obliterans in microwave popcorn plant workers associated with exposure to butter flavorings. We conducted an industrial hygiene survey at the popcorn popping plant on April 12 and 13, 2006. Air samples were collected for total and respirable particles, particle size distributions, volatile organic compounds, total hydrocarbons, ketones (diacetyl, acetoin, and 2-nonanone), inorganic acids, and acetaldehyde. Bulk samples of flavoring ingredients were collected and analyzed for the emission of volatile organic compounds (VOCs) on heating. We reviewed medical records for two former workers and one current worker and we interviewed two workers and the spouse of the other worker. In May 2006, subsequent to our survey, the plant closed its operation. The main findings from this HHE include: At this plant, popcorn was popped and bagged; powdered cheese and jalapeno pepper flavorings were manually applied to some of the popped popcorn. Popping and bagging operations were done approximately twice a week for 2 to 4 hours per day depending on orders. Popping was done in a small building with a wall exhaust fan; the worker wore a disposable dust mask during popping; however, this was not a NIOSH-approved respirator. Diacetyl was detected by gas chromatography with mass spectroscopy (GCMS) in vapors released from a bulk sample of flavored oil heated to 50 degrees C in an analytical laboratory, although it was not a predominant volatile organic compound released from the oil. Diacetyl was also detected by GCMS in two- and four-hour area air samples. Concentrations were too low to be detected (less than approximately 0.01 parts per million (ppm) in four-hour personal and area air samples by NIOSH method 2257). Using a direct-reading instrument, a peak diacetyl concentration of 0.14 ppm was measured in the air directly above a heated container of butter-flavored oil. Aldehydes were the predominant type of VOC identified in area air samples. However, acetaldehyde concentrations were less than the detectable (0.09 ppm) or quantifiable (0.15 ppm) concentrations. Average area particle concentrations in air using gravimetric analysis were 2.72 milligrams per cubic meter of air (mg/m3) for total particles and 0.89 mg/m3 for respirable particles. Particle concentrations were higher during popcorn bagging activities than during other activities; particle concentrations were also higher on the day that powdered flavorings were applied to the popcorn than on the day when powdered flavorings were not used. Airborne exposures of this popcorn popping operation included lower diacetyl concentrations and more aldehyde compounds than was observed in microwave popcorn production. All three workers who worked at the company developed respiratory disease while working there. One former worker, who had only worked at the original smaller plant and who eventually died as a result of his respiratory disease, had airways obstruction that improved with a bronchodilator, which is consistent with asthma. Two other workers who had worked at both the original smaller plant and the current plant had symptoms of asthma; one of these had pulmonary function test results that improved significantly with a bronchodilator, which also is consistent with asthma. Some evidence suggests possible bronchiolitis obliterans in the worker who died and in one of the other two workers. While employed at the plant, all three workers experienced worsening of their respiratory symptoms the days they worked. NIOSH investigators found that aldehydes were the predominant type of volatile organic compound identified in air samples at the plant. Diacetyl was present in the air of the plant with a concentration too low to be quantified. Average area particle concentrations in air using gravimetric analysis were 2.72 mg/m3 for total particles and 0.89 mg/m3 for respirable particles. All three workers who worked at the plant developed respiratory symptoms while working there and had worsening of respiratory symptoms on days worked. Evidence from medical records and radiographs of these three individuals was consistent with asthma in all three workers and suggestive of possible bronchiolitis obliterans in two of the workers.
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(2006) Gilster-Mary Lee Corporation, Jasper, Missouri. (Click to open report) In August 2000, the Missouri Department of Health and Senior Services requested technical assistance from the National Institute for Occupational Safety and Health (NIOSH) in an investigation of severe obstructive lung disease (bronchiolitis obliterans) in former workers of the Gilster-Mary Lee popcorn plant in Jasper, Missouri. Affected workers had worked in the room where butter flavoring was mixed into heated soybean oil (mixing room) and in the adjacent microwave popcorn packaging-area. A NI... (Click to show more)In August 2000, the Missouri Department of Health and Senior Services requested technical assistance from the National Institute for Occupational Safety and Health (NIOSH) in an investigation of severe obstructive lung disease (bronchiolitis obliterans) in former workers of the Gilster-Mary Lee popcorn plant in Jasper, Missouri. Affected workers had worked in the room where butter flavoring was mixed into heated soybean oil (mixing room) and in the adjacent microwave popcorn packaging-area. A NIOSH medical and environmental survey at the plant in November 2000 showed that plant employees had 3.3 times the rate of obstruction on NIOSH spirometry tests compared to national rates; the prevalence of obstruction in never-smokers was 10.8 times the national rate. Nineteen of 21 workers with obstruction had fixed obstruction (unresponsive to bronchodilators), and most chest x-rays and diffusing capacity tests were normal. These findings are consistent with constrictive bronchiolitis obliterans. Five of six quality control (QC) workers who repeatedly popped bags of product in microwave ovens (approximately 100 bags per worker per work shift) in a poorly ventilated room were found to have obstruction on spirometry. A strong exposure-response relationship was demonstrated between quartiles of estimated cumulative exposure to diacetyl (a volatile butter flavoring chemical contaminating the air in the plant) and the frequency of airways obstruction on spirometry tests. NIOSH investigators provided air purifying respirators that filtered both vapors and particulates for mixers and assisted with employee training in respiratory protection. In January 2001, NIOSH investigators conducted a detailed engineering control assessment and provided exposure control recommendations. NIOSH performed seven additional cross-sectional medical and environmental surveys from April 2001 through August 2003 to determine if controls were effective in reducing exposures and protecting workers. Follow-up Environmental Findings: As a result of the implementation of exposure controls from January 2001 through May 2003, average diacetyl air concentrations declined two orders of magnitude in the mixing room (from 38 ppm to 0.46 ppm) and the QC laboratory (from 0.54 to 0.002 ppm), and three orders of magnitude in the packaging area (from 1.69 ppm to 0.002 ppm for machine operators). Follow-up Medical Survey Findings: A total of 373 current workers participated in one or more NIOSH surveys. Participation by current workers at each survey ranged from 71% to 91%. One hundred eighty six of the 373 total participants participated in more than one survey (50%). However, participation in more than one survey was much greater for workers hired prior to the first NIOSH survey (Cohort-1; 100 of 146 participants, 68%) than for workers hired after the first NIOSH survey (Cohort-2; 86 of 227 participants, 38%). From the first to last survey, there was a statistically significant decline in the prevalence of eye, nose, and throat irritation in Cohort-1 participants but no significant changes in the prevalences of other symptoms or spirometry abnormalities, or in mean percent predicted FEV1. Cohort-2 participants had lower prevalences of symptoms and spirometry abnormalities, and a higher mean percent predicted FEV1, compared to Cohort-1 participants at their first survey. There were no statistically significant changes in these outcomes over time for Cohort-2 participants. Of the 88 Cohort-1 participants who participated in three or more NIOSH medical surveys, 19 (22%) had FEV1 declines of greater than 300 ml and/or 10% from their first to their last spirometry test, compared to 3 of 41 (7%) Cohort-2 participants who participated in three or more surveys. Four of nine participants who worked as mixers after the 1st NIOSH survey had FEV1 declines of greater than 300 ml and/or 10% of baseline, including one mixer who declined more than 1300 ml in nine months while working as a mixer. The total FEV1 decline in this mixer was 2800 ml over 2.75 years, which included a 1500 ml decline over two years after stopping work as a mixer. The NIOSH investigation at the Gilster-Mary Lee microwave popcorn plant in Jasper, Missouri, determined that inhalation exposure to butter flavoring chemicals is a risk for occupational lung disease. With the exposure controls implemented to date, workers in the microwave popcorn packaging area should now be at minimal risk as long as isolation of the mixing room and mezzanine is maintained and all ventilation systems are operational. The exposure controls implemented in the QC laboratory have likely minimized the risk to workers in this area as well. However, QC laboratory workers should have regularly scheduled spirometry to assure that their lung function remains stable. Mixers are still at potential risk from open handling of butter flavorings and from tank emissions. Use of appropriate respiratory protection by mixers and other workers who enter the mixing room and mezzanine area is a short-term solution to this problem. Re-engineering the oil and butter flavoring mixing process to a closed system (so that mixers do not have to handle open containers of flavoring and no longer have to open tanks that contain heated oil and/or butter flavoring) is recommended to eliminate this risk. Until a closed process is implemented, all workers who enter the mixing room or mezzanine should use appropriate respiratory protection when in those locations and should have regularly scheduled spirometry to identify early declines in lung function that may be due to exposures to butter flavoring chemicals.
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(2004) American Pop Corn Company, Sioux City, Iowa. (Click to open report) In July 2001, NIOSH received a request for technical assistance from the Iowa Department of Public Health to evaluate the risk for lung disease in American Pop Corn Company workers exposed to butter flavorings. This request was made after NIOSH investigated severe fixed obstructive lung disease consistent with bronchiolitis obliterans in former workers of a microwave popcorn plant in Missouri and identified an association between occupational lung disease and exposure to butter flavoring vapors.... (Click to show more)In July 2001, NIOSH received a request for technical assistance from the Iowa Department of Public Health to evaluate the risk for lung disease in American Pop Corn Company workers exposed to butter flavorings. This request was made after NIOSH investigated severe fixed obstructive lung disease consistent with bronchiolitis obliterans in former workers of a microwave popcorn plant in Missouri and identified an association between occupational lung disease and exposure to butter flavoring vapors. NIOSH conducted a walk-through survey at the American Pop Corn Company plant in Sioux City, Iowa on September 26, 2001. Limited industrial hygiene air sampling on that day showed that air concentrations of diacetyl, a predominant butter flavoring chemical measured as a marker of butter flavoring exposure, were very low compared to levels that were associated with abnormal lung function at the Missouri (index) plant. The company reported that workers who handled flavorings had used full facepiece respirators with particulate filters and organic vapor cartridges since shortly after the microwave popcorn plant began operating in December 1988. In June 2002, the company informed NIOSH that one of its mixing room workers had been diagnosed with fixed obstructive lung disease consistent with bronchiolitis obliterans. NIOSH conducted a medical survey from July 22 through July 26, 2002, and an industrial hygiene survey from July 29 through August 1, 2002. The main findings from these surveys included: 1. The mixing room was isolated and ventilated separately from the packaging area; 2. All tanks of heated soybean oil and flavorings were located in the mixing room and had local exhaust ventilation; 3. Workers (mixers) measured flavorings in open containers in a separate area in the warehouse and then carried the flavorings into the mixing room and poured the flavorings into open tanks of heated soybean oil; 4. Area diacetyl air concentrations in the mixing room were 0.57 parts per million (ppm) parts air by volume when liquid and paste flavorings were in use on July 29 and were below the limit of detection of the sampling method when powder flavorings were in use on July 31 and August 1; 5. Personal diacetyl exposures for the mixers for the three days of sampling were 0.04, 0.004, and 0.005 ppm respectively; 6. Mixers' exposure to diacetyl increased to 80 to 120 ppm for several minutes while pouring liquid butter flavoring into a tank; 7. Six of 13 workers with experience as mixers had abnormal lung function (three with fixed obstruction and three with restriction); 8. The average percentage of time that workers reported using respirators when in the mixing room prior to June 2002 was 20 percent (workers usually did not wear respirators when handling flavorings in the warehouse); 9. The highest measured diacetyl air concentration in the packaging area was 0.03 ppm; 10. Apart from workers with mixing experience, the prevalence of abnormal lung function in microwave popcorn plant workers did not differ significantly from the prevalence in nonmicrowave popcorn plant workers, and was similar to the expected prevalence based on national general population surveys; and, 11. Unlike the index plant, risk for lung disease in workers who popped many dozens of bags of product in microwave ovens per shift was not identified in this plant (these workers popped fewer bags per shift than at the index plant). NIOSH conducted an industrial hygiene survey on September 17 and 18, 2003 to measure air concentrations of respirable and total dust during the handling of powdered flavorings. This survey showed that: 1. Air concentrations varied depending on the particular powdered flavoring being handled and the manner in which it was handled, and 2. Some of the airborne dust was of respirable size The findings from the NIOSH medical and industrial hygiene surveys at this plant show an apparent risk for lung disease in mixing room workers at much lower air concentrations of butter flavoring chemicals than those initially measured at the Missouri index plant. Lung disease risk was not identified in other areas of the plant apart from mixing. Recommendations for engineering controls, use of personal protective equipment, and medical surveillance for exposed workers are provided in this report.
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(2004) ConAgra Snack Foods, Marion, Ohio. (Click to open report) NIOSH has identified evidence of fixed obstructive lung disease consistent with bronchiolitis obliterans in workers exposed to airborne butter flavoring chemicals at several microwave popcorn plants. In 2002, NIOSH learned that a worker who had mixed oil and butter flavorings for microwave popcorn production at the ConAgra Snack Foods plant in Marion, Ohio, had been diagnosed with severe fixed obstructive lung disease consistent with bronchiolitis obliterans. During an initial visit to the pla... (Click to show more)NIOSH has identified evidence of fixed obstructive lung disease consistent with bronchiolitis obliterans in workers exposed to airborne butter flavoring chemicals at several microwave popcorn plants. In 2002, NIOSH learned that a worker who had mixed oil and butter flavorings for microwave popcorn production at the ConAgra Snack Foods plant in Marion, Ohio, had been diagnosed with severe fixed obstructive lung disease consistent with bronchiolitis obliterans. During an initial visit to the plant in January 2003, NIOSH identified production processes and work practices similar to those of other microwave popcorn plants. Specifically, workers handled many different butter flavorings in open containers and poured the flavorings into open tanks of heated soybean oil. The tanks did not have local exhaust ventilation and the workers did not use respiratory protection. Oil and flavoring mixing activities and all heated tanks were located in one room (slurry room) adjacent to the packaging line area, and the air pressure in this room was positive relative to the packaging line area. NIOSH proceeded to conduct a detailed health and environmental survey at this plant from March 3 to March 10, 2003, in order to characterize exposures and lung function in mixers and other workers. The main findings from this survey included: 1. The mean time weighted average diacetyl air concentration in the slurry room was 1.14 parts per million parts air (ppm). This air concentration is similar to those measured by NIOSH at two other microwave popcorn plants where mixers also developed fixed obstructive lung disease. 2. Three of 12 current slurry room workers were found to have airways obstruction on NIOSH spirometry tests. Two did not respond to bronchodilators, while one did respond but the forced expiratory volume in the first second of exhalation (FEV1) remained below normal. All three had normal diffusing capacity. These findings are consistent with bronchiolitis obliterans. 3. After adjustments to the slurry room ventilation by ConAgra, the slurry room was found to have negative air pressure relative to the packaging area. 4. The mean time weighted average diacetyl air concentration in the packaging area was 0.02 ppm. 5. Five workers in the packaging area had fixed obstruction on spirometry, normal diffusing capacity, and no history of work in the slurry room. All were smokers but were relatively young (average age 36), making smoking a less likely explanation for their obstruction. If packaging area air concentrations of flavoring chemicals were higher in the past when the slurry room was under positive pressure, it is possible that some packaging area workers developed airways obstruction as a result. 6. Two of 11 current quality assurance (QA) lab workers were found to have abnormal spirometry. One had obstruction that was unresponsive to bronchodilator and had a normal diffusing capacity. Another had restriction. Prior to the installation of an enclosure with exhaust ventilation for the microwave ovens, the average diacetyl air concentration in the QA lab at the ConAgra plant was 0.018 ppm, compared to 0.56 ppm in the QA lab at another plant where five of six QA workers were found to have airways obstruction. At the ConAgra plant and other microwave popcorn plants, the pattern of lung function test abnormalities in workers who regularly mix butter flavorings with heated soybean oil implies a risk for the development of fixed airways obstruction from inhalation of flavoring-related chemicals. Nearby packaging workers may also be at risk if flavoring chemicals or dust in the air of the slurry room contaminate the air in the packaging area. Recommendations for engineering controls, use of personal protective equipment, and medical surveillance for exposed workers are provided in this report.
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(2003) Agrilink Foods Popcorn Plant, Ridgeway, Illinois. (Click to open report) In September 2002, the National Institute for Occupational Safety and Health (NIOSH) received a request for a health hazard evaluation (HHE) from employees at Agrilink Foods Popcorn Plant, Ridgway, Illinois. The respiratory health concerns cited in the request included cough, shortness of breath, and chest pain; and exposure concerns included butter flavorings, coloring agents, and salt. We conducted a walk-through survey October 22-23, 2002 and an industrial hygiene survey November 5- 6, 2002.... (Click to show more)In September 2002, the National Institute for Occupational Safety and Health (NIOSH) received a request for a health hazard evaluation (HHE) from employees at Agrilink Foods Popcorn Plant, Ridgway, Illinois. The respiratory health concerns cited in the request included cough, shortness of breath, and chest pain; and exposure concerns included butter flavorings, coloring agents, and salt. We conducted a walk-through survey October 22-23, 2002 and an industrial hygiene survey November 5- 6, 2002. Average area diacetyl air levels in the mixing tank area, microwave popcorn packaging line, and quality control room were 0.60, 0.33, and 0.19 parts per million parts air by volume, respectively. Average personal diacetyl air levels for the mixer, microwave popcorn packaging line machine operator, and quality control workers were 0.37, 0.64, and 0.06 parts per million parts air by volume, respectively. On November 19-21, 2002, 35 current workers (73%) participated in health questionnaire interviews and spirometry and lung diffusing capacity testing. Comparisons to national data were performed which controlled for race, age group, and smoking status. These comparisons demonstrated that plant employees aged 17 to 39 had about a 3 times greater rate of chronic cough, and plant employees aged 40 to 69 who had never smoked had about a 2 times greater rate of shortness of breath. We supplemented our 35 spirometry test results with company results for individuals who did not volunteer in our study, and used spirometry tests for 41 workers for our analysis. Plant employees overall and plant employees aged 40 to 69 had about a 2 times greater rate of airways obstruction, compared to national rates. Despite the small number of workers in this study, we were able to demonstrate statistical significance for the elevated airways obstruction rate in workers aged 40 to 69. None of the tested workers with obstruction demonstrated reversibility with the administration of bronchodilator. The survey findings are best explained by work-related bronchiolitis obliterans due to exposures arising from the open configuration of the mixing tanks which allowed volatile organic compounds (VOCs) to be disseminated to other areas of the plant, as well as due to the quality control process where many bags of microwave popcorn were popped in a small room with minimal general dilution ventilation.
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(2003) B. K. Heuermann Popcorn, Inc., Phillips, Nebraska. (Click to open report) On August 28, 2001, the National Institute for Occupational Safety and Health (NIOSH) received a health hazard evaluation (HHE) request from management at B.K. Heuermann Popcorn, Inc. to evaluate work processes and exposures occurring during the packaging of microwave popcorn. This request was motivated in part by the fact that several workers experienced eye injuries and cough while using a new flavoring in August 2001. The worker that prepares the mixture of oil, flavorings, salt, and coloring... (Click to show more)On August 28, 2001, the National Institute for Occupational Safety and Health (NIOSH) received a health hazard evaluation (HHE) request from management at B.K. Heuermann Popcorn, Inc. to evaluate work processes and exposures occurring during the packaging of microwave popcorn. This request was motivated in part by the fact that several workers experienced eye injuries and cough while using a new flavoring in August 2001. The worker that prepares the mixture of oil, flavorings, salt, and coloring, was found to have fixed airways obstruction on evaluation by a pulmonologist soon after this event. NIOSH investigators visited your plant on September 27, 2001, to perform an initial walkthrough, conduct an opening meeting with management and workers, and conduct confidential worker interviews and lung function testing with spirometry. A NIOSH industrial hygiene survey was conducted from December 11 to December 13, 2001. An interim letter containing medical findings, preliminary air sampling results, and recommendations, was sent to you on April 19, 2002. The current letter provides additional air sampling results, additional background information on flavoring-related lung disease in the microwave popcorn industry, and updated recommendations. It also constitutes the final report for this health hazard evaluation.
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(2003) Nebraska Popcorn, Clearwater, Nebraska. (Click to open report) While our lung function tests of workers at your plant did not reveal obstruction, the abnormality most associated with butter flavoring exposure, this should not be interpreted to mean that there is little, or no risk from flavoring exposure in your plant. As I discussed in my previous letter, while most of your microwave production workers had lung function that was in the normal range, it is possible that some had higher levels of function in the past. The respiratory symptoms reported by som... (Click to show more)While our lung function tests of workers at your plant did not reveal obstruction, the abnormality most associated with butter flavoring exposure, this should not be interpreted to mean that there is little, or no risk from flavoring exposure in your plant. As I discussed in my previous letter, while most of your microwave production workers had lung function that was in the normal range, it is possible that some had higher levels of function in the past. The respiratory symptoms reported by some of them may mean that their lung function could become abnormal in the future. In addition, since not all workers are equally susceptible to the effects of a chemical exposure, it is possible that the small number of workers we tested at your plant did not include workers that were sensitive to the air concentrations of flavoring chemicals that were present during our evaluation. Future new employees could be at risk, and changes in your production process, level of production, or the flavorings that you use could increase risk for current workers if exposures to flavorings chemicals increase as a result.
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