Health Hazard Evaluations (HHEs)

(2020) Exposures and respiratory health at a coffee roasting, flavoring, and packaging facility. (Click to open report)
Physicians at a university medical center diagnosed obliterative bronchiolitis, a serious, often disabling lung disease, in five former employees of the coffee roasting, flavoring, and packaging facility. In April 2012, the National Institute for Occupational Safety and Health's Health Hazard Evaluation Program received a confidential employee request from a coffee roasting, flavoring, and packaging facility with approximately 85 employees. The requestors had concerns about respiratory symptoms,... (Click to show more) Physicians at a university medical center diagnosed obliterative bronchiolitis, a serious, often disabling lung disease, in five former employees of the coffee roasting, flavoring, and packaging facility. In April 2012, the National Institute for Occupational Safety and Health's Health Hazard Evaluation Program received a confidential employee request from a coffee roasting, flavoring, and packaging facility with approximately 85 employees. The requestors had concerns about respiratory symptoms, lung disease, and eye irritation related to the manufacturing of coffee products, including ingredients used in the flavoring process. In July/August 2012, we conducted an initial walk-through site visit at the facility. In September 2012, we conducted a medical survey; we administered a questionnaire, performed breathing tests, and measured antibodies in blood. In November 2012, we conducted an industrial hygiene survey and ventilation assessment at the facility. The industrial hygiene survey consisted of collecting personal breathing zone and area air samples for alpha-diketones (i.e., diacetyl and 2,3-pentanedione) and dust. Bulk samples of whole bean green and roasted coffee, ground roasted coffee, and liquid flavorings were collected to evaluate the potential for emission of diacetyl and 2,3-pentanedione. We used continuous monitoring instruments to measure total volatile organic compounds, carbon monoxide, carbon dioxide, temperature, and relative humidity in specific areas and during tasks. We evaluated respiratory health and airborne exposures to alpha-diketones (diacetyl, 2,3-pentanedione, and 2,3-hexanedione), dust, other volatile organic compounds, carbon monoxide, and carbon dioxide during coffee roasting, grinding, flavoring, and packaging. Diacetyl and 2,3-pentanedione were detected in a majority of full-shift personal breathing zone air samples. During the November 2012 visit, the maximum concentration of diacetyl was 166.0 parts per billion in a personal sample from a packaging employee while the maximum 2,3-pentanedione concentration was 199.0 parts per billion from a personal sample collected on an employee in the flavoring room. In April 2017, personal samples from employees in the flavoring room gave maximum concentrations of 163.8 parts per billion diacetyl and 899.6 parts per billion 2,3-pentanedione. In November 2012, 58 of 59 full-shift personal samples exceeded the NIOSH recommended exposure limit for diacetyl of 5 parts per billion and 42 of 59 samples exceeded the NIOSH recommended exposure limit for 2,3-pentanedione of 9.3 parts per billion. In April 2017, 28 of 29 full-shift personal samples exceeded the NIOSH recommended exposure limits for diacetyl and 2,3-pentanedione. The production volume in April 2017 was approximately 70% higher than our first visit which likely contributed to the higher concentrations measured in some areas. During the medical survey, eye and nose symptoms were the most commonly reported symptoms; 1.6-fold excess of employees reported shortness of breath compared to the U.S. population with a similar demographic distribution, and 2.7 times as many employees as expected had spirometric obstruction than in the U.S. population. We recommend installing local exhaust and dilution ventilation and implementing administrative controls such as modification of work practices. Until engineering and administrative controls are in place, we recommend respiratory protection to reduce exposures to alpha-diketones. The choice of respirator should be guided by personal exposure sampling for diacetyl and 2,3-pentanedione and be made only by qualified personnel. We also recommended continuing the medical surveillance program. (Click to show less)
(Click to open report)

(2019) Exposures and respiratory health at a coffee roasting and packaging facility. (Click to open report)
In May 2016, the National Institute for Occupational Safety and Health's (NIOSH) Health Hazard Evaluation Program received a request from management of a coffee roasting and packaging facility regarding concerns about exposures to and health effects from diacetyl and 2,3-pentanedione during coffee roasting, grinding, and flavoring. In July 2016, we conducted an industrial hygiene survey and ventilation assessment at the facility. The industrial hygiene survey consisted of collection of air sampl... (Click to show more) In May 2016, the National Institute for Occupational Safety and Health's (NIOSH) Health Hazard Evaluation Program received a request from management of a coffee roasting and packaging facility regarding concerns about exposures to and health effects from diacetyl and 2,3-pentanedione during coffee roasting, grinding, and flavoring. In July 2016, we conducted an industrial hygiene survey and ventilation assessment at the facility. The industrial hygiene survey consisted of collection of air samples and bulk samples of coffee for 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. We also measured levels of carbon monoxide in employees' exhaled breath and conducted a ventilation assessment. In August 2016, we conducted a medical evaluation of employees that consisted of a health questionnaire and breathing tests. In February 2017, we returned to conduct an industrial hygiene survey of the finished goods warehouse All personal full-shift samples collected during the industrial hygiene survey exceeded the NIOSH recommended exposure limit for diacetyl of 5.0 parts per billion, with a maximum concentration of 420.9 parts per billion. Thirty-six of the 37 full-shift samples exceeded the NIOSH recommended exposure limit for 2,3-pentanedione of 9.3 ppb, with a maximum of 275.9 parts per billion. We identified work tasks that resulted in higher air concentrations of diacetyl and 2,3-pentanedione than other tasks. Specifically, flavoring coffee, grinding roasted coffee beans, roasting coffee beans, packaging roasted coffee, and cleaning equipment were associated with higher diacetyl levels. We observed high instantaneous levels of diacetyl and 2,3-pentanedione during flavoring, grinding, and packaging. Air levels of carbon monoxide collected on employees with duties that included flavoring and grinding coffee exceeded the NIOSH ceiling limit of 200 parts per million. Carbon dioxide levels were low throughout most of the facility. The most commonly reported symptoms were nose and eye symptoms. Some employees reported these nose and eye symptoms were caused or aggravated by green bean coffee burlap bags, green bean and roasted coffee dust, smoke, flavorings, or roasting coffee Wheezing or whistling in the chest was the most commonly reported lower respiratory symptom. Some employees reported their lower respiratory symptoms were caused or aggravated by grinding and flavoring, heat, or stress. Six (6%) of 99 participants had abnormal spirometry. Eight (8%) participants had high exhaled nitric oxide, a marker of allergic airways inflammation. Employees who reported grinding or flavoring had higher odds of waking up with chest tightness and episodes of flu-like achiness or achy joints in the last 12 months, and had lower lung function parameters, although these were not statistically significant. One participant with abnormal spirometry and work-related respiratory symptoms was referred to a pulmonologist and subsequently received a clinical diagnosis of obliterative bronchiolitis associated with occupational exposure to flavorings In response to our evaluation, the company implemented engineering controls and made administrative changes to reduce employees' exposure to diacetyl and 2,3-pentanedione. The company installed additional general exhaust ventilation in administrative and production areas, local exhaust ventilation in production areas where sources of high exposures to diacetyl and 2,3-pentanedione were documented, and equipment to monitor pressure differentials between production and administrative spaces. The company also enclosed the grinding area. Personal protective equipment requirements were implemented and included powered air-purifying respirators for employees in the flavoring room and grinding area, and half-face respirators for employees in other areas of the facility until exposures could be reduced and verified by additional air sampling. The company also instituted a medical surveillance program that included repeating spirometry every six months to identify employees who might be developing work-related lung disease (e.g., asthma, flavoring related lung disease). Of 53 employees who underwent spirometry testing conducted by NIOSH in 2016 and the coffee facility s occupational health provider in 2017, six (11%) had 15% or more decrease in lung function between tests, which is more than expected because of aging. One employee had 15% or more decrease between two occupational health provider spirometry tests conducted in 2017. We recommend follow-up air sampling to confirm the effectiveness of engineering controls and consulting with a ventilation engineer to install additional engineering controls near point sources. Additional engineering controls might be designed to capture diacetyl and 2,3-pentanedione in specific locations at sources where elevated levels of diacetyl and 2,3-pentanedione were measured. We recommend the company continue to train employees about potential workplace hazards, and continue to administer the medical surveillance program. (Click to show less)
(Click to open report)

(2018) Chemical exposures at two vape shops in Texas. (Click to open report)
The Texas Department of State Health Services requested assistance from the Health Hazard Evaluation Program to evaluate employees' exposures to chemicals associated with vaping at two vape shops. We collected air samples for flavoring chemicals (diacetyl, 2,3-pentanedione, 2,3-hexanedione, and acetoin), nicotine, volatile organic compounds, and formaldehyde; took wipe samples for nicotine and metals on commonly touched surfaces; and interviewed employees about their work and health. We found th... (Click to show more) The Texas Department of State Health Services requested assistance from the Health Hazard Evaluation Program to evaluate employees' exposures to chemicals associated with vaping at two vape shops. We collected air samples for flavoring chemicals (diacetyl, 2,3-pentanedione, 2,3-hexanedione, and acetoin), nicotine, volatile organic compounds, and formaldehyde; took wipe samples for nicotine and metals on commonly touched surfaces; and interviewed employees about their work and health. We found that employees vaped at work. Employees were exposed to low levels of flavoring chemicals in the air while working in the vape shops. Exposure to formaldehyde, other volatile organic compounds, and nicotine were also low. We found evidence of residual nicotine on commonly touched surfaces throughout both vape shops. All employees wore chemical protective gloves when they were mixing e-liquids and working with concentrated nicotine solutions. However, some employees reported liquid nicotine contacting their skin or eyes while handling liquid nicotine or vaporizers. At the time of our visit, none of the employees reported symptoms consistent with either nicotine toxicity or exposures to flavorings in the past 4 weeks. Although the measured concentrations were below all applicable occupational exposure limits, we recommend that the employer implement a policy prohibiting vaping in the workplace with e-liquids that contain diacetyl and 2,3-pentanedione. We also recommended determining which work tasks are associated with nicotine exposure to identify PPE needs, training employees on proper chemical handling procedures, and ensuring consistent use of chemical protective nitrile gloves when handling liquids containing nicotine or customers' e-cigarettes. (Click to show less)
(Click to open report)

(2018) Health hazard evaluation report: evaluation of exposures and respiratory health at a coffee roasting and flavoring facility. (Click to open report)
In November 2016, the Health Hazard Evaluation Program of the National Institute for Occupational Safety and Health received a request from management of a coffee roasting and flavoring facility with six employees regarding repetitive motion injuries, potential burns, general warehouse safety, and potential employee exposure to green coffee bean dust, diacetyl, and 2,3-pentanedione during coffee processing. In January 2017, we observed work practices and conducted an industrial hygiene survey an... (Click to show more) In November 2016, the Health Hazard Evaluation Program of the National Institute for Occupational Safety and Health received a request from management of a coffee roasting and flavoring facility with six employees regarding repetitive motion injuries, potential burns, general warehouse safety, and potential employee exposure to green coffee bean dust, diacetyl, and 2,3-pentanedione during coffee processing. In January 2017, we observed work practices and conducted an industrial hygiene survey and a medical survey at the facility. The industrial hygiene survey consisted of collecting personal breathing zone and area air samples for alpha-diketones (i.e., diacetyl, 2,3-pentanedione, and 2,3-hexanedione), carbon monoxide, and carbon dioxide. Bulk samples of whole bean coffee and flavoring were collected to evaluate the potential for emission of diacetyl, 2,3-pentanedione, and 2,3-hexanedione. We used continuous monitoring instruments to measure total volatile organic compounds, carbon monoxide, carbon dioxide, temperature, and relative humidity in specific areas and during tasks. The medical survey consisted of a health questionnaire and breathing tests. One interim report with recommendations was sent to the company following our visit. Overall, full-shift time-weighted average air concentrations of diacetyl and 2,3-pentanedione were higher in flavoring and grinding areas of the facility. All four of the personal full-shift samples collected in the production area exceeded the NIOSH recommended exposure limit for diacetyl of 5 parts per billion, with a maximum measured concentration of 20.7 parts per billion. One of the four personal full-shift samples collected in the production area exceeded the NIOSH recommended exposure limit for 2,3-pentanedione of 9.3 parts per billion, with a maximum measured concentration of 24.0 parts per billion. We identified some work tasks that resulted in relatively higher air concentrations of diacetyl than other tasks. Specifically, flavoring roasted coffee beans by hand, grinding flavored and unflavored roasted coffee beans, and weighing and packaging roasted coffee were associated with higher diacetyl levels. Some employees reported eye, nose, or sinus symptoms or wheezing or whistling in the chest that was aggravated at work. We also observed tasks that presented risk factors for repetitive strain injuries and burns, specifically the flavoring, grinding, and packaging processes. We recommend installing local exhaust ventilation, implementing administrative controls such as modification of work practices, and training employees about workplace hazards. We also recommend a medical monitoring program to identify any employees who might be developing work-related lung disease (e.g., asthma, obliterative bronchiolitis) and to help management prioritize interventions to prevent occupational lung disease. (Click to show less)
(Click to open report)

(2017) Health hazard evaluation report: evaluation of chemical exposures at a vape shop. (Click to open report)
The Health Hazard Evaluation Program received a request from the owner of a vape shop who was concerned about employees' potential exposure to vaping chemicals in the workplace. We collected air samples in the vape shop for flavoring chemicals (diacetyl, 2,3-pentanedione, 2,3-hexanedione, acetaldehyde, and acetoin), nicotine, formaldehyde, and propylene glycol. We took wipe samples for nicotine and metals on commonly touched surfaces. We found that employees vaped in the shop throughout the day,... (Click to show more) The Health Hazard Evaluation Program received a request from the owner of a vape shop who was concerned about employees' potential exposure to vaping chemicals in the workplace. We collected air samples in the vape shop for flavoring chemicals (diacetyl, 2,3-pentanedione, 2,3-hexanedione, acetaldehyde, and acetoin), nicotine, formaldehyde, and propylene glycol. We took wipe samples for nicotine and metals on commonly touched surfaces. We found that employees vaped in the shop throughout the day, but very few customers vaped. None of the airborne concentrations of the specific flavoring chemicals we measured were above applicable occupational exposure limits although we detected low levels of two flavoring chemicals, diacetyl and 2,3-pentanedione, in the personal and area air samples. We detected the presence of metals, such as chromium, lead, copper, and nickel, on surfaces in the shop. We found detectable levels of nicotine on the outside surface of a nicotine transfer bottle. This may have occurred when liquid was poured from one bottle to another without use of a funnel. We did not find nicotine on other surfaces that we sampled. We found that not all employees wore chemical protective gloves when handling liquids containing nicotine. The bottle of stock nicotine solution was stored in the same refrigerator used to store employees' food. We recommend that the employer implement a policy prohibiting vaping in the workplace with e-liquids that contain diacetyl and 2,3-pentanedione. We also recommended not storing chemicals in the same area where food is stored or eaten, training employees on proper chemical handling procedures, and inspecting and maintaining the shop's exhaust ventilation systems. (Click to show less)
(Click to open report)