Recognition and Control

of Respiratory Hazards in

the Flavoring IndustryTraining Developed by:

Photo by National Jewish Health used with written permission.

Disclaimers

This presentation was produced under grant number SH-22304-11-60-F-8 from the Occupational Safety and Health Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U.S. Department of Labor, nor does mention of trade names, commercial products, or organizations imply endorsement by the U.S. Government.

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Why are we here?

Provide information to workers:1. Signs and symptoms of potential flavor-related lung disease2. Ways to detect lung disease that may be related to flavoring

exposure3. Methods to reduce exposure to flavorings associated with

lung disease

http://www.osha.gov/SLTC/flavoringlung/index.html accessed 3/28/2012

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Outline

• Introduction to OSHA• Overview of flavoring exposures• Health effects of flavorings• Medical surveillance (testing) for

possible flavoring-related health effects

• Recognizing and controlling flavoring exposures

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Definitions• Part per million (ppm)

– Small unit of concentration– 1 ppm = 1 drop in 13 gallon gas tank

• Flavoring exposure– Inhalation of flavoring vapors or

particles• Bronchiolitis Obliterans Syndrome

(BOS)– An uncommon lung disease where

scars form in the small airways5

Introduction to OSHATraining Goals

• Understand the role of OSHA in occupational safety and health

• Describe employer responsibilities and employee rights provided by OSHA

• Understand specific OSHA and industry standards for handling flavorings

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What is OSHA?• Occupational Safety and Health

Administration• Government agency within the U.S.

Department of Labor• Responsible for worker safety and

health protection• Created in 1970 by the Occupational

Safety and Health (OSH) Act• OSH Act allows states to take

responsibility for implementing OSH Act providing their regulations are at least as stringent as Federal OSHA

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What does OSHA do?• Requires employers to implement

programs to reduce workplace safety and health hazards

• Investigates workplace fatalities or catastrophic accidents

• Enforces safety and health standards through workplace inspections by compliance officers

• Monitors job-related injuries and illnesses through required record-keeping

• Provides assistance, training, and other support programs to help employers and workers 8

What are employers’ responsibilities under OSHA?

Provide employment and a workplace that is:

1. In compliance with established OSHA standards.

2. Free from recognized hazards that are causing or are likely to cause death or serious physical harm to employees.

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What are employees’ rights under OSHA?

1. Get training from your employer as required by OSHA standards

2. Request information from your employer about OSHA standards, worker injuries/illnesses, and job hazards

3. Request action from your employer to correct hazards or violations of OSHA standards

4. File a complaint with OSHA if you believe there are violations of OSHA standards or serious hazards

• Must be submitted in writing, signed by a current employee or employee representative, and state the reason for the inspection request

• Forms and more information available at www.osha.gov

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What are employees’ rights under OSHA?

5. Be involved in OSHA’s inspection of your workplace

6. Find out results of an OSHA inspection7. Get involved in meetings or file a

formal appeal concerning your employer’s timely abatement of OSHA citations

8. File a discrimination complaint9. Request a research investigation by

the National Institute for Occupational Safety and Health (NIOSH)

10.Provide comments and testimony to OSHA during rulemaking on new standards 11

Are there specific OSHA standards that apply to my

workplace?• Recordkeeping• Housekeeping• Medical & First Aid• Walking/Work

Surfaces• Emergency Action• Noise• Hazardous materials

– Compressed gases– Flammable liquids

• Personal protective equipment

• Confined spaces

• Lockout/tagout• Fire protection• Powered industrial

trucks• Cranes• Machine guarding• Electrical• Respiratory

protection• Exposure to toxic

substances• Hazard

communicationThere may also be others that apply to your

workplace! 12

How are exposures regulated?

– Permissible Exposure Limit (PEL)• Maximum permitted 8-hour time-

weighted average concentration

– Short-Term Exposure Limit (STEL)• 15-minute time-weighted average

concentration not to be exceeded at any time during a workday

– Ceiling Limit• Maximum concentration to which an

employee may be exposed at any time 13

Limits the total amount of flavoring you can inhale in a

work day

OSHA sets legally enforceable limits

Makes sure that you don’t inhale

too much flavoring in a short time

Protects you from immediate irritation

Does OSHA have a standard for diacetyl?

• OSHA – No PEL or Federal OSHA Standard– Currently working on developing a standard

• CalOSHA (2010), No PEL– Exposure monitoring for airborne diacetyl – Regulated areas for all diacetyl processes– Controls to reduce exposures to lowest feasible

levels– Medical surveillance (every 6 months) for

workers– Respirators for workers

• At all times when working with diacetyl-containing powders

• When there are measurable diacetyl levels– 8-hour exposures are greater than 0.012 ppm– 15-minute exposures are greater than 0.035 ppm

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Are there other groups that recommend exposure levels for diacetyl and

substitutes?

• NIOSH=National Institute for Occupational Safety and Health

• ACGIH=American Conference of Governmental Industrial Hygienists

• TERA=Toxicology Excellence for Risk Assessment

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Agency or Organization

8-hour Limit(ppm)

15-min Limit(ppm)

NIOSH (2011, Draft) 0.005 0.025ACGIH (2012) 0.01 0.02TERA (2010) 0.2 N/ANIOSH (2011, Draft)

0.009 0.031

We don’t know which of these recommendations will be effective.

Best approach is to reduce exposures as low as possible using these numbers to measure progress.

Diacetyl

2,3-Pentanedione

Are there OSHA standards for other flavorings?

Chemical

OSHA PEL8-hour(ppm)

ACGIH TLV 8-hour/

STEL (ppm)

CalOSHA PEL8-hour/STEL

(ppm)Acetaldehyde 200 25 (c) 25 (c)Acetic Acid 10 10/15 10/15 & 40 (c)Formic Acid 5 5/10 5/10Furfural 5 2 2Phosphoric acid 0.25 0.25/0.75 0.25Propionic acid N/A 10 10Sulfur dioxide 5 N/A/0.25 2/5

> 2,000 individual flavorings and < 100 with exposure limits 16

Overview of Flavoring Exposures

Training Goals• Understand that some flavorings

may cause lung injury under some conditions

• Know where to find a listing of flavorings that may cause lung injury

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Why are exposures hard to predict in flavoring

manufacturing?• More than 2,000 flavorings– Some have irritant properties– Small number have exposure limits– Many with not enough information to

determine whether they are a respiratory health hazard

• Exposures to different forms– Pure flavorings– Concentrated liquid and powder

mixtures– Low concentration final products

• Multiple processes– Mixing, heating, packaging, etc.

• Batch processes– Volumes vary – Daily and seasonal variability

18Not much information on possible hazards from breathing flavorings.

Photo used by National Jewish Health with written permission.

Is there a list of flavorings that might be hazardous when inhaled?

• The Flavor and Extract Manufacturers Association (FEMA) has a list of “High Priority” flavorings

• “High Priority” flavorings may cause respiratory injury when:

• Exposure levels are high• Repeated exposures at lower

levels• Processed using heat• Processed without proper

exposure controlsImage by the Flavor and Extract Manufacturers AssociationUsed with written permission

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“High Priority” flavorings should be labeled to alert workers that they require careful handling.

What are the “High Priority” flavorings?

• Acetoin• Diacetyl• Diacetyl Trimer• 2,3-Heptanedione

• Methyl Mercaptan• Methyl Sulfide• 2,4-Pentadienal• 2-Pentenal• Phosphoric Acid• Propionaldehyde• Propionic Acid• Sulfur Dioxide• Triethylamine• Valeraldehyde

FEMA LISTED

HIGH PRIORITYMATERIAL

FOLLOW APPROPRIATE ENGINEERING AND PROCEDURAL CONTROLS TO MINIMIZE EXPOSURE

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Figure by National Jewish Health

Diacetyl & Substitutes

Other Flavorings• Acetaldehyde• Acetic Acid• Benzaldehyde• Butyric Acid• Ethyl Acrylate• Formic Acid• Furfural• Hydrogen Sulfide• Isobutyraldehyde• Isobutryic Acid

• 2,3-Hexanedione• 3,4-Hexanedione• 2,3-Pentanedione

These flavorings may cause respiratory injury

when not handled properly.

What about natural flavoring complexes?

• Capsaicin• Oils

– Balsam fir– Bitter almond– Garlic– Grapefruit– Lemon– Lime– Mustard– Onion– OrangePhoto by Scott Bauer available under public domain from Wikimedia Commons

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Natural flavoring complexes may also cause irritation and respiratory symptoms when not handled properly.

Health Effects and Medical Surveillance

Training Objectives• Learn about respiratory health

effects • Learn methods to detect possible

flavoring-related health effects• Understand the importance of

medical surveillance

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Definitions• Airways

– The tubes that carry air into and out of your lungs

• Airway Disease– Airways become narrowed.– Causes slowing of the flow of air into and out of your lungs

• Bronchiolitis Obliterans Syndrome (BOS)– Airway disease in small airways in the

lungs– Injury from a chemical or infection– Scars form, causing airways to narrow.

• Associated with exposure to diacetyl • Possibly diacetyl substitutes

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Normal Airway

Image by National Jewish Health

Narrow Airway

Image by National Jewish Health

PermanentScarring

Respiratory Health Effects• Irritation

– Eyes, nose, throat– Chest– Skin irritation (high exposure)

• Airway diseases–Bronchiolitis

Obliterans Syndrome (BOS)

–Asthma• Allergies

– Allergic reactions– Asthma

Air travels through the small airways to the air sacs and into the blood stream.

Diagram of a Normal Lung

Image by National Jewish Health

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• Cough– Dry cough– Cough with phlegm

• Wheeze• Chest tightness• Shortness of breath

Photo by National Jewish Health

There are many causes of breathing symptoms.

Photo by National Jewish Health

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Airway irritation and airway diseases cause breathing

symptoms.

A medical evaluation is needed to know the cause of the

symptoms.

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• Colds and other infections • Cigarette smoking• Airway Irritation• Asthma• Bronchiolitis Obliterans Syndrome (BOS)• Allergies• Other lung diseases

– Chronic obstructive pulmonary disease

Photo by National Jewish Health

It is important to find BOS early!This is the true story of one worker •29 years old with no lung problems. He never smoked.•He worked for 2 years as a flavor compounder.

– When he used a respirator, his beard prevented a good fit.

•He began to have breathing symptoms.– He was treated for bronchitis.

•His symptoms continued to worsen.•He had to stop working.•He saw a doctor who knew about flavorings and BOS.•He already had severe airway disease (BOS).•He was not able to work or do many other things again.

If his BOS had been diagnosed earlier, the ending to the story might have been different.

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Not all “High Priority” flavorings are irritating.

Flavorings can cause irritation and injury.

• Usually, there is only irritation– Burning in the throat, nose, and eyes– Burning in the chest, cough, and chest

tightening– Symptoms get better away from exposure

• Airway injury can occur– High levels of exposure– Very irritating flavorings

Figure by National Jewish Health

Photo by Cliff Hutson available under public domain from Wikimedia Commons

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Normal Airway

Some flavorings can trigger asthma “attacks”.

• During an asthma “attack”:– Airway muscles tighten.– Airways become inflamed and narrowed.– Symptoms may be mild or severe.

• Treatment with medications is often needed.• Airways return to normal.

Figures by National Jewish Health

Asthma

Airways inflamed and narrowed

Medications

Normal airway

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Muscletightening

Swelling

Mucus

Asthma “attacks” can be triggered in workers who already have

asthma.• Triggered by irritant flavorings

–Capsaicin–Some natural oils–Some “High Priority” Flavorings

•Acetic acid •Acetaldehyde (aldehydes)

• The higher the exposure, the higher the risk.

Workers with asthma should be extra careful to avoid breathing in irritating flavorings.

Photo by Cliff Hutson available under public domain from Wikimedia Commons

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Some natural flavorings can cause allergic reactions.

• Not common in this industry• Runny nose (rhinitis)• Asthma

– Allergic reactions to• Shellfish, fish, eggs, flour, some spices

• Rarely, a body-wide allergic reaction– Hives– Swelling of the mouth and throat– Chest tightness, shortness of breath– Allergic reactions to

• Shellfish, fish, some spices• Peanuts and other tree nuts

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Photo available under public domain from Wikimedia Commons

Photo by Bierfaß available under public domain from Wikimedia Commons

Bronchiolitis Obliterans Syndrome (BOS) is scarring in small airways.

• Diacetyl, possibly diacetyl substitutes• After injury, scars form. • Scars cause airways to narrow.

Normal airway Late BOS

Images by National Jewish Health

Early BOS

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EarlyScarring

Inflammation

Airwayinjury Permanent

Scarring

Diacetyl and diacetyl substitutes do not have good warning properties.

It is important to find BOS early!

• Early: Mild airway narrowing– Mild breathing symptoms– Removal from exposure can help prevent

worsening.• Late: Severe airway narrowing

– Severe breathing symptoms– Nothing makes BOS better -- medications do not

help.

Normal airway

Late BOS

Figures by National Jewish Health

Early BOS

EarlyScarring

Inflammation

Airwayinjury Permanent

Scarring

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Avoid breathing in diacetyl and substitutes.

• BOS has been found in workers exposed to butter flavorings.– Popcorn manufacturing workers – Flavor manufacturing workers – Diacetyl production workers

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Photo by NIOSH available under public domain

• These workers had exposure to high levels of diacetyl.• In animals, diacetyl causes airway injury and

scars. • Diacetyl substitutes may not be better.

It is important to keep exposures to diacetyl and diacetyl substitutes as low as possible.

It is important to find BOS early!

If you are exposed to diacetyl or diacetyl substitutes:

– Report unexplained breathing symptoms to Human Resources or Health and Safety and to your doctor.

– Participate in medical surveillance.

Photo by National Jewish Health

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Talk to your doctor about your symptoms and your work with

flavorings

Flavoring-Related Lung Disease (NIOSH)– Available on the NIOSH website

(www.cdc.gov/niosh)

NIOSH 2011

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Medical Surveillance:Questionnaires and Breathing

Tests• Breathing Test (Spirometry)

– How much air you can breathe in and out– How fast you can blow air out– Testing is recommended at

least every year.• Every 6 months (CalOSHA)

• Are the results normal?– Compared to other people who are your same

age, height, and gender• Are the results normal for you?

– Are the results similar to your past test results?

Photo by National Jewish Health

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Repeated breathing tests are needed.

25 years of age

FirstTest

1) Is the result normal? YES

Test After 5 Years

of Work 2) Is the result

normal for you?YESNO

Keep your test results.

Normal

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Special tests are needed to diagnose work-related lung

disease.• If your test results

are not normal for you– Repeat the

breathing test.

• If the test is still not normal for you, the doctor will do more testing to find out the cause.

Photo by National Jewish Health

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Photo by National Jewish Health

Protect Your Lungs!• Keep your exposure to all

“High Priority” flavorings as low as possible.

• Do not rely on smell or irritation to warn you about exposure.

• Report new or worsening breathing symptoms.

• Don’t smoke!Photo available under public domain from Wikimedia Commons

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FEMA LISTED

HIGH PRIORITYMATERIAL

FOLLOW APPROPRIATE ENGINEERING AND PROCEDURAL CONTROLS TO MINIMIZE EXPOSURE

Image by National Jewish Health

Flavoring Exposure Recognition and

Control

Training Goals• Recognize flavorings and work processes where you might be exposed

• Understand the methods used to measure flavoring exposure

• Understand the proper use of control methods to reduce exposure to flavorings 41

How do I know if it is hazardous?

• Labeling of individual flavorings and compounded flavors

• Handling precautions on batch sheets– Health effects– Proper handling– Necessary

precautions• MSDS or SDS

readily availableFigure by National Jewish Health

Figures by Torsten Henning available under public domain from Wikimedia Commons

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Workers need to be alerted when working with “High Priority”

flavorings

WARNING – This flavor may pose an inhalation hazard if improperly handled. Please contact your workplace safety officer before opening and handling, and read the MSDS. Handling of this flavor that results in inhalation of fumes, especially if the flavor is heated, may cause severe adverse health effects.

Hazard Communication

What does exposure to flavorings look like?

Possible exposure anywhere “High Priority” flavorings are:

– Sampled– Weighed– Mixed– Poured– Transferred– Packaged

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Flavoring particles and vapors quickly move into a worker’s

breathing zone unless removed at the source.

How are exposures measured?• Personal air samples

– Estimate the amount of flavoring a worker might inhale into their lungs

– Workers wear sampling pump for entire work shift

• Different air sampling collectors for different flavorings

• Currently, no method for diacetyl powders

Sample collector in “breathing zone”

Worker “wears” sampling pump

Particle/Dust Collectors

Gas/Vapor Collectors

Photos by National Jewish Health

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Exposures can change depending on the tasks performed and the products

produced.

What does the level of exposure depend on?

• Amount of “High Priority” flavoring used

• Amount of time exposed• How well the vessels are sealed• Ventilation• Liquids

– Pouring distance– Use of funnels

• Powders – Hand scooping– Sifting– Packaging

Photo used by National Jewish Health with written permission.

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Short-term high exposures AND longer term lower exposures are both important.

Photo used by National Jewish Health with written permission.

• 0.91 ppm (n=63)

• 0.99 ppm (n=2)• 0.46 ppm (n=3)• 0.099 ppm

(n=21)• 0.030 ppm

(n=2)

Liquid CompoundingAverage

8-Hour Exposures

Photo used by National Jewish Health with written permission.

What levels of diacetyl havebeen measured in

flavorings?

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NJHOSHANIOS

H

8-Hour Exposure Limits• NIOSH: 0.005 ppm• ACGIH: 0.01 ppm• TERA: 0.2 ppm

Many flavor worker tasks have short-term diacetyl exposures over 2 ppm.Little information available on exposures to other “High Priority” flavorings.

QA LaboratoriesAverage

8-Hour Exposures• 0.004 ppm

(n=7)• 0.07 ppm (n=3)• 0.009 ppm

(n=3)Photo used by National Jewish Health with written permission.

Powder ProcessingAverage

8-Hour Exposures

• 0.71 ppm (n=31)

• 0.05 ppm (n=10)

• 0.34 ppm (n=3)• 0.22 ppm (n=9)

Photo used by National Jewish Health with written permission.

2-Hour Exposures

Spray Drying8-Hour Exposure

• 1.5 ppm (n=1)

• 2.6 ppm (n=6)

How are flavoring exposures controlled?

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Elimination & Substitution

Engineering ControlsWork

Practice Controls

PPE

High Exposure

Acceptable Exposure

Personal protective equipment: respirators, gloves, goggles, and

protective clothing

Changes in procedures or worker behavior to reduce

exposure

Changes that capture or enclose the source

of exposure

Changes in raw materials or flavoringsDecreasing

Effectiveness Increasing dependence on worker behavior

Does substitution work?

Larger molecules– Pros:

• Lower exposures• Less evaporation at room

temperature – Cons:

• Chemically similar to diacetyl• May have similar health effects

Figures by National Jewish Health48

Diacetyl Substitutes

Until there is more information available, diacetyl and diacetyl substitutes should be controlled the same.

O

O

Diacetyl

2,3-Pentanedione

O

O2,3-Hexanedione

O

O 2,3-Heptanedione

O

O

What is the best solution?

• Closed lines for all ingredients and finished products

• Closed vessel cleaning system

• Containment verified with air sampling

• Maintenance workers may still be exposed.

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Completely Enclosed Processes

Photo by National Jewish Health used with written permission.

May not be a realistic solution due to cost and production variability.

What is the next best solution?

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Local Exhaust

Ventilation

Process Isolation

Work Practice Controls

Combination of controls used to

reduce exposures to acceptable levels

What is process isolation?• Designated area or

room for work with “High Priority” flavorings

• Separate ventilation system from offices or other production areas

• Lidded tanks and vessels

• Flavorings stored in sealed containers

• Volatile “High Priority” flavorings kept in cold storage

Photo by National Jewish Health used with written permission.

51Reduces exposure levels and the number of exposed

workers

What is local exhaust ventilation?

• Suction to remove flavoring prior to worker exposure

• Effective if properly designed and used

• Requires worker training

52Most important control to reduce exposure to

flavorings!

Photo used by National Jewish Health with written permission.

Does ventilation reduce exposure?

53

Photo by NIOSH available under public domain.

Figure by NIOSH available under public domain.

Ventilation reduces exposures when properly

designed and used correctly!

How do I use ventilation correctly?

• Capture depends on distance from the capturing hood• Capture greatly decreases at a distance of two duct

diameters• Cross drafts reduce the capture of flavorings

Contains public sector information published by the Health and Safety Executive and licensed under the Open Government Licence v1.0

54Work as closely as possible to the ventilation hood!

What can I do to reduce exposure?

• Keep temperatures of liquids as low as possible.

• Replace lids immediately after adding flavorings.

• Pour slowly and use funnels.• Add “High Priority”

flavorings last.• Avoid pouring from 55 gallon

drums.• Avoid hand scooping

powders.• Make sure other workers in

your area know when you are using “High Priority” flavorings.

Photo used by National Jewish Health with written permission

55Use engineering controls properly all of the

time!

What if I am a laboratory worker?

• Use the lab hood for handling “High Priority” flavorings.

• Keep containers closed as much as possible.

• Avoid odor evaluations of high concentration or neat “High Priority” flavorings.

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Photo by New-Tech™ used with written permission.

Laboratory workers can have high exposures!

What about cleaning?• Use HEPA vacuum for

cleaning powder spills.• Use cold water to pre-

rinse mixing vessels prior to cleaning with hot water.

• Keep work areas where flavorings are handled clean.

57Photos used by National Jewish Health with written permission

Clean-up spills immediately to prevent unnecessary exposure.

When should I use a respirator?• When exposures cannot be

controlled in other ways• When employees complain

of irritation regardless of exposure level

• When using diacetyl and diacetyl substitutes– Always with diacetyl or

diacetyl substitute powder exposures

– Always when exposures have not been measured

– To keep exposures as low as possible

Photo by National Jewish Health

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Respirators are a last choice for controlling exposures, but may be an important part of the

solution in the flavoring industry.

How do I know my respirator is working?• Yearly training

• Must fit properly– Fit tested annually– No facial hair

• Must have the right cartridges– Organic vapor for liquid

exposures– Organic vapor + P100 for

powder exposures• Cartridges don’t last

forever– Need change-out schedule– If you can smell it, you

should change it.59

Photo by Jeanne Mozier available under public domain.

Respirators are only effective when used properly!

Photo by Stuart Butterfield available under CCA-2.0.

Human Hair

Glass Fiber

Asbestos Fiber

Fume Particles

Figure by National Jewish Health

What about skin and eye protection?

• Use gloves and aprons appropriate for flavoring exposure– Chemical resistant gloves

and aprons are made from:• Nitrile• Butyl rubber• Teflon™• Tychem ™

• Tight-fitting eye goggles not safety glasses

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Photo used by National Jewish Health with written permission

PPE is only effective when used properly!

How does it all fit together?

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Elimination & SubstitutionEngineering

ControlsWork Practice

ControlsPPE

Acceptable Exposure

Use of “High Priority” FlavorsExposure Recognition

Exposure MonitoringHigh Exposure

Temporary controls when

not enough exposure

measurements

No controls needed

Medical surveillance:Helps protect workers when little is known

about exposure

Questions?

Photo by National Jewish Health

This material was produced under grant number SH-22304-11-60-F-8 from the Occupational Safety and Health Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U.S. Department of Labor, nor does mention of trade names, commercial products, or organizations imply endorsement by the U. S. Government.

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