2. HAZARDOUS SUBSTANCES IN BAKERIES
The aim of this presentation is to provide information for inspectors on hazardous substances present in Bakeries;
Hazardous substances involved & their effects on employee health
Requirements of the Risk Assessment
Options for controlling exposure
Safety Risks from Bakery Dust

3. HAZARDOUS SUBSTANCES IN BAKERIES
Many substances found in bakeries are hazardous to the health of the workers.
The main health risks described for this sector are;
Respiratory Illness - including occupational asthma
Occupational Dermatitis

4. HAZARDOUS SUBSTANCES IN BAKERIES
Respiratory Illness / Occupational Asthma
Many substances in the workplace can cause Occupational Asthma (OA).
Most common triggers for OA are wood dust, grain dust, fungi, or other chemicals (grain dust 2nd highest cause of OA after isocyanates).
Actual rate of occurrence of OA is unknown, it is suspected to cause % of all asthma cases in industrialised nations
Bakers / Millers / Grain Handlers are all identified high risk groups

5. HAZARDOUS SUBSTANCES IN BAKERIES
Respiratory Illness / Occupational Asthma
1st literature reference to asthma in Bakers from 1700s
Evidence of reduced trend for OA frequency overall but flour as causative agent remains static (THOR )
Bakers and pastry makers were the most frequently affected worker group reported to the SWORD*
Flour is most important causative agent of OA in France / Finland
Work related asthmatic symptoms are usually preceded by rhinitis and conjunctivitis
*Surveillance of Work-related Occupational Respiratory Diseases (SWORD) program with annual incidence of 19 per million of working population in 1989–91 and 38 per million of working population in 1992–97 for the UK as a whole.
THOR – The Health & Occupational Reporting network – flour / grain exposure responsible for ~ 15% of OA

6. HAZARDOUS SUBSTANCES IN BAKERIES
Occupational Dermatitis
Skin disorder caused by coming into contact with substances in the workplace
Skin becomes red, itchy and can be blistered
2 forms; Irritant Contact Dermatitis (80%)&
Allergic Contact Dermatitis (20%)
ICD occurs only on parts of body in direct contact
ACD depends on substance, nature of contact, person exposed
Once sensitised, likely to remain so for life
Skin Sensitisers – Flour, latex, chromates, nickel
Is substance a skin sensitiser?
Frequency / duration of contact
Vulnerability of Host

7. HAZARDOUS SUBSTANCES IN BAKERIES
Occupational Dermatitis
ICD & ACD can occur simultaneously (exposure to irritants and sensitisers)
Substances which are skin irritants or sensitisers have Xi on the packaging
CPL CLP
Corrosive substances can also cause burns
This is the symbol for an irritant (skin/eye) or a skin or respiratory Sensitiser (old CPL)
New CLP
This is the pictogram for skin irritation and serious eye irritation and for skin sensitization
This pictogram is used for respiratory sensitization

8. HAZARDOUS SUBSTANCES IN BAKERIES
What should be in the Hazardous Substance Risk Assessment?
Establish which hazardous substances are present
Identify who can be affected, how and likelihood of harm
Identify measures needed to eliminate / control or reduce exposure
Record findings of assessment, required controls and actions taken to implement
Review and re-assess
This general approach can apply to all safety and health hazards in the workplace
1. Literature review / SDS / Labels – No SDS required for Flour as it is exempt from this requirement under REACH due to the fact that it falls under Reg (EC) No 178/2002

9. HAZARDOUS SUBSTANCES IN BAKERIES
What are main hazardous substances in the Bakery?
- Flour / bakery dusts used in manufacturing process;
Liquid ingredients used in manufacturing process;
Cleaning agents – hygiene requirements of industry
Skin contact through wet work / ingredient handling / equipment maintenance & cleaning

10. HAZARDOUS SUBSTANCES IN BAKERIES
How may Workers be exposed?
- Breathing in flour / bakery dusts, process /cleaning vapours
Contact with the skin – solid and liquid ingredients, pastes
Contact with the eyes – dusts, liquid splashes
Can apply to any worker involved in production / maintenance / cleaning operations
Irritant gases from production processes or cleaning agents
Skin contact through wet work / ingredient handling / equipment maintenance & cleaning

11. HAZARDOUS SUBSTANCES IN BAKERIES
Flour Dusts (from cereal and non-cereal grains)
Most common raw material used in process
It is an occupational hazard present throughout most of the production process stages
Equipment cleaning & maintenance
can lead to significant exposure
potential

12. HAZARDOUS SUBSTANCES IN BAKERIES
FLOUR / BAKERY DUST
Effects on the safety of workers
- Risks of fire and explosion
Effects on the health of workers
- eye and skin irritation
- dermatitis
- respiratory system effects (including asthma)

13. HAZARDOUS SUBSTANCES IN BAKERIES
FLOUR / BAKERY DUST
Routes of exposure
- inhalation (most relevant)
By breathing in flour dust from working environment. Flour dust is listed as respiratory sensitiser – can lead to allergic response - asthma
- eye or skin contact
Through contact with flour dust during material handling / cleaning operations. Can also act as skin sensitiser.

14. HAZARDOUS SUBSTANCES IN BAKERIES
FLOUR / BAKERY DUST
Signs and symptoms of exposure
Acute exposure: can result in irritation of the eyes, nasal passage and skin
Chronic exposure: can result in dermatitis reactions both irritant and allergic, and also asthma as flour dust is a listed respiratory sensitiser
Example of conjunctivitis of the eye / irritation of the nasal passages / classic dermatitis on hands

15. HAZARDOUS CHEMICAL AGENTS
FLOUR DUST
EXPOSURE LIMITS
European legislation
EU Commission SCOEL – does not recommend an
iOELV for Flour Dust as none can be identified to protect all workers.
- SCOEL concluded that exposures ≤ 1 mg/m3 of inhalable flour dust would protect the majority
- However concentrations < 1 mg/m3 may trigger symptoms in already sensitised workers
Note: Measured or calculated in relation to a reference period of eight hours.
Other references
Each European country may have established legal or normative OELVs, some based on American Conference of Governmental Industrial Hygienists (ACGIH). These range from 1 – 10 mg/m3 depending on MS.
(SCOEL)Scientific Committee on Occupational Exposure Limits
iOLEV – indicative Occupational Exposure Limit Value
As a general rule, SCOEL committee does not recommend health-based occupational exposure limits – OELs - for sensitizers as no threshold can be identified. However, in view of the large number of workers exposed and the relatively large data base, SCOEL recognises that exposures ≤ 1 mg/m3 of inhalable four dust would protect the majority of exposed workers from the on-set of disease and that the envisaged symptoms would be mild. However concentrations < 1 mg/m3 may trigger symptoms in already sensitised workers. As an OEL that protects all workers cannot be identified, health surveillance systems should be routinely applied to bakery and mill environments”

16. HAZARDOUS SUBSTANCES IN BAKERIES
Safety Information on Flour / Bakery Dusts
Not required to have SDS supplied under REACH
Under Article 2(6) of REACH the provisions of Title IV(dealing with supply chain) does not apply to ‘food of feedingstuffs in accordance with Regulation (EC) No. 178/2002’
Regulation (EC) No. 178/2002 applies to all stages of production, processing and distribution
Food (or foodstuff) defined as ‘any substance or product, whether processed, partially processed or unprocessed, intended to be ingested by humans’
Not required to have hazard label under Article 1(5) of CLP
(same as above)
Art 1(5) of CLP: CLP Reg shall not apply to subs and mix in the following forms which are in the finished
state, intended for the final user: (e)) food or feedingstuffs in accordance with Regulation (EC) No 178/2002

17. HAZARDOUS SUBSTANCES IN BAKERIES
Other Respiratory Hazards in Bakery Environment
Non-cereal flours: buckwheat, soybean flour
Enzymes: amylase, cellulase, xylanase, proteases, glucose oxidase
Nuts & seeds : almonds, hazelnuts, sesame seeds
Food colourings ; carmine red
Powdered ingredients; spices, egg powder, milk powder
Moulds: Alternaria, Aspergillus
Heat, SOx, NOx and other irritant gases
Most of the allergens of cereal grains involved in asthma and rhinitis belong to the albumins and globulins protein fraction of the grain. They are mainly enzymes, stress or defense proteins

18. HAZARDOUS SUBSTANCES IN BAKERIES Controls for Flour / Bakery Dust (1)
What is a Control Measure?
A measure taken to reduce exposure to a hazardous substance. Can include; provision of safe system of work, training & supervision, cleaning of workplace, plant, equipment, provision of engineering controls and PPE.
Little or no evidence of any level of control present at this table
Focus should be on minimising uncontrolled release at all times

19. HAZARDOUS SUBSTANCES IN BAKERIES
10 Top tips to control exposure to flour
( courtesy of Health & Safety Executive, UK)
Handle flour/powdered products carefully. Minimise the use of dusting flour. Dropping flour from a height or throwing with force will cause dust to be thrown up.
Use dredgers or sprinklers to spread dusting flour rather than hand throwing
Avoid spillages of flour where possible and where spillages do occur clean up immediately.
Take care to avoid raising dust while loading ingredients into mixers.
Start up mixers on slow speed until wet and dry ingredients are combined.

20. HAZARDOUS SUBSTANCES IN BAKERIES
10 Top tips to control exposure to flour
( courtesy of Health & Safety Executive, UK)
Avoid damage to ingredients bags.
Minimise the creation of airborne dust when folding and disposing of empty bags. One effective method is to roll the bag up from the bottom while tipping avoiding the need to flatten or fold empty bags.
Avoid the use of compressed airlines for cleaning.
Do not use brushes to dry-sweep. Use high efficiency industrial vacuums fitted with 2 filters (including a HEPA filter) for general cleaning
Wear a suitable respirator for any essential short-term tasks

21. HAZARDOUS SUBSTANCES IN BAKERIES Controls for Flour / Bakery Dust (2)
Control measures should be appropriate, consistent with the RA and applied in accordance with the Principles of Prevention. Should not increase overall risk
Controls chosen should be agreed through consultation with workforce and appropriate information and instruction given on proper use
Where dust extraction is fitted, it should be checked to see that it is working every day, checked for damage every week and thoroughly inspected and tested at least every 14 months. 
Where tight-fitting RPE is worn, face-fit testing should have been done. The RPE should be suitable for the individual wearer.  RPE should only be used as a last line of protection to control exposure.
Elimination / Substitution / Workplace & process design / Engineering Controls / Collective Measures / PPE as last resort
Enclosures / LEV may reduce exposure to dust but could increase explosion risk (ATEX)
There are many variations and types of respiratory protective equipment on the market that offer different levels of protection. P2 / P3 masks in general offer protection against flour / bakery dust, however always check their suitability for the specific task undertaken.

22. HAZARDOUS SUBSTANCES IN BAKERIES
Cleaning Agents
Typical chemical cleaners used in bakeries
sodium hydroxide (used for cleaning hard surfaces and, in stronger
concentrations, for cleaning ovens);
bleach (a mixture of calcium hydroxide and chlorine);
other detergents and sanitisers.
Hazards associated
Irritants – typically to skin
where prolonged use during wet work
Corrosives – eyes / nose / skin
- require greater controls
Used for cleaning surfaces / floors / equipment
Labels are CPL currently – black on orange. New CLP for danger / warning symbol

23. HAZARDOUS SUBSTANCES IN BAKERIES Risks from Cleaning Agents
Typically irritant in the diluted form (1 in 10 dillution)
Corrosives act more harshly on skin and PPE necessary
Irritation occurs primarily to skin – particularly prolonged use when cleaning surfaces / equipment
Also risk of splashes to eyes / inhalation risk where used in enclosed / restricted places / equipment cleaning
Mixing of incompatible cleaning agents can liberate toxic gas
Mixing hydrochloric acid with any alkali based cleaning agent can liberate Chlorine gas

24. HAZARDOUS SUBSTANCES IN BAKERIES Controls for Cleaning Agents
Information Supply
must be appropriately labeled and Safety Data Sheet provided
Information on hazards, correct use, storage, PPE required
Storage
Segregated and safely stored
in lockable store
Use
Follow recommended concentrations / dilutions
Use suitable PPE for application in tight / restricted areas
Mixing of incompatible products can result in generation of toxic gases
Procedures for spills / waste disposal / health surveillance

25. HAZARDOUS SUBSTANCES IN BAKERIES
Health Surveillance
Required by CAD 98/24/EC where appropriate to nature of risk
Determine workers respiratory history pre-employment
Inform workers of respiratory / dermatological symptoms to look out for and the reporting mechanisms to be used
Referral to competent medical practitioner where relevant

26. HAZARDOUS SUBSTANCES IN BAKERIES
Safety Risks from Bakery Dusts
ATEX Regulations
ATEX Directive 1992/92 apply where flammable substances are stored /used
Applies to flammable liquids or flammable dusts used / generated in process
Flour is an flammable dust - when combined with air can result in an explosive atmosphere
Hazardous Area Classification should be conducted and work areas suitably zoned (20,21, 22) depending on nature of dust and likelihood of presence
Suitably ATEX rated equipment used in these zones & EPD prepared
Explosion Protection Document;
Technical or organizational measures so as to reduce or prevent the risk of explosions (as set out in Schedule 2) and measures used to mitigate the effects of an explosion.
The operation of early warning devices.
Training instruction and supervision given to workers who work in places where an explosive or flammable atmosphere may occur.
Operational procedures, maintenance, operation of permits to work, and co-ordination between employers.
Classified places (according to Schedule 1) where explosions may occur called hazardous zones and detail marking of areas as well as location.
Means of escape in the event of an explosion.
The properties of substances that present an explosion hazard.
Selection and use of suitable equipment for use in hazardous zones including certification and calibration documents.
Equipment used that is CE marked and in compliance with S.I. 83 OF 1998 (the ATEX product Regulations).
How often the EPD is reviewed and when is it due to be reviewed again.

27. HAZARDOUS SUBSTANCES IN BAKERIES
Safety Risks from Bakery Dusts
ATEX Regulations / Guidance on Vacuums
ATEX certified vacuum in hazardous area
(zones 20, 21 or 22)
Do not use domestic vacuum
Avoid use of wire reinforced hoses
Ensure wet materials are not picked up
Periodically, competent person to inspect
motor for dust and thoroughly clean
Change filters regularly

28. HAZARDOUS SUBSTANCES IN BAKERIES Recording Risk Assessment
Employer required to have suitably documented RA (required under CAD 98/24/EC)
Must be kept up to date (reviewed periodically)
Must address exposure potential from routine operations and also maintenance activities and non-routine operations
Reviewed if health surveillance results show it is required
Reviewed when OELVs are modified / exposure monitoring

29. HAZARDOUS SUBSTANCES IN BAKERIES
Baking industry – Risk Assessment Synopsis
Hazardous Substance
Exposure Occurrence
Health risk
Flour Dust
Fine dust derived from cereal & non-cereal grains
All stages of ingredient handling
Equipment cleaning / maintenance
Irritation of the eyes, respiratory tract & skin. As a respiratory sensitiser can cause asthma. Can cause irritant & allergic dermatitis
Other Bakery dusts
Enzymes , powdered ingredients, spices
Relevant stages of ingredient handling
Irritation of the eyes, respiratory tract & skin. Some are respiratory sensitisers - can cause asthma. Can cause irritant & allergic dermatitis
Cleaning Agents
Can be irritant / corrosive
Area / equipment cleaning / enclosed spaces
Irritation of the eyes, respiratory tract & skin. Irritant dermatitis

30. HAZARDOUS SUBSTANCES IN BAKERIES
Inspection Approach
Written Risk Assessment in Place
Evidence of Control measures in place where required under RA & suitably maintained & tested
Evidence of Workers informed of risks and trained in use of specified controls
Enforcement should be considered where;
- No controls in place / not defined in writing
- workers unaware of risks / use of controls
- Engineering control measures not maintained / routinely tested
- Where unsuitable PPE / RPE supplied

31. HAZARDOUS SUBSTANCES IN BAKERIES Thank You for your attention!!
Any Questions?