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Common Hazards in the
Food Manufacturing Sector
Photo credit: Thong Siek Food Industry
This set of slides may be used to complement your company’s in-house
Workplace Safety & Health (WSH) training for workers.
Common hazards highlighted can be contextualised to meet your
workplace needs. Case studies with recommendations serve as good
learning points. Safe work practices can help to prevent workplace
accidents and injuries.
All rights reserved, May 2019. The information provided in this training slides is accurate at time of publication. All
examples shared in this training slides are meant for learning purposes only. The learning points for each example are not
exhaustive and should not be taken to encapsulate all the responsibilities and obligations of the user of this training slides
under the law. The Workplace Safety and Health Council does not accept any liability or responsibility for any modifications
made to this set of training slides.
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Contents
1.
2.
3.
4.
5.
6.
Workplace Safety and Health (WSH) Policy
WSH Rules and Regulations
Risk Assessment
Communication of WSH Hazards
Common Hazards
Other Hazards
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1. Workplace Safety & Health (WSH) Policy
The objective of the WSH Policy is to show the management’s
commitment in ensuring a safe and healthy environment for everyone,
and this includes all employees, visitors, interns, vendors, contractors,
etc at the workplace.
Example of a WSH Policy Statement (Source: www.wshc.sg)
The WSH Council is committed to ensuring the safety and health of its
members and employees. We believe that all WSH incidents are
preventable. We will continually work towards building a strong WSH
culture and achieving zero work injuries. We also recognise that every
staff has a part to play in making the WSH Council a safe and healthy
workplace for everyone.
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Workplace Safety & Health (WSH) Policy
Insert your company’s
WSH Policy here.
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2. WSH Rules and Regulations
1.
2.
3.
4.
5.
Follow all safe work procedures (SWP) and instructions.
Report all unsafe work conditions and unsafe work practices to your
supervisor or WSH Officer.
… Please insert your organisation specific WSH rules and regulations.here.
This can include work flow processes, equipment operation and
… maintenance, emergency response etc.
Emphasise on the Risk Management programme to prevent injury and ill
health to employees.
… Includes Workplace Health programmes/initiatives for staff well-being,
where applicable too.
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3. Risk Assessment
• We can do our part to ensure a safe workplace for everyone.
• Simple risk assessment using Look. Think. Do.
• Look out for danger or potential risk(s).
• Think of how to protect yourself and fellow co-workers.
• Do your work safely.
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Risk Assessment
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3.1 Addressing Risks
Step 1
Identify the Hazards.
- Types (e.g., machinery hazards) and the associated risks.
Step 2
Evaluate the Risks.
- Is risk level acceptable? Low, medium and high.
Step 3
Implement Risk Control Measures.
- Take action to eliminate or reduce risks.
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3.2 Risk Control Measures
•
Reduce the need for direct interaction
with machine through the use of
technology or automation.
•
Replace with a safer machine or
manufacturing process.
•
Use of machine guards and interlock
system.
•
Use of safe work procedures and
lock-out tag-out.
•
Use of hardhat, safety goggles, safety
gloves, hearing protectors and
safety footwear etc.
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4. Communication of WSH Hazards
• Supervisor to highlight site-specific/equipment-specific WSH hazards
(e.g., during toolbox meetings).
• Workers are encouraged to inform Supervisor of any unsafe situation
encountered at their worksite.
• Near-miss incidents should be reported so that actions can be taken
to prevent accidents.
Ref: WSH Guide to Effective Toolbox meeting. Click guide.
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5. Common Hazards
5.1
5.2
5.3
5.4
5.5
5.6
Slips, trips and falls
Caught in machine
Struck by falling object
Contact with hot objects/surfaces
Musculoskeletal Disorder
Fires and explosions
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5.1
Slips, Trips and Falls
Slips, Trips and Falls are the most common
causes of workplace injuries and can result in
sprains, fractures, severe head injuries and even
fatalities in some cases.
Insert picture of
obstructed
walkway or spills
Do:
• Practise good housekeeping.
• Wear anti-slip shoes.
• Report uneven/damaged flooring.
• Put up warning signs:
 slippery floors
 uneven floor
 damaged floors
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Slips, Trips and Falls
Some control measures include:
• Cable trench to cover cables
• Increase floor resistance e.g.,
placing anti-slip tape/mat/tiles
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Cable trench
covering cables
Anti-slip mat
Warning strips
on steps
Anti-slip tile
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Slips, Trips and Falls
Case Study
•
A worker slipped, fell and hit her head on the floor
at a bread factory around 1.30 am.
•
The slippery floor was caused by condensation
outside the freezer. Worker was wearing her own
footwear and walking towards the freezer when
the accident happened.
•
The worker became unconscious and
subsequently passed away.
Recommendations
•
Practise good housekeeping by keeping the floor
dry.
•
Install signages to warn others of wet floor.
•
Wear safety footwear at all times and ensure that
it is in good condition by checking it regularly.
Ref: Case Studies for Food Manufacturing (link).
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5.2
Caught in machine
• Machines with moving parts, if not handled
properly, can cause severe injuries.
• Injuries may also occur when working with
unguarded machinery.
• Many machines pose mechanical hazards
which may lead to cuts entanglement,
crushing, etc.
• Use of machine guard is an effective
engineering risk control measure.
Mixer without guard
Interlock installed such that mixer
will shut off once the cover is lifted
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Caught in machine
Do:
• Allow only trained, competent and authorised
personnel to operate the machine.
• Install warning sign(s) to alert machine
operator the presence of hazard.
• Ensure machine guarding is in place before
operating the machine.
• Turn off the main power switch before
carrying out repair, maintenance and
inspection.
• Apply Lockout Tagout (LOTO ) procedure.
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Caught in machine
LOTO procedure
• Announce the shutdown
• Notify all affected workers that the machine is to be shut down.
• Shutdown the machine
• Proceed to shut down machine after ensuring that all moving parts have
come to complete stop.
• Ensure that there is no hazard caused to the workers during the shutting
down of the machine.
• Disconnect the energy source
• Ensure the hazardous energy to the machine is properly isolated using
circuit breakers, valves or isolating switches.
• Confirm stored energy (e.g., present in springs, electrical,
hydraulic and pneumatic systems) is dissipated before starting work.
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Caught in machine
LOTO procedure
• Apply lockout tagout
• Use a padlock to ensure hazardous energy cannot be restored
unexpectedly or accidentally.
• Affix a durable tag to provide identity of the person placing the lockout,
and to warn that a work activity on the machine is in progress.
• Verify the isolation and lockout
• Check isolation and lockout is in use and effective.
• Test the machine to confirm that it is unable to start by switching the
controls to ‘on’ position.
• Switch back to ‘off’ after the test.
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Caught in machine
Do not:
•
•
•
Work if you are unwell or on medication that can
affect your alertness at work.
Wear loose clothing or jewellery when operating
the machine.
Place your hands inside the machine while it
is in operation.
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Caught in machine
Case Study
Worker was collecting a sample of blended food
product from a mixing tank.
•
Mixing tank was still in operation when the worker
opened its cover to collect the sample.
•
Co-worker found the injured worker inside the mixing
tank and he was pronounced dead at the scene.
Recommendations
•
Install a safety interlock to power off the mixing tank
once its cover is opened.
•
Collect the sample from the missing tank only if the
mixer rotating mechanism has been de-energized.
•
Collect the sample from a safe location (e.g., from the
storage container of blended product) instead of
directly from the mixing tank.
•
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Cases in the news
Past cases where machine guarding could be used to prevent accidents:
1. Worker caught by mixer rotating arm while preparing bean paste.
URL: https://www.straitstimes.com/singapore/bakery-owner-died-when-he-was-caught-by-rotating-mixer-arm-and-pulled-inside
2. Worker’s arm caught in meat grinder in supermarket.
URL: https://www.straitstimes.com/singapore/giant-supermarket-worker-hurt-after-arm-caught-in-meat-grinder
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Caught in machine
All hand injuries are preventable!
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5.3
Struck by falling object
Struck by falling object (SBFO) can lead to head
or body injuries and even death. SBFO may
occur in warehouses and store rooms with rack
systems.
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5.3
Struck by falling object
Do:
•
Store loose, small or irregularly shaped items in
boxes/crates.
•
Secure items from falling off with bars or straps
across the shelf.
•
Store heavy items on lower shelves.
•
Use a step stool or ladder for access to foods
above head level in a store room.
•
Adhere to the safe working load of the storage
rack.
•
Inform Supervisor of unstable racks or
loose/corroded joints encountered daily during
periodic inspection.
•
Put a safety helmet in work areas where there is a
risk of falling object.
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Struck by falling object
Case Study
•
A worker was found dead after he was pinned
beneath the fruit crates in a warehouse.
•
He was standing next to a stacked column of
metal racks which collapsed on him.
•
The racks were used to store crates of fruits.
Recommendations
•
Use engineered racks to store heavy items.
•
Store heavier items on lower racks
•
Ensure no over-loading of items on the rack.
•
Conduct periodic inspection to look for defects
in the racks (e.g., corrosion, dents and loose
bolts and nuts).
Heavier items placed
on lower racks
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Struck by falling objects
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5.4
Contact with hot objects/surfaces
Contact with hot objects/surfaces may involve contact
with hot machines or processing equipment (e.g.,
steamer, oven), hot medium (e.g., deep frying oil) and
hot food intermediate/product. Serious injuries such as
burns or scalds can take place, and even resulting in
death.
Do:
•Ensure all hot surfaces are insulated..
•Check for presence for warning signage(s) on hot
surfaces including gauges and sampling points where
insulation is not present..
•Wear appropriate PPEs ( e.g. gloves) when there is a
need to work with hot equipment.
Hot surface where insulation not present
Photo credit: Thong Siek Food Industry
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Contact with hot objects/surfaces
Case Study
A worker closed the door of an oven after
placing meat into the oven for roasting.
After 30 mins, he opened the oven door
and turned the gas knob to release gas to
the stove. He then lighted up the gas stove.
Fire suddenly gushed out from the oven
and injured the worker.
Fig 1: Gas stove
inside oven
Fig 2: Releasing knob for gas
Fig 3: Gas lighter
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Contact with hot objects/surfaces
Recommendations
•
Train the worker on the safe use of the stove and oven.
•
Provide a physical barrier or better position the gas knob so as to
avoid the possibility of accidental contact with the gas knob.
•
Carry out periodic inspection of the oven, gas knob and piping as part
of preventive maintenance regime.
•
Ensure there is adequate ventilation provided at the workplace.
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5.5
Musculoskeletal Disorder (MSD)
MSD refers to body disorders involving muscles, tendons
and nerves. Symptoms of MSD include pain, cramp,
swelling, numbness and tingling sensation. Examples of
MSD include trigger finger, carpal tunnel syndrome, pain
(neck, shoulder, lower back).
Do:
•Bend your knees and keep your back straight when
lifting an item.
•Seek help or use a trolley when moving heavy items.
•Use hand tools which are ergonomically designed (e.g.,
soft grip handle) to minimize excessive exertion.
•Inform your Supervisor if you experience bodily
discomfort (e.g., aches, cramps) which could be
symptoms of ergonomic problems.
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Musculoskeletal Disorder (MSD)
Do not:
•
•
•
•
•
Engage in prolonged repetitive activities
without taking breaks.
Adopt awkward posture.
Adhere to static posture throughout
work.
Bend down when carrying a heavy item.
Subject yourself to prolonged vibrations.
Awkward posture of overstretching
Incorrect lifting of
heavy objects
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Musculoskeletal Disorder
Case Study
•
•
Worker is required to manually transfer 4 bags of
dairy product every day. Each bag weighs 25kg.
Worker experiences severe strain on back, arms and
legs, resulting in high absenteeism from work.
Recommendations
•
Eliminate the need for manual lifting where possible.
•
Use a mechanical aid to reduce the strain posed on
the worker.
•
Seek help from co-worker or transfer smaller
quantities (e.g., 10kg) per trip.
Worker lifting bags of
dairy product
Worker using mechanical
aid for the lifting
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5.6
Fires and explosions
Fires can occur in the presence of flammable materials,
oxygen and an ignition source. Explosion can happen when
the equipment or piping are over-pressurised. Fires and
explosions can also occur when dealing with finely divided
materials (e.g., flour, icing sugar).
Insert pictures
of flammable
materials
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Fires and explosions
Do:
•
Keep area work free of ignition source or flammable materials wherever
possible.
•
Ensure the workplace is well-ventilated when handling finely divided materials.
•
Periodically maintain the local exhaust ventilation system (e.g., canopy hood
with associated ducting used for deep frying to ensure no accumulation of
flammable materials (See recent fire at local hotel here).
•
Ensure proper electrical bonding/grounding when transferring materials from
one tank/ container to another.
•
Ensure fire fighting equipment (e.g., extinguishers,hose reels), alarms and
detectors are checked and tested periodically.
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Fires and explosions
Case study: Dust Explosion involving Flour
• A worker was cutting the support of an old conveyor pipe system with a cutting
torch when flour poured out from the bottom opening of the silo.
•
Flash fire and dust explosion occurred when the flour came into contact with air.
•
Worker suffered burns on arms, face and other parts of body.
Recommendations
•Establish
a permit-to-work system for hot work activity so that the work area
can be assessed to be safe. In this case, the silo must be checked to be fully
drained before work commencement.
•Ensure work area is well-ventilated when handling flammable dust.
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6. Other hazards
6.1
6.2
6.3
6.4
6.5
6.6
Cut by object
Fall from height
Exposure to electrical current
Noise-induced deafness
Fatigue
Exposure to chemicals
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6.1
Cut by object
When preparing raw food for processing, hand
injuries may occur if working with sharp tools (e.g.,
knives) or machines (e.g., band saw).
Do:
•Use designated tool and ensure that it is sharp
before use.
•Work on flat surfaces to ensure stability when
cutting.
•Wear cut-resistant gloves when working with a
sharp tool.
•Segregate sharp tools from other tools.
•Return tools to designated place after use.
Use of sharp tools
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Cut by object
Do:
•
Wrap all waste containing sharp objects before
disposing.
•
Use push plate when cutting meat with a band
saw.
Use of push plate
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6.2
Fall from heights
Fall from height accidents in the food manufacturing
sector often involve the improper use of ladders.
Do:
•Use a ladder of the correct height for the job.
•Maintain 3 points of contact with the ladder
at all times while ascending or descending.
•Use anti-slip footwear.
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Fall from heights
Do not:
•
•
•
Carry loose items in your hands when using
a ladder.
Use the ladder on uneven ground.
Use the ladder if there is visible defect
(e.g., missing step, leg broken or bent).
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6.3
Exposed to electric current
There is a risk of electrocution when working
with electrical equipment. Some pointers to note
include:
Do:
•Switch off electrical equipment when not
in use.
•Isolate and replace damaged equipment.
•Report any damaged wiring found.
•Keep electrical equipment away from moisture
or steam.
Unsafe act to use re-joined
wires
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Exposed to electrical current
Do not:
•
•
•
Overload an electrical point.
Use damaged electrical equipment.
Repair damaged equipment if not qualified to
do so.
Overloaded electrical point
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6.4
Noise-induced deafness
Frequent and long term exposure to loud sounds
during work can cause noise induced deafness
(hearing loss).
Do:
•Wear ear plugs/muffs properly.
•Practise job rotation for work in noisy areas.
•Maintain your hearing protectors.
•Take rest breaks in quiet place.
Do not:
•Work in a noisy environment without hearing
protection.
•Use hearing protectors that are damaged or in poor
condition.
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Noise-induced deafness
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6.5
Fatigue
Fatigue is a state of tiredness leading to reduced mental and/or physical
performance that can endanger workplace safety. It can decrease a person’s
alertness and compromise a worker’s motor skills, reflex ability, judgement and
decision-making while at work.
Do:
•Ensure sufficient sleep before reporting for work.
•Take rest breaks after working for long hours or carrying our strenuous work.
•Ensure workplace is brightly lit and well-ventilated.
•Report to your supervisor if you are severely fatigued.
Do not:
•Consume excessive alcohol or over-eat before work.
•Continuously skip meals due to work commitments.
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6.6
Exposure to chemicals
Workers who are in regular contact with chemicals may experience skin
sensitisation and/or respiratory problems.
Do:
•Read the label on the chemical container to understand the nature of its contents
and how it can be handled safely.
•Check that the chemical container is in good condition.
•Close containers tightly and return to designated place after use.
•Ensure there is proper ventilation in the work area when using chemicals.
•Use the appropriate PPE (e,g, face shield, gloves apron) to protect against
chemical contact.
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Exposure to chemicals
Do not:
•Use chemicals without knowing its nature.
•Store incompatible chemicals together.
•Try to contain a chemical spill unless equipped with a proper spill kit.
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END
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