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FISHEP. 1st case of BO in 2004; 2nd in 2006Inspections, citations, and special ordersFISHEP initiated in early 2005Additional 28 companies identified as formulatorsNo popcorn makersConsultation or EnforcementDHS HESIS fact sheet. California. Food Flavoring. Couple thousand food
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1. Cal/OSHA and DHS “Flavor Industry Safety and Health Evaluation Program” (FISHEP) Kelly Howard, CIH
Senior Industrial Hygienist
Cal/OSHA Consultation Service
Division of Occupational Safety and Health
2. FISHEP 1st case of BO in 2004; 2nd in 2006
Inspections, citations, and special orders
FISHEP initiated in early 2005
Additional 28 companies identified as formulators
No popcorn makers
Consultation or Enforcement
DHS HESIS fact sheet
3. Food Flavoring Couple thousand food “production” companies
28 food “flavoring” companies
Flavors are used in everything
Diacetyl (2,3-butanedione) is a natural ingredient in beer, milk, bay oil, and other foods
4. What is a flavor? Break apart a strawberry and you get 400-500 ingredients
Reverse engineer it with 20-30 to make up the core “strawberry” flavor, such as:
5. Where does diacetyl come in? Butter
Diacetyl is what imparts butter flavor, along with other things, like acetoin
“creaminess”
Cream strawberry flavor
“Cheese cake”
Butterscotch
Chocolate
6. FISHEP Focus Onsite evaluations at all 28
IIPP
HazCom
Respirator Protection
Annual ingredient use
Employee ingredient exposure assessment
Ventilation
Medical screening
Follow-up
7. Formulation Process Hundreds of ingredients
Never the same thing two days in a row
High variability in tasks in any given day
Production vs. Batch process
8. Formulation Process 4 - 40 ingredients
20 - 180 minutes
<1 lb to 2000 lbs of diacetyl per year
A couple of ounces to 50 lbs of diacetyl in a batch
1-2 flavors per employee in a week, to 4-5 flavors per employee per day
Powder vs. Liquid product Batch ticket developed
Collect ingredients
Weight/mix
Transfer
Ethanol
PGA
Water
Package
9. Exposure Assessment Issues Adequate minimum quantification levels
Personal acute, chronic and area samples equally important
Limited direct-read capabilities
Big-time interferences
10. Issues High degree of unknown
“FEMA Priority” ingredients
>2000 ingredients
34 high priority
14 with PELs
Additional 2 with RELs
Additional 4 with WEELs
42% without any known safe exposure levels
Additive/synergistic effects?
11. Issues Use of markers to estimate overall exposures
Acetoin
Acetic acid
Benzaldehyde
Acetaldehyde Acetoin and Diacetyl very similar in molecular structure.
Acetoin has one less double bond, and one more hydrogen.
Acetoin and Diacetyl very similar in molecular structure.
Acetoin has one less double bond, and one more hydrogen.
12. Issues Respirators
Employees not clean shaven
Subjective fit-testing
Insufficient filter change schedules
Hazard communication
“been doing this for years”
Employee medical removal
What is “removal”?
Definitive vs. ambiguous measures
13. Typical Diacetyl Exposure Levels Direct reading peaks: 107-590 PPM
OBZ STEL
Liquids: <0.13-38.6 PPM
Powders: 0.91-3.8 PPM
OBZ Process Averages
Liquids: <0.017-8 PPM
Powders: 1.1-5 PPM
14. FISHEP Exposure Control Respirators
Full-face, quantitative fit-test
Filter change-out schedule
Work-practices
Heating
Hot water
Compressed air
Enclosure