What is OSHA?

OSHA, or the Occupational Safety and Health Administration is tasked with assuring safe and healthy working conditions for the working class by setting strict health standards and providing training, outreach, education, and assistance. OSHA has established guidelines for the poultry processing industry due to high serious injury rates (injuries that require a day or more away from work or restricted activity to recuperate).

Common Safety Concerns
in Poultry Processing Plants

Lack of Personal Protective Equipment

Ergonomics and Musculoskeletal Disorders

Lockout/Tagout

Machine Guarding

Slips, Trips, and Falls

Chemical Hazards: Ammonia, Chlorine, Hydrogen Peroxide, Peracetic Acid, Carbon Dioxide

Loud occupational noises

Blocked exits

Lack of sanitation and cleanup operations

Delong’s Gizzard Equipment Safety

While we are talking safety, we thought we would include some safety tips to utilize when using our Peeling Rollers. These rollers are designed to pinch and pull any loose material whether it is skin, clothes, or any other loose items coming into contact with them.

No Gloves
No Long Sleeves
No Loose Shirts or Smocks
No Long Fingernails
No Pressing tips of fingers toward or in rollers
Yes, apply pressure to gizzard with horizontal flat part of palm and bottom flat of fingers only
Yes, inspect every gizzard before peeling it for best quality.
Yes, if the gizzard has been peeled it goes to the good product chute.

It is our hope that you and your processing plant will put OSHA requirements and the safety of your workers at the forefront of your operation. We hope this guide will help you get on the road to doing just that. DeLong’s is one of the leading authorities on poultry processing rollers in the United States, providing some of the best rollers in the industry, providing you with safer processes (and safety information!), higher yield, and a better bottom line. Contact us today to learn how we can be of assistance to you.

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To help our customers and other industry professionals stay aware of how they can help maintain a safe workplace, we have compiled a guide that will help you understand and enforce an OSHA inspired plan of action in preventing and treating illnesses, injuries, and disorders in your workers. This guide will be based on ergonomic data used to create OSHA’s guidelines and programs that encourage a safe workplace.

What is OSHA?

OSHA is the Occupational Safety and Health Administration that assures workplaces are safe and healthy by setting standards, providing outreach, education and assistance.

The Occupational Safety and Health Act of 1970 was passed to assure safe and healthful working conditions for working men and women; by authorizing enforcement of the standards developed under the Act; by assisting and encouraging the States in their efforts to assure safe and healthful working conditions; by providing research, information, education, and training in the field of occupational safety and health.

Because of the high volume of hazards at a poultry processing facility, OSHA has strict and specific standards for the meat industries. In 1993, OSHA published its Ergonomics Program Management Guidelines for Meatpacking Plants, which recommended that employers implement an ergonomics process to identify and correct ergonomics-related problems in their worksites.

In 2004, OSHA published the first version of these guidelines, Guidelines for Poultry Processing — Ergonomics for the Prevention of Musculoskeletal Disorders. We will explore these guidelines in this blog.

What are Musculoskeletal Disorders?

There are a plethora of hazards and possible ways to injury yourself working in the poultry processing industry. However, one that is often overlooked due to the asymptomatic and nonvisible nature of the injury are musculoskeletal disorders.

We use the term MSD to refer to a variety of injuries and illnesses that occur from repeated use or overexertion, including:

• Carpal tunnel syndrome;
• Tendinitis;
• Rotator cuff injuries (a shoulder problem);
• Epicondylitis (an elbow problem);
• Trigger finger;
• Muscle strains; and
• Lower back injuries.

MSDs are strikingly common in the poultry processing industry. The incidence rate of occupational illness cases reported in this industry in 2011 and 2012 has remained high at more than five times the average for all U.S. industries. The rate of carpal tunnel syndrome, in particular, was more than three times the national average in 2012 and seven times the national average in 2011.

The culprit? Repetitive motion. Workers who performed the following tasks require the most repetitive hand manipulation and should be carefully watched not to develop carpal tunnel syndrome:

• Cutting,
• Eviscerating,
• Washing,
• Trimming,
• Deboning,
• And multiple tasks.

OSHA’s Process for Protecting Workers

According to OSHA’s Prevention of Musculoskeletal Injuries in Poultry Processing guidelines, their process for protecting workers is as follows:

1. Provide Management Support
2. Involve Workers
3. Provide Training
4. Identify Problems
5. Encourage and Utilize Early Reports of Injuries
6. Implement Solutions
7. Evaluate Progress

OSHA’s Assistance, Services and Programs

OSHA offers help in protecting your business and your workers in the form of:

• Establishing an Injury and Illness Prevention Program;
• Providing Compliance Assistance Specialists;
• Free On-site Safety and Health Consultation Services for Small Business;
• Cooperative Programs;
• Occupational Safety and Health Training; and
• OSHA Educational Materials.

For more information about OSHA’s guidelines, and how they can help protect the wellbeing of your workers, read the in depth descriptions provided in OSHA’s Prevention of Musculoskeletal Injuries in Poultry Processing. It is always important to identify and address concerns, listen to worker feedback, and check OSHA standards as they are updates to ensure total worker safety.

DeLong’s is committed to keeping poultry processing safe and efficient and we hope that you continue to trust DeLong’s with poultry tips, tricks and important information.

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What Chemicals Are Used In Poultry Processing Plants And What Are Their Hazards?

Chemicals associated with accidents in the poultry processing industry include:

• Ammonia- burning of the eyes, nose, throat and respiratory tract and can result in blindness, lung damage or death
• Heavy Alkalines- severe burning of the skin
• Chlorine- can rapidly lead to respiratory distress with airway constriction and accumulation of fluid in the lung
• Carbon dioxide- rapid breathing, rapid heart rate, clumsiness, emotional upsets and fatigue can resul
• Phosphoric acid in combination with sodium hydroxide- severe burning to the ski
• Foam cleaner- grinding of foam cleaner can lead to  potential exposures to isocyanates and other toxic emission
• Hydraulic fluid- swallowing or inhaling can cause nerve damage or deat
• Crystalline silica- breathing crystalline silica dust can cause the lung fibrosis, silicosis

When using Heavy Chemicals, DO:

Make sure that all equipment is unplugged and on lockout. Too many horrific accidents in the meat processing industries have occurred because lockout was not used correctly. To protect the integrity of your plant and employees’ lives, double check that all equipment is turned off and ready to be cleaned.

Always ensure that your plant employees wear proper personal protective equipment (PPE). The most important part of using heavy chemicals is making sure your cleaning staff has adequate equipment.

• Eyes- Safety spectacles, goggles, face screens, face shields, visors should be worn at all times. Make sure the eye protection chosen for your plant has the right combination of impact/dust/splash eye protection for the task and fits the user properly
• Head and neck- Protect the head and neck areas by wearing bump caps, hair nets and scarves. Some safety helmets incorporate, or can be fitted with, specially-designed eye or hearing protection. Be sure to replace head protection if it is damaged
• Hands and arms- Gloves, gloves with a cuff, gauntlets and sleeving that covers part or all of the arm should be worn by workers within your plants. Some materials are quickly penetrated by chemicals so take care in selecting the best ones for your plant. Barrier creams are unreliable and are no substitute for proper personal protective equipment. Additionally wearing gloves for long periods can make the skin hot and sweaty, leading to skin problems. Using separate cotton inner gloves can help prevent skin problems from over exposure to moisture.
• Feet and legs- Have plant workers invest in good safety boots and shoes with protective toe caps and that are  penetration-resistant. Midsole wellington boots and specific footwear, like foundry boots and chainsaw boots are great types of protective footwear. Footwear can have a variety of sole patterns and materials to help prevent slips in different conditions, including oil – or chemical-resistant soles. Footware can also be anti-static, electrically conductive or thermally insulating. Appropriate footwear should be selected for the risks identified within your plant.
• Lungs- The right type of respirator filter must be used as each is effective for only a limited range of substances. Filters have only a limited life. Where there is a shortage of oxygen or any danger of losing consciousness due to exposure to high levels of harmful fumes, only use breathing apparatus – never use a filtering cartridge. You will need to use breathing apparatus in a confined space or if there is a chance of an oxygen deficiency in the work area
• Whole body- Protecting the whole body is key. Conventional or disposable overalls, boiler suits, aprons, chemical suits should be worn, depending on plant functionality and equipment. Materials available include flame-retardant, anti-static, chain mail, chemically impermeable, and high-visibility. When applicable, other protection, like safety harnesses or life jackets should be worn.

Ensure all eye washing stations and shower stations are properly maintained and ready to be used in the case of an emergency. Not checking an eye washing station before starting a cleaning job can be the difference between recovery and blindness.

Always have an emergency plan in place. Ensure your employees know the plan in the case of an emergency.

Chemical use is necessary in a high-risk environment like poultry processing. Ensuring your employees are trained properly, following standards on chemical usage and double checking that equipment is ready to be cleaned are all essential factors in running a successful and safe processing plant.

At DeLong’s, and at all meat processing plants across the country, equipment safety and safe working environments are essential parts of the day-to-day operations. By addressing these concerns, taking steps to prepare workers for potentially hazardous conditions, and looking for creative solutions, processing workers can safely produce and provide for consumers.

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Delong’s offers an assortment of Gizzard Peeling Rollings that consist of a rotating shaft with a helical gear designed to peel the skin from the gizzard. Though these machines excel at what they do, they can also pinch and pull any loose material like skin, clothing, or any other hanging items coming into contact with them.

Working with specialized equipment comes with its own set of hazards and safety procedures. There are many kinds of machines that workers could come across in their workplace. Below are a few common hazards found from working with heavy machinery.

Specific Machine Hazards:

Debris – Working with machinery, especially processing and cutting machinery, can often be messy and lead to debris going airborne from the machine during the procedure. To avoid any debris hurting your workers, they should be wearing the proper personal protective equipment (PPE). Especially in the case of raw meat, wearing PPE will help avoid bacterial infections such as salmonella and campylobacteriosis.

Lacerations and Amputations – A fairly obvious danger of working with heavy machinery, but a very important one. If you are working with cutters, shears, blades, saws, etc. they must be safeguarded.

Noise – Machines can make a lot of noise that can damage the ears of your workers. PPE such as headphones or earplugs should be worn when working with loud machines. If crucial information needs to be discussed, make sure the noise of the machines are not leaving your workers uninformed.

Electrical Shock – Machines require a lot of energy and power to function. This high amount of energy can pose man threats to workers. Workers should operate high voltage equipment with care to avoid shock, and should always wear PPE. Water and other liquids should be kept away from electrical machinery.

Fire – If proper electrical safety precautions are not met, or flammable material is handled improperly, fire is a serious threat to the entire workplace. Proper fire safety training including a fire escape plan, necessary signs, and easily accessible exits are a must.

To ensure that workers are using the equipment properly and promote efficiency, we have compiled a list of tips to follow for the safest roller usage.

Follow these guidelines to safely and appropriately operate gizzard peelers:

• Do not wear gloves, long sleeves, loose shirts or smocks as they can get caught in the rollers.
• Remove all dangling jewelry before working, as they can also get caught in the rollers.
• Trim long fingernails so they do not get caught, or break and cause unexpected actions.
• Tie up, or cut, long hair. Long hair is easily caught in machines.
• Do not press the tips of your fingers toward or in rollers, apply pressure to gizzard with the horizontal flat part of your palm and bottom flat of your fingers only.
• Inspect every gizzard before peeling it for best quality, if it looks bad, infected, or unsafe, dispose of it properly.
• If the gizzard has been peeled it goes to the good product chute.
• Never remove or try to work around machine safeguards while the machine is functioning.
• Don’t create new hazards, such as allowing objects to fall into the moving parts or by creating a new pinch point.
• Report problems with machine safeguards to your supervisor immediately.
• Never leave machines unattended with parts still moving. Remember that parts may still be moving after the machine has been turned off.
• Remove guards only when the machine has been locked out and tagged out.
• Operate equipment only when guards are in place and properly adjusted.
• Do not use unauthorized or damaged guards.
• Ask your supervisor if you have any questions about machine safety or how to work with machine guards safely.

At DeLong’s, and at all meat processing plants across the country, equipment safety and safe working environments are essential parts of the day-to-day operations. By addressing these concerns, taking steps to prepare workers for potentially hazardous conditions, and looking for creative solutions, processing workers can safely produce and provide for consumers. If you’re ready to order rollers, contact us.

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Personal protective equipment is worn to minimize exposure to a list of hazards. These include:

• Electrical shock

• Heavy chemicals, which can lead to an increased risk of different cancers

• Mechanical Machinery

• Electrical inter-workings within the poultry processing plants

Even where engineering controls and safe systems of work have been applied, some hazards might remain. These include injuries to:

• The lungs, from breathing in contaminated air

• The head and feet, from falling materials

• The eyes, from flying particles or splashes of corrosive liquids

• The skin, from contact with corrosive materials

• The body, from extremes of heat or cold

Properly fitting and clean equipment encourages worker usage, thus making employees safer. Employees should be trained on what kind of equipment is necessary for specific tasks, when it is necessary, how to properly adjust, wear and take off equipment, and the maintenance required to maintain the integrity of the equipment.

Types Of Personal Protective Equipment

Protection equipment must be properly maintained and cleaned. It should also fit securely as ill fitting equipment can result in exposure to the risks even when properly following safety procedures.

Equipment is specific to tasks and the kinds of hazards at risk. Here are some examples of the types of personal protective equipment worn for poultry processing:

• Eyes- Safety spectacles, goggles, face screens, face shields, visors
  • Make sure the eye protection chosen has the right combination of impact/dust/splash/molten metal eye protection for the task and fits the user properly
• Head and neck- Industrial safety helmets, bump caps, hair nets and firefighters’ helmets
  • Some safety helmets incorporate, or can be fitted with, specially-designed eye or hearing protection
  • Don’t forget neck protection, like scarves for use during welding
  • Replace head protection if it is damaged
• Ears- Earplugs, earmuffs, semi-insert/canal caps
  • Provide the right hearing protectors for the type of work, and make sure workers know how to fit them
  • Choose protectors that reduce noise to an acceptable level, while allowing for safety and communication
• Hands and arms- Gloves, gloves with a cuff, gauntlets and sleeving that covers part or all of the arm
  • Avoid gloves when operating machines such as bench drills where the gloves might get caught
  • Some materials are quickly penetrated by chemicals – take care in selection
  • Barrier creams are unreliable and are no substitute for proper PPE
  • Wearing gloves for long periods can make the skin hot and sweaty, leading to skin problems. Using separate cotton inner gloves can help prevent this
• Feet and legs- Safety boots and shoes with protective toe caps and penetration-resistant, midsole wellington boots and specific footwear, like foundry boots and chainsaw boots
  • Footwear can have a variety of sole patterns and materials to help prevent slips in different conditions, including oil – or chemical-resistant soles. It can also be anti-static, electrically conductive or thermally insulating
  • Appropriate footwear should be selected for the risks identified
• Lungs- Respiratory protective equipment (RPE)
  • The right type of respirator filter must be used as each is effective for only a limited range of substances
  • Filters have only a limited life. Where there is a shortage of oxygen or any danger of losing consciousness due to exposure to high levels of harmful fumes, only use breathing apparatus – never use a filtering cartridge
  • You will need to use breathing apparatus in a confined space or if there is a chance of an oxygen deficiency in the work area
• Whole body- Conventional or disposable overalls, boiler suits, aprons, chemical suits
  • The choice of materials includes flame-retardant, anti-static, chain mail, chemically impermeable, and high-visibility
  • Don’t forget other protection, like safety harnesses or life jackets

Ensuring that employees know the proper steps for safety and the appropriate equipment is critical to everyone’s safety. Employers are required to purchase personal protection equipment when needed.

Prevention is cheaper, more effective and better for employees than waiting until an issue occurs. Poultry processing is a work environment that poses many risks unless proper care and concern is taken. Making sure employees are effectively trained, protected and re-trained will minimize risk and ensure that a safe working environment is maintained for all. Make sure to educate yourself and your staff by checking the OSHA standards for personal safety and maintaining a clear line of communication between employees and employers.

At DeLong’s, and at all meat processing plants across the country, equipment safety and safe working environments are essential parts of the day-to-day operations. By addressing these concerns, taking steps to prepare workers for potentially hazardous conditions, and looking for creative solutions, processing workers can safely produce and provide for consumers. If you’re ready to order rollers, contact us.

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In general, processing plants must be “cleaning friendly”, making the sanitation job as easy as possible. This means areas that must be cleaned be smooth and easily accessible, and workers should be regularly trained in operation sanitation methods.

Quick tips for sanitation:

• Remove all food products from the area
• The first step is removing organic substances like fat, proteins and dirt. This can be done by physically removing the scraps, called “dry cleaning,” with a large dry brush, broom or shovel.
• After cleaning areas, disinfection must occur to remove the remaining 10% of resilient microorganisms.
• A cleaning method that is popular to ensure total sanitary conditions is high pressure cleaning. Pressurized water is applied by high pressure units and special spraying lances.
• When utilizing high pressure water cleaning, the pressure must be between 30-70 bar and the spraying nozzle 15 cm from the surface.
• Commercial cleaning agents in modern cleaning practices are complex compositions of either alkaline, acid or neutral chemicals. In some cases, surfactants or detergents are added to ensure full sanitation.
• For larger plants, foam cleaning can be used to get more contact in with surfaces. The foam stays on the surface longer, making the sanitation more effective.
• Absolute germ-free surfaces are not achievable, but disinfectants will kill all pathogens.

When dealing with meat and poultry processing, DeLong’s encourages poultry plants across the country to commit to properly sanitizing plants to ensure worker and consumer safety. With the help of guideline compliance and regular check ups on the procedures, your plant and workers can eliminate food-borne and workplace illness. If you have any questions about sanitizing Delong’s rollers, contact us.

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Personal Protection Signs

Remaining safe in a dangerous work environment begins with being able to protect oneself from hazardous equipment and materials.

Here are a few personal protection signs commonly found in a processing plant:

• Eye Protection Signs: Goggles or face masks to keep debris out of eyes.
• Hard Hat Signs: Should be worn around heavy machinery at all times.  Must fit securely to protect from falling elements.
• Foot Protection Signs: Impermeable boots necessary to protect from liquids, machinery, etc.
• Hand Protection Signs: When hand protection signs are posted, gloves are required to be worn to protect workers against hazardous materials.
• Hearing Protection Signs: Headphones or earplugs are necessary to protect ears from loud noises.
• Fall Hazard Signs: Denote slippery surfaces.
  • Note: These signs signify protective clothing that should be worn when working in a poultry processing plant.  It is important to note a few other attire regulations while working:
    • No jewelry, long sleeves, or loose shirts while operating machinery.  Loose materials can easily become stuck in an active machine.

Machine Safety Signs

When working around machinery it is important to be aware of the potential hazards each machine possesses.

Below is a list of safety signs found when heavy machinery is present:

• Automatic Start Signs: Some machines are not run manually thus can start unexpectedly.  Be alert when around these machines.
• Pinch and Nip Point Signs: Avoid putting body parts around pinch and nip points to prevent being caught in machine.
• Machine Caution Signs: Signifies machinery is present.  Take general precautions.

Electrical Safety Signs

Electricity plays a vital role in running a processing plant.  However, it can also pose the most serious threats.

Here are some electrical safety signs:

• High Voltage Signs: Operate with care to avoid shock.  Always wear personal protection care when around high voltage electrical equipment.
• Electrical Panel Signs: Area in front of electrical panel must be kept clear for 36 inches.
• Electric Shock Sign: Possibility of shock when coming in contact.  Be cautious around equipment.

Fire Safety Signs

If electrical safety regulations are not carefully followed, fire is a potential outcome.  Workers must also be aware of flammable objects to avoid the risk of starting a fire in the plant.

Here are common fire safety signs:

• Fire Exit Signs: Be able to locate exit signs in case of fire.  Always keep doors unlocked to ensure safe exit.
• Fire Department Connection (FDC) Signs: Do not block FDC areas so the Fire Department can easily access the building.
• Flammable No Smoking Signs: Avoid smoking in areas that have flammable liquids/materials present.

These signs should help prevent accidents within poultry processing plants. Plants should always have appropriate signs for designated areas to inform workers of potential hazards.  Workers need to be able to locate and recognize safety signs in order to stay safe while working in a dangerous work environment.

If you have any safety-related questions regarding any of our equipment contact us.

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DeLong’s offer several gizzard rollers such as manual gizzard peeling rollers, breast cleaning rollers, gizzard harvesting rollers, and neck and thigh skinning rollers.  All of these peeling rollers have been personally designed and operated by DeLong’s throughout the years.

Working with specialized equipment comes with its own set of hazards and safety procedures. To ensure that workers are using the equipment properly and promote efficiency, we have compiled a list of tips to follow for the safest roller usage.

Peeling Rollers

Peeling rollers consist of a rotating drum with a raspy surface designed to peel the skin from the gizzard. These rollers are constructed from stainless steel and hardened stainless steel.   This machine has unique risks associated with using it and should be carefully operated to ensure employees do not come into contact with the peeler.

Proper Peeling Roller Techniques

Peeling rollers are designed to grab onto a piece of skin and strip it from the carcass.  To properly use a peeling roller, apply pressure to the carcass with the palm, inspect each gizzard before peeling and finally sort the final product into the “good product” shoot. These procedures ensure that the bird is peeled properly, the meat is maintained and the worker does not come into contact with the peeler.

DeLong’s also recommends replacing the brass bushings every time you replace the peeling rollers.  Bad bushings can cause a good peeling roller to perform poorly. Proper techniques and equipment are essential for a desired outcome.

Peeling Roller Hazards

There are conditions you should never operate a roller in. A worker should never have gloves, long sleeves, loose clothing, long fingernails, loose hair or press fingertips onto the roller. Since the roller is designed to grab loose material, excess clothing and hair are at risk of becoming stuck in the machine.  Making sure all clothing is tight fitting, hair is away and caution is used around rollers will minimize worker injury.

The specific hazards associated with the roller include getting fingers or materials caught in the roller as well as holding the body in specific positions to perform this task. For workers, minimizing movement and having rotating shifts will keep the body from being over exerted and prevent reduced blood flow to the legs and arms.

At DeLong’s and at meat processing plants across the country, equipment safety and safe working environments are essential parts of the day-to-day operations. By addressing these concerns, taking steps to prepare workers for conditions and looking for creative solutions, processing workers and consumers can enjoy the safest final product. If you’re ready to order rollers, contact us.

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In times before OSHA was established, there was no set way of regulating personal protection equipment, nor ergonomics programs established to prevent musculoskeletal injury. Agreeably, employees were found obligated to have a grasp on their rights as employees. Luckily, OSHA has created strict standards that minimize risk and assure employees of their rights.

What Kinds Of Hazards And Threats Might You Encounter In The Poultry Processing Industry?

The poultry and meat processing industries pose a variety of risks to employees and are among the most dangerous environments to work in. From illness, to physical harm, there are a variety of dangers that exist in the poultry processing industry. Let’s take a look at some of the hazards you might come across:

• Avian Flu – Without proper personal protective equipment workers may be exposed to avian flu when working with poultry.
• Electrical Accidents – Employees can be exposed to dangers such as electric shock, electrocution, fires, explosions, and unsafe electrical installations.

• Ergonomics/Musculoskeletal Disorders – Repetitive actions can cause wear and tear on the body that might result in musculoskeletal disorders or effect ergonomics. A program should be set in place to prevent these negative effects on workers.

• Evacuation Mishaps – In the case of an emergency, employers should have explained and trained their employees on proper evacuation procedure. Exit doors should not be blocked or locked when employees are in the building.

• Fire Hazards – Fire is always a serious threat that can cause excess amounts of damage. Fire retardant paints should be used, and appropriate lighting and markings leading to exits should be visible. Fire alarms and sprinkler systems should also be functioning and prepared for incidents like this one. Proper evacuation plans should be disseminated amongst employees in the case of a fire.

• Hazardous Chemical Exposure – Exposure to hazardous chemicals is not uncommon in the poultry processing industry. Here are some examples of chemicals that are usually found in poultry processing plants.

• Ammonia – Often used for refrigeration. Could cause irritation of the eyes and respiratory tract.
• Chlorine – Often added to water as a disinfectant used in washing birds. May cause respiratory irritation and breathing difficulties. Chlorine is also frequently added to was and chiller bath water; if used in excessive concentrations it can cause irritation symptoms.
• Carbon Dioxide –  Occasionally used in the form of dry ice to keep meat cold. Inhaling CO2 can cause an increase in breathing rate, which could lead to shortness of breath, dizziness, and vomiting.
• Hydrogen Peroxide – Sometimes used as a disinfectant. These chemicals may cause eye, nose, and respiratory irritation.
• Peracetic Acid – Occasionally used as a disinfectant, and is linked to respiratory irritation.

• Lack of Lockout/Tagout Features – During maintenance of machines lockout and tagout features must be present and appropriately affixed. The unexpected start up or release of stored energy could cause injury to employees or maintenance workers.

• Machine Guard Malpractice – Moving machine parts have the potential to cause severe injuries such as crushed body parts, amputations, lacerations, burns, or blindness. Machine guards are essential to prevent machine related injury.

• Overexposure to Noise – Machines and other plant processes can cause severe noise-induced hearing loss and ear damage. Proper personal protective equipment (earplugs or earmuffs) should be utilized to prevent the damage noise could do to your ears.

• Respiratory Problems – Respiratory problems can arise from chemical inflation and other unsanitary processes. Proper personal protective equipment (respirators, full body suits, and masks) should be used when working with potentially harmful material.

• Slips and Falls – Slips and falls are huge threats in crowded factories that contain temperamental contents and dangerous heavy machinery. Proper personal protective equipment such as non slip shoes should be used at all times when on the job. Proper sanitation methods should also be utilized to reduce the chance of slipping conditions being prevalent in the workplace.

So What Does OSHA Do To Help?

OSHA provides employers and workers with general information about all of the above topics. They provide effective strategies for controlling and preventing exposure to illness and injury. You can also find information on how to train workers to understand their risks, appropriate behavior and precautions in the workplace. Thanks to OSHA and other governmental agencies that set safety standards, employees can rest assured that employers will be held accountable for violations and have a clear way of handling risks.

For more information about safety in poultry processing plants, check out our latest free guide, Poultry Plant SafetyChecklist.

*Image courtesy of Freepik

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What to Guard?

Machines in the poultry processing industry are highly specialized and necessary for production. They require proper instruction and safety measures to be used. Machines must be guarded if there are hazards related to point of operation, ingoing nip points, rotating parts, flying chips, and sparks. If there is not a possibility to attach the guard to the machine, it must be attached to surrounding areas and ensure machine cannot harm an employee.

According to OSHA, the following machines also need to be guarded at all times:

• Guillotine Guards
• Alligator Shears
• Power Presses
• Milling Machines
• Power Saws
• Jointers
• Portable Power Tools
• Forming Rolls and Calendars
• Barrels Drums
• Blades

Anchoring machinery so that it cannot move or harm an employee is essential to maintaining a safe working environment. Without recognizing these hazards, they cannot be addressed. Guarding machines, staying alert to hazardous conditions and listening to employee concerns are all essential elements to a safe workplace.

Why Do Machine Injuries Occur?

Machine guarding is one of the most important things to consider when working with heavy and dangerous machinery. Even when applied, injuries still occur. Here are some of the most common ways these injuries take place:

Pressuring Demands – When employees are pressured to increase their work pace and rate of production, they may remove the machine guards. Production incentives may also cause workers to take a faster, but riskier approach.

Old Machinery – New machinery is often designed with guards built in to the construction of the machine. However, older machines need to be retrofitted with guards. Unfortunately, many factories and production plants keep using their old, outdated machines until they no longer work properly; this poses many safety threats in itself. If a machine is too old to be fit with guards, look for alternatives to safeguard it.

Adjusting and Fixing – If a machine has a problem that needs to be adjusted or fixed, the guards are likely to be taken off during maintenance. The guards must be replaced after maintenance is done to the machine to ensure safety of workers. If not replaced, workers will be exposed to dangerous parts of machinery.

Jams – If the production line, or a specific machine jams, make sure to completely turn off the machine before working on unjamming it. Employees often remove or bypass guards to clear the jam, and if the machine isn’t properly disabled it could recommence its action when you’re in a danger zone.

Cleaning –  When a machine needs to be cleaned, guarding is often removed for adequate cleaning. The machine guards should always be put back on immediately following the completion of sanitation.

How Can Proper Management Help?

Production speed is important, but employee safety is more important. Management should never encourage workers to cut corners on safety, in order to produce at a faster rate.

Employee’s should be properly trained on how and why machine guards are used. They should be trained to:

• Identify, describe, and recognize potential hazards associated with the machine
• Understand the type of guard they will be working with and how it protects them from danger
• Know when to, how to, and who can remove the guard on their machine.
• Know what to do if a guard is damaged, missing, or not working to its full efficiency.
• Not take independent action in machine guard related matters, and to involve supervision if necessary.

Understanding what it takes to create a safe work environment is the first step to having one. For further safety education and tips on creating a safe workplace, check out our latest free guide, Poultry Plant Safety Checklist.

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