Grejikebe Bakery Employee Safety Handbook

OVERVIEW 0

Grejikebe Bakery Employee Safety Handbook

March 31st, 2013

Grejikebe Bakery Employee Safety Handbook

March 31st, 2013

Developed by Hapapelo Creative: Lorelei Betke Harmeet Grewal Paula Jiles Peter Kehoe

Copyright © 2013 by Hapapelo Creative All rights reserved. No part of this publication may be reproduced, distributed, or transmitted in any form or by any means, including photocopying, recording, or other electronic or mechanical methods, without the prior written permission of the publisher, except in the case of brief quotations embodied in critical reviews and certain other non-commercial uses permitted by copyright law. For permission requests, write to the publisher, addressed “Attention: Permissions Coordinator,” at the address below.

Hapapelo Creative #122, 11222-40 Ave. Edmonton, Alberta T4J 9K9 Printed in Canada

Table of Contents Overview ....................................................................................................................................................... 1 Chapter 1: Hazard Assessment and Control ................................................................................................. 2 1.1

Introduction .................................................................................................................................. 3

1.2

Hazard Assessment ....................................................................................................................... 3

1.3

Control Methods ........................................................................................................................... 4

1.3.1

Administrative Controls......................................................................................................... 4

1.3.2

Engineering Controls ............................................................................................................. 5

1.3.3

Personal Protective Equipment ............................................................................................. 6

1.4

Summary ....................................................................................................................................... 6

Chapter 2: Physical Hazards .......................................................................................................................... 8 2.1

Introduction .................................................................................................................................. 9

2.2

Wet Surfaces ............................................................................................................................... 10

2.2.1 2.3

Moving Parts ............................................................................................................................... 11

2.3.1 2.4

Control Methods ................................................................................................................. 15

Noise ........................................................................................................................................... 15

2.6.1 2.7

Control Methods ................................................................................................................. 14

Fire .............................................................................................................................................. 15

2.5.1 2.6

Control Methods ................................................................................................................. 11

Thermal Hazards ......................................................................................................................... 14

2.4.1 2.5

Control Methods ................................................................................................................. 10

Control Methods ................................................................................................................. 16

First Aid Kit .................................................................................................................................. 16

Chapter 3: Occupational Exposure ............................................................................................................. 19 3.1

Introduction ................................................................................................................................ 20

3.2

Ingredients .................................................................................................................................. 20

3.2.1 3.3

Control Methods ................................................................................................................. 21

Cleaning Products ....................................................................................................................... 24

3.3.1

Control Methods ................................................................................................................. 24

Chapter 4: Other Hazards ........................................................................................................................... 28 4.1

Introduction ................................................................................................................................ 29

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4.2

Ergonomics.................................................................................................................................. 29

4.2.1 4.3

Control Methods ................................................................................................................. 29

Working Alone ............................................................................................................................ 33

4.3.1

Control Methods ................................................................................................................. 33

Chapter 5: Personal Hygiene....................................................................................................................... 35 5.1

Introduction ................................................................................................................................ 36

5.2

Germs and Bacteria..................................................................................................................... 36

5.2.1 5.3

Control Methods ................................................................................................................. 36 Proper Sanitation ....................................................................................................................... 38

5.3.1

Control Methods ................................................................................................................. 39

Equipment Cleaning ............................................................................................................................ 39 Chapter 6: Emergency Procedures ............................................................................................................. 42 6.1

Introduction ................................................................................................................................ 43

6.2

Recognizing Emergencies ............................................................................................................ 43

6.2.3

Control Methods ................................................................................................................. 44

Appendix 1: Workplace Hazard Assessment Form ..................................................................................... 48 Appendix 2: Grejikebe Bakery Evacuation Plan .......................................................................................... 49 Glossary ....................................................................................................................................................... 50 Index............................................................................................................................................................ 53 References .................................................................................................................................................. 54

Grejikebe Bakery

Employee Safety Handbook

OVERVIEW 1

Overview At Grejikebe Bakery, safety is our first priority. As a dynamic business that produces approximately 4,000 baked goods daily, it is imperative that all Grejikebe personnel know and understand the company’s current safety standards. Employees are required to follow and uphold these standards, as well as any other policies and regulations regarding safety. The Grejikebe Bakery Employee Safety Handbook emphasizes these standards in a comprehensive and easy-to-follow format. The manual provides personnel with hazard identification techniques, risk-reduction strategies and other key information regarding safety precautions and conduct in the workplace. Glossary terms are bolded the first time that they appear in the text.

Questions and/or concerns regarding any of the content in this manual may be addressed to Grejikebe Bakery directly via one of the following channels: Phone (Mon. to Fri. between 9 a.m. and 5 p.m.): (780) 322-8791 Email: administration@grejikebe.com Standard mail: #124, 11222-40 Ave., Edmonton, AB, T4J 9K9

Chapter 1: Hazard Assessment and Control

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1.1

Introduction While the baking profession can be both enjoyable and rewarding, many

processes can be hazardous. To support a fast-paced work environment, Grejikebe Bakery uses high volume mixers and food processers, industrial ovens, fryers, and packaging machinery. Spills and wet surfaces are common; bakers also encounter moving blades, conveyors, rollers, and dividers. Bakery staff face daily exposure to flour dust and dough -- both known to sensitize skin -- and must handle heavy loads regularly.

This chapter details specific hazards of Grejikebe Bakery and provides strategies to reduce risk. It also specifies legislation that requires employees to reduce hazards in the workplace and employers to abide by workplace best practices. This chapter—as well as each preceding chapter—ends with “key concepts” to review safety messages and reinforce principles.

1.2

Hazard Assessment To identify and ultimately reduce the risks commonly associated with bakery

operations, Grejikebe Bakery employers and staff should conduct a hazard assessment.

Mandated by Part 2 of the Occupational Health & Safety Code, an assessment should be done before work begins, and then annually or as processes change (2009). Employers must ensure that all new staff members are made aware of potential work site hazards during orientation. Staff should review hazard assessment regularly and suggest revisions as necessary.

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To complete a hazard assessment, all personnel should review bakery operations, itemize hazards associated with each process and suggest methods to control or eliminate the hazards. Appendix 1 provides a hazard assessment template.

1.3

Control Methods Control methods are used to reduce workplace hazards. Controls may be

categorized as administrative, engineering or personal protection equipment.

1.3.1 Administrative Controls Administrative controls include rules or limitations designed to reduce worker exposure to hazards. Examples of administrative controls include shortened work hours, job-rotation schedules and training. Others include equipment maintenance, good housekeeping and personal hygiene practices (“Hazard Control�).

Figure 1.1 Good Housekeeping Practices

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1.3.2 Engineering Controls Engineering controls are alterations made to a process or equipment to minimize workplace hazards. Revisions to a process, isolation of an emission source or improvements to the ventilation system can reduce risks associated with tasks. For example, a specially designed vacuum might be used to control dust or to reduce an inhalation hazard.

Figure 1.2 Engineering Control

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1.3.3 Personal Protective Equipment Personal protective equipment (PPE) is the final strategy for hazard control.

Ideally, PPE should only be used when administrative and engineering controls cannot adequately minimize workplace hazards. In a bakery, PPE might include safety glasses, gloves or dust masks, depending on the task.

Figure 1.3 Personal Protective Equipment

1.4

Summary Grejikebe Bakery is a fast-paced, productive workplace. To reduce hazards

inherent to bakery operations, personnel should first identify all possible hazards associated with an activity and then determine appropriate control strategies. Controls include administrative and engineering methods, as well as personal protective equipment.

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Key Safety Concepts:  Hazard assessments are required by law.  Hazard assessments outline specific risks and control measures.  Controls can be administrative, engineering, or PPE.

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Chapter 2: Physical Hazards

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PHYSICAL HAZARDS

2.1

9

Introduction Physical hazards are unsafe conditions in the workplace that pose a risk to

physical safety (Worksafe Alberta, 2007). They include visible things that can hurt you (such as heavy equipment or blades) and forms of physical energy (noise or temperature extremes). For example, an individual who handles frayed cords is at risk of electrical shock. Other examples of physical hazards include cluttered aisles in a workplace, wet floors or hot work surfaces. During a hazard assessment, Grejikebe Bakery management and employees should identify all physical hazards in the workplace and eliminate or mitigate them using administrative and engineering controls, as well as personal protective equipment if necessary.

Typical physical hazards and associated injuries in a bakery include the following: 

Wet surfaces (slips)



Moving parts (cuts, pinches)



Thermal hazards (hot surfaces and liquids [burns])



Fire



Noise

This chapter describes each category of physical hazard and how it pertains to Grejikebe Bakery, and offer strategies to reduce or eliminate the hazard. First aid kit contents are suggested at the end of the chapter.

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10

Wet Surfaces Slips and falls are common injuries in bakeries due to splashed or spilled

ingredients. At Grejikebe Bakery, floors are mopped at least three times a day, presenting a major slipping hazard. Although wet surfaces are unavoidable in a bakery, personnel should use a combination of control methods to minimize risks.

2.2.1 Control Methods To reduce risks associated with spills and cut down on cleanup time, Grejikebe Bakery personnel should assemble a spill kit and place it in an accessible location. The kit should be checked regularly and restocked as necessary. Table 2.1 suggests contents for a bakery spill kit.

Table 2.1

Spill Kit Contents Item

Quantity

Bucket Degreasing solution (for oil and grease spills) Mop

1 x 20L 2L 1

Absorbent mixture (e.g. kitty litter)

1 kg

If a spill occurs, the worker responsible should immediately clean it up after posting cautionary signage (Figure 2.1). Individuals mopping the floor should also post signage during and for 30 minutes after mopping.

Figure 2.1 Cautionary Signage

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To further reduce risks associated with wet surfaces, all employees who work in the kitchen area should wear disposable shoe covers or footwear with slip-resistant surfaces. Examples of appropriate footwear are shown in Figure 2.2.

Figure 2.2 Slip-Resistant Work Shoes

2.3

Moving Parts Grejikebe Bakery has wide array of equipment including conveyors, pie and tart

machines, mixers, rollers, dividers, and packaging machines. Many have moving blades and components that can crush hands or arms, sever fingers or cause permanent eye damage.

2.3.1 Control Methods Prior to operating any bakery equipment, Grejikebe employees should read and understand the safe handling instructions, observe the equipment in action and receive training on its usage.

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To reduce the risks associated with moving parts, Grejikebe personnel should clean, maintain and promptly repair equipment as required. When disassembling or repairing equipment, personnel must use “lockout and tag out� processes to protect themselves and others. This process is legislated by the Occupational Health and Safety Code Part 15, and ensures that a piece of equipment has been powered down and tagged before any maintenance activities begin (2009). Figure 2.3 shows a lock and tag assembly typically used during equipment servicing.

Figure 2.3 Lock and Tag Assembly All Grejikebe Bakery personnel must complete lockout/tag out training prior to conducting maintenance work on equipment. Training should also be part of orientation for new employees.

When operating bakery equipment, personnel must maintain appropriate clearance, position warning signage on equipment to indicate equipment dangers, and

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use equipment safeguards as intended. To be effective, safeguards must do the following (Worksafe Alberta, 2007): 

Prevent workers from contacting moving parts



Be secure



Prevent entry of falling objects



Create no new hazards



Not interfere with worker duties

Figure 2.4 provides an example of an effective safeguard.

Figure 2.4 Mixer with safeguard

Before working with bakery equipment, Grejikebe personnel must be trained to operate built-in safety devices designed to stop machinery immediately. Examples of emergency devices include power interlocks, two-handed controls and emergency stop buttons (Worksafe Alberta, 2007). Figure 2.5 demonstrates an emergency stop device.

Figure 2.5 Emergency Stop Device

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2.4

14

Thermal Hazards Boiling water, hot oil and hot ingredients can scald bakery workers. At Grejikebe

Bakery, workers frequently use steamers, boil ingredients and operate the fryer.

Grejikebe workers also work on or alongside hot surfaces such as warming trays, grills, ovens and cooking pans.

2.4.1 Control Methods

Figure 2.6 Hazard label

To reduce hazards associated with hot liquids, bakery personnel should wear heat-resistant gloves when handling vessels, pour carefully and refrain from carrying liquids around the work area. Label hot water pipes and other vessels to indicate contents. Figure 2.6 demonstrates a hazard label.

To handle hot surfaces safely, Grejikebe Bakery employees should use heat-resistant gloves or mitts (Figure 2.7). Employees should also wear long trousers and closedtoe shoes to minimize injuries caused by contact with hot surfaces.

Figure 2.7 HeatResistant Mitts

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15

Fire Gas and electric heat sources at Grejikebe Bakery, such as ranges, grills and

griddles, pose a risk of fire. Employees also face fire hazards associated with fryers and splattered grease.

2.5.1 Control Methods To reduce the risk of fire, Grejikebe personnel should turn off all appliances when not in use and should use kitchen appliances equipped with high temperature cutoff switches. To control grease buildup and to reduce the risk of fire, worker should regularly clean grills, deep fryers and vessels used with these appliances. All fryers should be positioned near fire extinguishers and emergency shower systems.

Prior to beginning work at Grejikebe Bakery, all new employees must read and understand the bakery evacuation plan (Appendix 2). The bakery should also designate an in-house “Fire Warden� to conduct regular fire drills and train new personnel as necessary. Fire extinguishers (ABC Class for general fires and K Class for kitchen fires) must be easily accessible; all new employees should receive fire extinguisher training (OHS Code, 2009).

2.6

Noise Bakeries are noisy environments; equipment operates up to 16 hours a day and

typically generates noise levels up to 90 dBA (WorkSafe BC). The Occupational Health and Safety Code (2009) requires employers to take all practicable measures to ensure that continuous noise levels generated do not exceed 85 dBA.

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2.6.1 Control Methods To control noise levels in the workplace, Grejikebe management must post warning signage in any areas where noise levels exceed 85 dBA (OHS Code, 2009).

Grejikebe personnel who work with loud equipment should wear hearing protection (Figure 2.8) and undergo audiometric testing annually.

Figure 2.8 Hearing Protection

Hearing protection must meet or exceed requirements listed in CSA Standard Z94.2-02 Hearing Devices – Performance, Selection, Care, and Use and be an appropriate Class A hearing protection and grade 3 or 4 (OHS Code, 2009).

2.7

First Aid Kit As per the Occupational Health & Safety Code, Grejikebe Bakery must maintain a

first aid kit and ensure that at least one employee trained in first aid is available per work shift (2009). Table 2.2 provides suggested contents for a first aid kit.

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Table 2.2 First Aid Kit Contents Quantity 10 25 10 2 2 2 3 5 1 1 1 1 1 4 1 1 1 10

Item antiseptic cleansing towelettes, individually packaged sterile adhesive dressings, individually packaged 10 centimetres x 10 centimetres sterile gauze pads, individually packaged 10 centimetres x 10 centimetres sterile compress dressings, with ties, individually packaged 15 centimetres x 15 centimetres sterile compress dressings, with ties, individually packaged conform gauze bandages — 75 millimetres wide cotton triangular bandages safety pins — assorted sizes pair of scissors pair of tweezers 25 millimetres x 4.5 metres of adhesive tape crepe tension bandage — 75 millimetres wide resuscitation barrier device with a one‐way valve pairs of disposable surgical gloves first aid instruction manual (condensed) inventory of kit contents waterproof waste bag antiseptic cleansing towelettes, individually packaged

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Key Safety Concepts:  Physical hazards pose a risk to physical health.  Physical hazards at Grejikebe Bakery include wet surfaces, moving parts, thermal hazards, fire, and noise.  Control risks with administrative, engineering and/or PPE controls.  Maintain a first aid kit in the bakery.

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Chapter 3: Occupational Exposure

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3.1

Introduction Occupational exposure refers to materials/substances in Grejikebe Bakery that

may cause adverse health effects amongst personnel. Employees must repeatedly handle ingredients such as flour, dough, and spices over the course of a day and are regularly exposed to cleaning products; all of which can lead to health issues.

Personnel may be susceptible to the inhalation of flour dusts, which can lead to occupational asthma. They are also expected to repeatedly wash their hands throughout the course of a day, which may lead to the skin condition dermatitis (“Diet, occupational exposure and early asthma incidence among bakers, pastry makers and hairdressers.”)

In order to maintain a sanitary work environment, caretaking staff at Grejikebe Bakery must also regularly use cleaning products; however, exposure to cleaning products can potentially lead to health effects that range anywhere from eye irritation to burns (“High prevalence of skin symptoms among bakery workers”).

This chapter will outline the appropriate control methods that must be used in order to avoid adverse health effects from exposure to ingredients and cleaning products in Grejikebe bakery.

3.2

Ingredients After breathing in flour dust for prolonged periods of time, bakery personnel run

the risk of developing occupational asthma (OA). OA is characterized by a runny nose in its first stages, and coughing, wheezing, nasal irritation, tightness of the chest, and

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OCCUPATIONAL EXPOSURE 21

shortness of breath in its more advanced stages (“Diet, occupational exposure and early asthma incidence among bakers, pastry makers and hairdressers”).

Repeated exposure to irritants, wet substances and frequent hand washing can also lead to dermatitis on the hands and arms. This condition is marked by redness, swelling, skin cracking, blisters, flaking, and itching (“High prevalence of skin symptoms among bakery workers”).

3.2.1 Control Methods To avoid exposure to harmful ingredients, the following methods will be used: Cleaning Equipment, machinery, tools and other surfaces will be cleaned daily and weekly to prevent the buildup of ingredients.

Personnel will have access to liquid detergent, sanitizer, glass cleaner, floor cleaner, surface degreaser and other cleaning products. High-efficiency vacuum cleaners (as shown in Figure 3.1) will be used to clean ingredients from the ovens and off the floor to prevent the spread of ingredients (“Bakery Operation

Figure 3.1 High Efficiency Vacuum Cleaner

Safety”).

Daily Cleaning 

Dividers: cleaned with water and a towel/cloth.



Drains: cleaned with degreaser.



Floors: cleaned with floor cleaner and sanitizer.

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

Ingredient bins: cleaned with water and a towel/cloth.



Phones: cleaned with sanitizer.



Rounders: cleaned with water and a towel/cloth.



Sheeters: cleaned with water and a towel/cloth.



Showcases: cleaned with glass cleaner (as demonstrated in Figure 3.2).

Cleaned with liquid detergent and sanitizer: 

Cabinets



Freezers



Hand tools (e.g. whisks)



Mixers



Mixing bowls



Ovens



Proof box



Scales



Sheet pans



Sinks



Walls



Work benches

Grejikebe Bakery

Figure 3.2 Employee wiping down showcases with glass cleaner

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OCCUPATIONAL EXPOSURE 23

Weekly Cleaning 

Hoods and filters: cleaned with degreaser.



Storage and shelving units/racks: cleaned with detergent and sanitizer (“Bakery Cleaning Procedures”).

Ingredient Handling Techniques The following techniques can also be used to reduce the unnecessary spread of ingredients: 

When pouring ingredients, gently tip and shake bags.



Sprinkle or rub flour onto work surfaces rather than throwing it on.



Place ingredients gently into flour rather than dropping them in.



Start mixers at a slow speed when beginning to mix ingredients to prevent dry ingredients from becoming airborne (safety and health in bakeries).

Storage of Ingredients All ingredients are to be stored in closed bins (like the one shown in Figure 3.3) in order to prevent them from spreading and becoming airborne. Each bin will be clearly marked and ingredients will only be mixed in enclosed containers or drums.

Figure 3.3 Ingredient Storage Bin

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Protective Wear Bakery personnel will wear long sleeve shirts and food handling gloves (Figure 3.4) in order to protect their skin from exposure to ingredients. They will also wear a nuisance dust mask when performing tasks that result in the spread of ingredients, such as mixing (“Bakery Operation Safety�).

Figure 3.4 Food handling gloves

3.3

Cleaning Products Caretaking staff are required to regularly clean equipment and machinery they

use in the food preparation process as well as the floors, walls, sinks, and other surfaces; as such, staff are regularly exposed to a variety of cleaning products. Exposure to the chemicals in the cleaning products can lead to adverse health effects such as skin, throat, and eye irritation, dizziness, headaches, and even burns.

3.3.1 Control Methods The following methods will be used in order to avoid exposure to harmful chemicals:

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Training on Cleaning The company will train staff on how to clean every piece of equipment, machinery, tools, and surfaces within the bakery. This training will include choosing the appropriate products for the correct surface, handling cleaning products, cleaning spills, wearing protective equipment, understanding warning labels (Figure 3.5), and storing the cleaning Figure 3.5 Poison Label

products away safely.

Storage of Cleaning Products All cleaning products will be stored in their original containers and will be

securely closed to prevent spillage or the escape of odours/fumes. All containers and cleaning products will be clearly labeled to inform staff of their uses as well as possible dangers (Figure3.6). A clear set of instructions should accompany each product so as to further prevent the misuse of the products and potential risk of exposure.

Figure 3.6 Securely stored and labeled cleaning products

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Cleaning products will be kept in a clean, cool and dry closeted space, away from any heat sources, in order to prevent the emission of chemicals into the air. Once finished using these products, personnel should ensure that they have securely closed the containers and returned them to the closet.

Protective Wear Bakery personnel should also wear long sleeve shirts and pants in order to minimize the amount of skin they have exposed to cleaning products. They should minimize contact by using latex gloves as well. Another safeguard employees are required to implement is wearing a face mask, like the one shown in Figure 3.7, in order to prevent the inhalation of chemicals.

Figure 3.7 Face Mask

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Key Safety Concepts:    

Clean the bakery on a daily and weekly basis.

Employ correct cleaning techniques.

Use appropriate ingredient handling techniques.

Store ingredients and cleaning products in securely closed, labeled containers.  Wear face masks and gloves when cleaning and handling ingredients.

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Chapter 4: Other Hazards

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OTHER HAZARDS 29

4.1

Introduction In addition to physical and chemical risks, Grejikebe Bakery workers may

encounter other workplace hazards. For example, bakery workers may have ergonomic issues associated with performing work tasks repetitively. This chapter also addresses hazards associated with working alone and suggests safety measures to reduce risks.

4.2

Ergonomics An ergonomic hazard is a physical factor in the environment that can harm the

musculoskeletal system (“Ergonomic Hazard”). At Grejikebe Bakery, the following tasks may pose ergonomic hazards: 

Stocking supplies or receiving items



Loading or unloading pans from racks



Cake decorating



Standing for entire shifts

4.2.1 Control Methods To minimize strain associated with repetitive activities, Grejikebe Bakery should use a rotation system to allow staff to vary work tasks and posture. Staff should also take regular, short rest breaks during work cycles.

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Stocking supplies/receiving items When stocking or receiving items, employees should use a staggered squat or mini-squat to evenly distribute their weight. Figure 4.1 demonstrates the proper stance to use when holding, lifting or carrying items (OSHA, 2004).

Other suggestions for safely moving items include the following: 

Before lifting bakery equipment, determine its weight.



When lifting, avoid twisting at the waist.



Maintain a straight back.



Bend at the knee and lift using leg muscles.



Lift smoothly without jerking.

Figure 4.1 Proper stance when lifting

Loading or Unloading Pan To minimize injuries associated with loading or removing pans from racks, bakery workers should use a staggered or mini-squat to reach low racks, and avoid lifting trays beyond shoulder height. Figure 4.2 demonstrates proper maneuvering of a bakery pan.

Figure 4.2 Proper positioning when loading a pan

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Employees may also use mechanical aids (lifts, or carts) to transport equipment safely. Figure 4.3 demonstrates trays that can be used to carry glassware.

Figure 4.3 Trays for easy transport of glassware

Cake Decorating To reduce the risk of injury when using piping bags, workers should position the turntable so the cake is at elbow height: use adjustable height tables, place a riser under the turntable or position a platform for shorter people to stand on. Figure 4.4 demonstrates proper placement of a cake to minimize ergonomic hazards while piping.

Figure 4.4 Stand for Ingredients

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When working with large quantities of icing or batter, place buckets of ingredients on risers (e.g. small stands or empty buckets) to raise them to the best work zone (Figure 4.5).

Figure 4.5 Stand for Ingredients

Standing Bakery workers often stand for entire shifts. To reduce fatigue and painful feet, workers should use footrests or stand on anti-fatigue mats, shown in Figure 4.6.

Workers should also wear shoes designed to comfort foot soles, and take regular stretch breaks.

Figure 4.6 Anti-fatigue Mat

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4.3

Working Alone At Grejikebe Bakery, employees may occasionally work alone during early

morning shifts or when closing in the evening. Part 28 of the Occupational Health and Safety Code (2009) requires employers to conduct a hazard assessment and develop controls to reduce risks associated with working alone.

4.3.1 Control Methods To minimize risks associated with working alone, Grejikebe Bakery should implement a communication system to allow workers to easily call for assistance. The system must enable workers to send a signal to someone who could assist them and should incorporate devices such as two-way radios, cellular telephones or personal alarms. It should also include a check-in between workers at shift change or contact with a supervisor at the end of the day (OHS Code, 2009).

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Key Safety Concepts:  Ergonomic hazards at Grejikebe Bakery include lifting, decorating and standing.  Employ correct posture and support equipment to reduce hazards.  If working alone, maintain regular contact with designated personnel.

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Chapter 5: Personal Hygiene

PERSONAL HYGIENE 36

5.1

Introduction In the food service industry, cleanliness and hygiene are of the utmost

importance. Bakery personnel are expected to clean and groom themselves in order to prevent the potential spread of germs and disease. Proper hygiene practices must be stressed and strictly enforced, as any violations or mishandling of food may result in sickness or health issues for those consuming the products.

This chapter will outline which control methods must be used in order to prevent the contamination of food due to poor personal hygiene. Besides complying with food and health standards of the area, correct food handling, equipment sanitization and storage are some of the areas that will also be addressed in this chapter.

5.2

Germs and Bacteria Staff may encounter germs and bacteria in the workplace either from coming in

contact with other sick individuals or not practicing proper hygiene when coming in contact with unclean surfaces such as those found in bathrooms. Improper hygiene could lead to staff transferring these germs and bacteria to machinery, equipment, and tools, which all come in contact with and may contaminate food.

5.2.1 Control Methods Proper hand washing is essential in order to ensure the quality and standard of the products prepared and sold at Grejikebe Bakery. Before handling any ingredients or

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equipment, all bakery personnel must carefully wash their hands (Figure 5.1 shows proper hand-washing technique).

Figure 5.1 Proper Hand-washing Technique

The following steps outline the proper hand-washing process: 1. Turn the tap on and wet your hands and wrists with water.

2. Dispense liquid soap into your hands or pick up a bar of soap.

3. Work the soap into a lather by rubbing it between your hands.

4. Rub the soap over every part of your wrists and hands—including your cuticles, under your fingernails, around your fingers, and the back of your hands—for at least 15 seconds.

5. Rinse every part of your hands and wrists under warm water for at least 10 seconds.

6. Turn the tap off with your elbow or a paper towel (avoid touching the tap with your clean hands to avoid getting them dirty again).

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7. Dry your hands completely under a hot air drier or with a disposable paper towel (avoid touching the drier or paper towel dispenser with your hands).

Hand-washing should be done regularly and thoroughly after using the washroom, touching the face or other body parts, handling money, or leaving the food preparation area. If an employee is responsible for both money and food handing, gloves may be used (as shown in Figure 5.2) to quickly transfer from one area of the operation, such as cash register, to another area, such as the preparation table.

Figure 5.2 Latex Gloves

5.3

Proper Sanitation Proper sanitation of bakery equipment is also necessary to ensure personal and

workplace hygiene. Equipment and food preparation surfaces must be cleaned on a regular basis so that staff and food are not exposed to any contaminants. This can be done through the use of cleaning machines, washers and chemicals that are safe use in the food preparation industry. Furthermore, the maintenance of ingredient quality is

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fundamental; expiration logs will be updated and posted to keep these procedures and protocols current, comprehensive and in compliance with safety standards.

5.3.1 Control Methods

The following control methods will be used to prevent the spread of germs and bacteria on workplace surfaces.

Equipment Cleaning Appliances, equipment and cooking utensils must be regularly washed and sanitized. These utensils may include (but are not limited to) pans, trays, mixing bowls, spoons, spatulas, and cutting boards. These utensils may need to be cleaned several times a day, before and after each use. Counters and appliances also need regular and thorough wipe-downs with an appropriate surface cleaner. Personnel must be aware of the handling instructions of such cleaning chemical, as they may require special instruction and the use of protective gear. Charts and/or logs should be kept throughout the bakery (near appliances, in food preparation areas, inside washrooms, etc.) so that cleaning personnel can initial and log the frequency of cleaning within the facility. Figure 5.3 shows typical cleaning equipment.

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Figure 5.3 Cleaners Storage Grejikebe Bakery personnel must properly log and store ingredients in order to maintain the freshness and quality of these foods. Employees should update the storage logs by recording the item name, date of purchase and date of expiration. Expired items should never used under any circumstances and must be immediately discarded to maintain the quality of the product and the dignity of the company brand. Figure 5.4 depicts fresh, quality bakery ingredients.

Figure 5.4 Quality Ingredients

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Key Safety Concepts:  Wash hands frequently and thoroughly.  Maintain the sanitation of surfaces, utensils, appliances etc.  Maintain quality ingredients by employing proper storage and logging techniques.

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Chapter 6: Emergency Procedures

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6.1

Introduction The health and safety of Grejikebe Bakery employees and clients is fundamental.

As such, it is important that the company be prepared for the worst possible health and/or safety threats. Any business that uses machinery or equipment to produce a product is at risk for an emergency, and failures or malfunctions to equipment can be the direct result of improper monitoring and upkeep. This chapter highlights some worst-case scenarios, explains safety standards and discusses personnel expectations.

6.2

Recognizing Emergencies Emergency evacuations and procedures are essential points of training for new

Grejikebe Bakery employees. It is imperative that all new hires are given a tour of the facility, and that trainees stress the location of emergency exits and equipment shutoffs. Fire and evacuation drills should be a routine part of the bakery’s operations.

Figure 6.1 depicts a standard fire alarm.

Figure 6.1 Standard Fire Alarm

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6.2.3 Control Methods The following control methods will be used to manage emergency situations that may arise.

Evacuation Plan Grejikebe Bakery’s safety standards must always be in compliance with current fire and evacuation laws/bylaws. This may include a maximum capacity of employees and clients allowed in the facility at any given time. This may also include the placement of highly visible fire exit maps throughout the workplace, for both personnel and the public to reference. Lights and exit indicators must also be in regular working condition.

Figure 6.2 shows an effective exit sign.

Figure 6.2 Exit sign

The location of fire alarm switches should be properly indicated for all personnel to recognize; personnel should also be familiar with any audio emergency indicators. In

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the case of an emergency, personnel should maintain a calm demeanour while escorting themselves, and any others, to the appropriate meeting place (the muster point). If the signs of a fire are apparent (heat, smoke, etc.), employees should stay low to the ground and move swiftly toward the closest available exit. Once outside, personnel should head toward the muster point. All personnel should be aware of the muster point; management should remind personnel of this designated area on a regular basis. A sign is sometimes used to help indicate the muster point. The Grejikebe Bakery evacuation plan is provided in Appendix 2.

Emergency Equipment In case of minor blazes or flames, fire extinguishers should be readily available and well-maintained. The location of fire extinguishers should be communicated to all bakery personnel. Figure 6.3 shows a typical fire extinguisher.

Figure 6.3 Fire Extinguisher

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In addition to all other safety kits, emergency stations are common in compliance with local bylaws and business standards. Grejikebe personnel should be aware of eye wash, emergency shower, and fire blanket locations.

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Key Safety Concepts:  The potential for emergency is a concept that all personnel should understand and accept.  Emergency evacuation indicators and plans should be regularly communicated to all personnel.  Safety equipment must be easily-accessible.

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Appendix 1: Workplace Hazard Assessment Form

Work Area Hazard Category (physical/chemical/ biological/ ergonomic/other) Identified Hazards Frequency (13)

Assessment

Probability (1-4)

Severity (0-5)

Training Required Controls in Place

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Appendix 2: Grejikebe Bakery Evacuation Plan

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GLOSSARY 50

Glossary

Administrative controls

Changes to the way people work

Dermatitis

An inflammation of the skin that may result from repeated exposure to irritants, wet substances and/or frequent hand washing; physical symptoms include redness, swelling, skin cracking, blisters, flaking, and/or itching.

Emergency Indicators

Any signal or warning that indicates an emergency; may include audio and/or visual clues (alarms, smoke, flames, etc).

Emergency stations

Areas designed for the immediate treatment of emergencies or to treat contact with hazardous materials (such as an eyewash station).

Engineering controls

Methods built into the design of equipment or a process to minimize a hazard

Ergonomic hazard

A physical factor within the environment that harms the musculoskeletal system

Hazard

A situation that poses a level of threat to life, health, property, or environment

Hazard assessment

The process of identifying hazards so they can be eliminated or controlled

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Hygiene

A set of practices followed to maintain proper health standards.

Irritants

A stimulus or agent that induces physical irritation (e.g. inflammation, allergic reaction, dry or itchy skin, etc.)

Lockout/tag out

A safety procedure used to ensure that dangerous machines are properly shut off and not started up again prior to the completion of maintenance or servicing work

Maximum capacity

The maximum number of people allowed in a specific area at any given time.

Muster point

A designated place where individuals meet in the event of an emergency; usually located away from the workplace

Nuisance dust mask

A dust mask that covers the nose and mouth and filters out nuisance dust (dust that is considered an irritant, though it does not pose any chemical or biological threat to the body).

Occupational asthma

A condition caused by the workplace environment that may limit a person’s air passages and may restrict breathing.

Personal protective

Protective clothing, helmets, goggles, or other garments

equipment (PPE)

or equipment designed to protect the wearer's body

Physical hazards

Unsafe conditions that can cause injury, illness and death

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Sanitation

The application of measures and means to protect public health and prevent contact with hazardous materials.

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INDEX 53

Index Administrative controls, 4, 49 Alarm, 43, 44 Bacteria, 36, 39 Cake decorating, 31 Chemicals, 24, 25, 26, 38 Cleaning, 1, 2, 21, 22, 24, 25, 39, 52 Ceaning products, 20, 21, 24, 25, 26 Control methods, 4 Dermatitis, 20, 21 Drills, 15, 43 Dust masks, 5

Hazard assessment, 3, 9, 33 Hazards, 3, 4, 5, 6, 9, 13, 14, 15, 29, 31, 49, 50 Hygiene, 4, 36, 38 Irritants, 21, 49 Lifting, 30 Lockout and tag out, 12 Malfunctions, 43 Maximum capacity, 44 Muster point, 44 Noise, 9, 15, 16

Emergency, 2, 43, 45, 49 Emergency indicators, 44 Emergency stations, 45 Emergency stop device, 13 Engineering controls, 5, 49 Equipment, 4, 5, 6, 9, 11, 12, 13, 15, 16, 24, 30, 31, 36, 38, 39, 43, 49, 50 Ergonomic hazard, 29 Evacuation plan, 15 Evacuations, 43 Fire, 15, 43, 44, 45 Fire exit, 44 Fire extinguisher, 15, 45 Fire extinguishers, 15 First aid kit, 9 Footwear, 11 Germs, 36, 39 Gloves, 5, 14, 17, 23, 26, 38 Hand washing, 21, 36, 49

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Occupational asthma, 20 Occupational exposure, 20 Personal protective equipment, 5 Physical hazards, 9 Protection, 4, 16 Safety devices, 13 Safety glasses, 5 Sanitation, 38 Shoes, 14, 32 Signage, 10, 12, 16 Spill kit, 10 Standing, 29, 32 Stocking, 29 Storage, 22, 23, 25, 40 Thermal Hazards, 1, 14 Wet surfaces, 3, 10, 11 Working alone, 2, 33

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REFERENCES 54

References “Bakery Cleaning Procedures.” Essential Industries, Inc. Web 27 March 2013.

“Bakery Operation Safety.” State Compensation Insurance Fund. Web 27 March 2013.

“Ergonomic hazard.” Tooling.com ToolingU: An SME Company. n.d. Web. 18 Mar. 2013.

Ergonomics for the Prevention of Musculoskeletal Disorders. Ohsa.gov. Web. 18 March 2013.

Government of Alberta, Human Services. (2009) Occupational Health & Safety Code,

“Hazard Control.” ccohs.ca. Canadian Centre for Occupational Health & Safety, n.d.

Web. 14 March 2013.

Occupational Safety and Health Administration. (2004). Guidelines for Retail Grocery Stores.

Quilley, Alan D. The Emperor Has No Hard Hat. Edmonton : 2012.

Remen, T., et al. “Diet, occupational exposure and early asthma incidence among bakers, pastry makers and hairdressers.” Pub Med Central Canada. (2012). Web. 27 March 2013.

Steiner, M.F.C., et al. “High prevalence of skin symptoms among bakery workers.”

Occupational Medicine. Oxford Journals. (2011) Web. 27 March 2013.

Work Safe Alberta. (2007). Occupational Health & Safety Teacher.

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Work Safe BC. (2013). “Food Processing – how loud is it?” Manufacturing Toolbox Meeting Guide.

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