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Safety Labeling for the Food Processing Industry

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IntRoductIon ............................................................................................................. pg 1

Highest Injury Rates

VIsuAL communIcAtIon ................................................................................... pg 2

We Learn With Our EyesFind It Fast

5s LeAn mAnufActuRInG ............................................................................... pg 3

5S for Food ProcessingSortSet In OrderShineStandardizeSustain

sIGns tRAnsmIttInG cRItIcAL InfoRmAtIon ............................... pg 5

AmmonIA RefRIGeRAnt .................................................................................... pg 7

Visual Communication and OSHAAccidents Can Be CostlyPreventing Ammonia Leaks

cemA sAfety comPLIAnce ............................................................................ pg 8

fAcILIty LAbeLInG suPPLIes ..................................................................... pg 1o

Typical Applications

Important Signs for Food Processing Workers

Organizing your workplace with 5S Lean Manufacturing3

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This document contains information derived from sources we deem reliable. Graphic Products, Inc. has made reasonable efforts to ensure correctness but does not guarantee accuracy or completeness. Graphic Products makes no warranties express or implied regarding the contained subject matter. Contents are subject to change without notice. Graphic Products disclaims liability for injury, damage, or loss arising from reliance on the information contained herein. Users of this information should independently consult municipal, state, or federal code and/or verify information with the appropriate regulatory agency.

Content may have been updated to reflect the latest codes, standards, and regulations or to address any errors or omissions. For the most up to date edition, visit: GraphicProducts.com/guides

contents

IntRoductIonOne of the most critical challenges facing today’s food processing industry is the issue of worker safety.

To deal with these challenging conditions and comply with safety regulations, food processing plants are redesigning equipment, initiating ergonomic programs, and implementing safe practice training programs. Still, OSHA regulations are always changing and what was legal yesterday may not be today.

There are ways to improve the work environment in food processing plants so workers are safer, codes are met, and facilities operate with greater efficiency. Through the strategic use of signage and labeling, food processing companies can inform employees about a range of important issues. Bold labels and signs, displaying everything from safety information to equipment operation, help employees focus on the task-at-hand.

The following pages demonstrate how to improve worker safety through the effective use of labels and signs. In creating a more visual workplace, companies make the workplace safer, reduce worker stress, and increase efficiency.

Highest Injury RatesThe food processing industry has one of the highest worker injury rates in the United States. A 2007 study of food processing plants, conducted by the US Department of Labor, found work-related injuries or illnesses were higher in this industry than those recorded in all other industries. This is a significant issue for the industry as a whole, but there are proven methods available to minimize injury and illness rates.

Food processing plants can be inherently dangerous places to work. Workers routinely lift heavy objects, operate dangerous equipment, and make repetitive motions—all while standing for long periods. Plants may also be noisy, limiting communication between workers. The combination of physical demands and environmental distractions makes working in a food processing plant a hazardous line of work.

Not only are food processing plants hazardous environments in which to work, they must remain very clean at all times. State and federal codes regulate how workers handle food and these regulations must be followed at all times. Inadvertent contamination of food or equipment could lead to a temporary plant closure, resulting in lost time and money.

Strong visual communication keeps facilities safer and more efficient.

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We Learn With our eyes Workers may be told repeatedly about a safety procedure or the proper way to operate a machine, but a visual representation conveys information more rapidly and effectively. This “visual communication” helps simplify critical details so workers don’t waste time thinking about them.

Labels and signs deliver information where and when it’s needed. There’s no mistaking the meaning of a label showing safety glasses and a hard hat displayed on a large mixer. The message should be clear to all workers—no matter their language or level of reading comprehension: “I need safety glasses and a hard hat to operate this equipment.”

Danger, warning, caution, and safety signs help keep workers safe. A sign’s OSHA/ANSI-standardized colors, designs, and wording should be visually recognized and easily understood.

find It fastFew things are as frustrating as not being able to find something you need. Identifying the location of a tool or piece of equipment eliminates confusion in the workplace and reduces down-time.

The workplace is safer and more efficient when tools, equipment, and inventory are well-labeled and stored as closely as possible to where they’re used.

Workers are less distracted when personal protective equipment (PPE) and other items can be found without searching. When easy-to-see signs are not present, critical tools and inventory are easily overlooked.

Clearly labeled hazards, safety equipment, tools, and PPE increase worker awareness and help keep facilities up-to-code.

VIsuAL communIcAtIon

A red “DANGER” label or sign should communicate danger to everyone—even from a distance.

Materials are easily found when locations are clearly marked.

An illustrated, color-coded caution sign keeps workers out of harm’s way.

Looking for more info on OSHA/ANSI Safety Sign Standards?

check out this video.

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Successful facilitation of “Sort” requires effective visual communication. Storage locations, with wayfinding labels directing workers to them, should be posted using industrial-grade labeling supplies.

set In orderThe second step of 5S implementation is to visually identify each item and then determine a permanent storage location. To increase efficiency, items should be stored close to where they are used.

Take time to critically evaluate all signs and labels used in and around a facility. Evaluate label and sign sizes, font sizes, design colors, and text content. Ensure they are clearly visible to workers at locations where hazards may occur.

• Hazards, warnings, cautions, equipment locations, and safety information all need to be identified with labels or signs.

• Pipes, valves, tanks, and storage areas should be clearly labeled.

• Floor marking tapes can identify storage, provide directions, cautions, and traffic information.

5s for food ProcessingIntegrated with Lean Manufacturing, 5S is useful in helping workers organize the spaces they work in for long-term success. Lean Manufacturing implementations are also more efficient with 5S already in place and fully functioning.

The term “5S” stands for five steps used to help workers organize their work areas. These steps are:

•Sort—Throw away rubbish and unrelated materials.

•Set in order—Set things in proper place for quick retrieval/storage.

•Shine—Clean the workplace. Everyone should be a janitor.

•Standardize—Create guidelines for maintaining cleanliness.

•Sustain—Make it a way of life. This means commitment.

The goal of each step is to help workers regularly focus on scheduled organization duties.

sortThe implementation of 5S begins with “Sort.” This step involves sorting through workplace inventories and tools to remove infrequently used items.

These items can get in the way—reducing productivity, creating hazards, frustrating work area personnel and impairing job performance. Eliminating clutter improves worker safety and morale, while raising product quality and increasing efficiency.

To eliminate work area clutter, useless or rarely used items are prioritized by workers for removal. “Red tags” are used to clearly identify these items for storage or disposal.

5s LeAn mAnufActuRInG5S Lean Manufacturing is a simple system of organization used to improve plant safety and efficiency. The system has been used successfully, throughout the world, in many industrial facilities—including many food processing plants.

Red tag storage zones are identified with easy-to-see floor markings. Creating “red tag” zones for unused items results in safer, more efficient work areas and allows for easy retrieval of materials.

Discover Your Path to SafetyPathFinder offers a wide range of floor marking and wayfinding solutions to protect workers, organize workflow, and direct traffic. Visit us online to identify the right solution for you.

FloorMarking.com | 877.534.5157ContaCt us today!

by Graphic Products, Inc.

Click the video link for more info about Pathfinder!

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shineA poorly kept workplace is a sign of inefficiency. Dirty and messy environments allow leaks and other problems to go unnoticed. Eliminating these conditions helps keep workers safer and more productive.

Put “Shine” into action by ensuring employees have adequate cleaning supplies. A detailed checklist should be posted for each work area. Equipment, tools, inventories, storage areas, floors, and lighting all require routine cleaning. As morale and safety improve, workers become more motivated to keep their areas clean.

standardizeThe backbone of the 5S System ensures previously implemented steps become permanent activities. Duty lists featuring workers’ names and responsibilities are key to obtaining facility-wide commitment to 5S. Managers should review 5S with workers regularly, soliciting input and supporting continuous improvements.

“Standardize” formalizes visual communication standards. Activities such as designating specific font sizes and styles, selecting safety symbols, and establishing a color-coding system provide label and sign standards to improve facility-wide recognition rates. Workers will identify color-coded labels in less time and from greater distances.

Food processing conveyors can also benefit from color-coding. Colors can be standardized to visually communicate specific information so workers waste less time and make fewer mistakes. Standardized colors can be used to indicate conveyor entry points, assembly locations, exit points and any other location where simple information would improve efficiency.

sustainIn this final step, 5S should be programmed to help the system function indefinitely. Signage can now be used to display scheduled duties and placed strategically for workers to review. 5S should be integrated into new worker training programs, with well-established work area and facility organization goals.

Signs and banners, displaying progress, create enthusiasm and help workers visualize established goals. 5S successes should be communicated to all work area staff, with results posted where workers will see them. Internal publications, awards, signs and banners are excellent ways to communicate success stories to workers.

A sample bar graph displays achievement scores for an individual month. These are used to recognize facility-wide achievement.

Want more info on 5S? Get the complete 5S System Best Practice Guide and the 5S Standard Color Code Wall Chart. Call 877.534.5157 or visit GraphicProducts.com/guides to get your FREE guide today!

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5s LeAn mAnufActuRInG

Notice Sign (OSHA/BLUE)Indicates potential safety issues or gives direction to avoid safety hazards.

Caution Sign (OSHA/YELLOW)Indicates hazards that may result in moderate injury.

Arc Flash Label (NFPA/RED/ORANGE)Provides information about explosive discharge of electrical energy resulting from short-circuit fault.

General Safety Sign (OSHA/GREEN)Provides health, first aid, medical equipment, sanitation, housekeeping, and general safety information.

Danger Sign (OSHA/RED)Indicates immediate hazards that will result in death or serious injury if not avoided; most extreme situations.

High Pressure PipeMay cause severe injury or death.

KEEP AWAY

Warning Sign (OSHA/ORANGE)Indicates hazards that could cause death or serious injury.

Keep hands away from rotating blade.Lock out power beforeservicing equipment.Replace guards immediately after repair or adjustment.

CAUTIONForkliftAreaKeep Aisles Clear

sIGns tRAnsmIttInG cRItIcAL InfoRmAtIonSigns can relay important workplace information and safety instructions to workers in food processing facilities.

EmergencyEye WashFountainKeep area clear.

EYEWASH

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Emergency LabelsPhotoluminescent exit markings offer security during low-light emergency conditions.

Pipe Marker (ANSI/ASME COLOR STANDARDS)Identifies contents and flow of direction of gasses and liquids.

Ammonia Pipe Marker (IIAR COLOR STANDARDS)Indicates ammonia system components, physical state, pressure level, and flow direction.

Metal-Detectable Label (ANSI/ASME)Ideal for food manufacturing or anywhere metal contaminants may harm the product.

Floor MarkingIdentifies storage locations, and provides directions and traffic information.

Valve Tag (ANSI/ASME)Identifies contents and operation.

Non-Hazard SignProvides directions, maintenance information, work procedures and general information.

Pitchin!

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sIGns tRAnsmIttInG cRItIcAL InfoRmAtIon

Violations of ammonia-related OSHA regulations are becoming more widespread. Between 1993 and 2007, OSHA cited 144 companies across the nation for violations involving ammonia. The combination of accidents and violations cost companies millions of dollars in fines and likely slowed or stopped production—costing them even more money. During this same period, 32 individuals died in the United States from ammonia-related accidents.

Preventing Ammonia LeaksAmmonia is generally delivered by rail car or an over-the-road truck. It is transferred to a storage vessel or other part of the ammonia refrigeration system via pumps, compressors or through differential pressure. Once the transfer is complete, workers must perform standard shutdown procedures. Generally, workers must know how to safely turn off pumps, compressors, and disconnect hoses.

Most ammonia leaks are known to occur while ammonia is being transferred. Clear instructions for critical procedures and labeling of equipment can help workers perform their tasks successfully and help bring attention to potential leak issues.

Present in both liquid and vapor forms, ammonia is corrosive to skin, eyes and lungs—posing dangers from physical contact or inhalation.

Ammonia releases typically occur when improper hoses are used, or containers are damaged in shipping or receiving. Accidental releases have been known to cause injuries and deaths. Because ammonia refrigeration systems operate at elevated pressure levels, considerable care must be taken to prevent ammonia releases.

Itchy eyes and a burning nose are the early symptoms of hazardous exposure levels. However, short-term exposure may lead victims to tolerate the smell and overlook the symptoms until it is too late.

Visual communication and osHAAmmonia refrigeration systems are subject to OSHA requirements. OSHA’s regulations address emergency action plans, evacuation, training, fire prevention, housekeeping, and equipment maintenance. OSHA requires facilities using ammonia refrigerant to:

• Train workers

• Provide proper personal protective equipment

• Label pipes and other storage containers

• Make safety data sheets easily accessible to workers

Regulations also specify visual communication standards to direct workers into safe zones when leaks occur. Color-coded floor plans, chemical labeling, and proper HazCom all work together to protect workers from the dangers of ammonia leaks.

One of the easiest ways to protect workers is to ensure every hazard is appropriately labeled with OSHA-compliant safety labels and signs. Proper signage can also save a facility from costly OSHA violations.

Accidents can be costly Ammonia leaks are a serious issue in food processing plants nationally. Some accidents have resulted in fatalities. In June of 2009, an ammonia leak at a North Carolina food processing plant killed one worker and injured three. In a 5-year state-wide study, conducted by the state of North Carolina, 82 ammonia releases were reported—resulting in injuries to 39 individuals. Many required hospitalization.

AmmonIA RefRIGeRAntAnhydrous ammonia is a widely used refrigerant chemical and one of the most common hazards in food processing facilities.

Color-coded ammonia pipe markers indicate contents, flow directions, physical states and pressure levels. Clear labeling of ammonia pipes and other food processing equipment can reduce accidents and hazard communication violations.

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CEMA was instrumental in creating the first national standard on conveyor safety and subsequently developed specifications for conveyor safety labels. CEMA remains active in promoting design, safety, and application standards for the conveyor equipment industry.

Conveyors present a wide range of hazards with which food processing workers must be concerned about:

• Exposed and moving parts

• High voltage levels

• Trip hazards

• Low clearances

• Equipment starting automatically and unexpectedly

• Pressurized systems

• Sitting, walking or climbing on equipment

• Hot surfaces

• Rotating shafts

• Falling parts

Properly labeling these hazards can prevent serious injury. Ensure an industrial-grade printer, capable of printing strong adhering labels and signs, is used to properly label critical conveyor hazard locations.

Adhering to CEMA’s conveyor equipment safety standards requires the right labeling supplies, printers, and applications. Application-specific labeling supplies provide the necessary adhesion to provide lasting service in locations where harsh liquids or unusual conditions are anticipated.

cemA sAfety comPLIAnceThe Conveyor Equipment Manufacturers Association (CEMA) is a trade organization comprised of conveyor equipment manufacturers, installers, and designers.

Integrate CEMA’s label placement specifications into a comprehensive conveyor safety program to help reduce conveyor-related injuries.

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typical ApplicationsMany food processing employees are commonly exposed to harsh liquids and debris. Proper labeling to visually communicate hazards, procedures, and efficiency techniques is critical. Industrial-grade labeling supplies offer food processing facilities a wide selection of labeling supplies to ensure lasting performance in most work area locations.

fAcILIty LAbeLInG suPPLIesFood processing facilities benefit from using application-specific labeling supplies for HazCom, procedure labels, and many other labels and signs used to improve efficiency and safety.

Some of the more popular supplies used in food processing facilities include: premium vinyl for making pipe markers; ANSI-compliant die-cuts for making arc flash labels, and OSHA safety signs; metal-detectable tapes for marking equipment and conveyors; and many other types of labeling.

Graphic Products®, DuraLabel®, PathFinder®, Toro®, Bronco® and Lobo® are Registered Trademarks of Graphic Products, Inc. ©2010, 2017. Graphic Products, Inc. grants a limited revocable right to reuse portions of the material contained herein for non-commercial, internal, and educational/training use. Any use beyond that described here requires the written consent of Graphic Products, Inc. Licensee agrees to reproduce the Trademark, Copyright, and Legal disclaimers in all works created under this license.

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