Basics for a Bakery

8/3/2019 Basics for a Bakery

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Basic requirements for

bakeriesInformation from the labour inspectorate

INSPEKTION

ARBEITS


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Table of contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1. Lighting, safety lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2. Electrical plant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73. General ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4. Floors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5. The flour silo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5.1 Primary explosion protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5.2 Secondary explosion protection. . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5.3 Tertiary (constructional) explosion protection . . . . . . . . . . . . . . . . 9

6. Technical measures for reducing flour dust . . . . . . . . . . . . . . . . . 10

6.1 Mixing space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

6.2 Work equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

6.3 Technical ventilation plant for reducing hazardous substances. . 12

7. Working practices for reducing flour dust . . . . . . . . . . . . . . . . . . . 148. Keeping to the limit value and carrying out measurements . . . . . 15

9. Protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

10. Work clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

11. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

12. Sanitary and social facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

13. Despatch and loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

14. Other burdens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

15. Legal foundations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Contacts for the bakers' campaign . . . . . . . . . . . . . . . . . . . . . . . . 19


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Introduction

This leaflet represents a working document within the framework of the"Campaign for health and safety protection in bakeries".

This leaflet is intended to provide ideas for measures to reduce flour dust, and toprovide information and advice about possible measures.

At the same time, it represents an aid when assessing evaluation measures, andthus also forms a guide for the production of the health and safety protectiondocument.

The recommendations (marked in yellow as minimum standards) which shouldbe implemented by all Austrian bakery businesses by the end of 2005 have

been laid down depending on the size of the business and the productionquantities, as well as taking into account the prevailing conditions of workplacesthat have evolved over time, and work equipment that is already present.

A distinction has been made here between firms with an average annual flourconsumption of less than 100 tonnes (small and very small businesses), andfirms with a flour consumption of more than 100 tonnes. Account was also takenof whether the firm was an old, existing firm that was approved by the trade

inspectorate authorities, whether it involved building conversions or additionsthat had been carried out, whether new machinery had been acquired, or thebusiness had been set up completely new.

As far as possible, in the structure of the leaflet we have taken into account theproduction sequence in bakeries:

General outline conditions relating to the workplace, such as lighting, escaperoute lighting etc.,

Requirements made of flour silos, The supply, mixing and working of dough by means of machines - technical

measures to be taken,

Changing working practices,

Cleaning,

Ventilation equipment for reducing flour dust, and

Measuring the dust limit value.

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The colour coding used in the leaflet is intended to helpmake it easier to find the required minimum standard that is

applicable to the concrete situation in each case.Those portions of text that are not colour-coded are general

recommendations and measures.

The measures that are described and recommended in the leaflet, and are tosome extent obligatory, are based on

Experience from the EU project "Let's bake it",

Experience from the implementation of this EU project in Austria,

Statutory minimum standards of employee protection, and International and European standards and norms.

All the measures were successfully trialled within the framework of the UpperAustrian project, including the provincial guild of bakers, the vocational school,representatives of bakery firms, machine manufacturers, the accident insuranceagency and scientific institutions.

The leaflet is aimed at bakers, project workers, qualified safety staff, manualworkers, such as e.g. electricians, silo manufacturers.

Businesses with an average annual consumption of more than 100tonnes of flour

Minimum standard for all bakery businesses

Newly-established business, or additional building or buildingconversion for a bakery business, purchase of new machines, settingup of a flour silo plant, and an average annual consumption of lessthan 100 tonnes of flour *)

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Newly-established business, or additional building or buildingconversion for a bakery business, purchase of new machines, settingup of a flour silo plant, and an average annual consumption of more

than 100 tonnes of flour *)*) The increased requirements apply only to the new machines and to those

areas that are newly built or converted.


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1. Lighting, safety lighting

1.1 Lighting

For existing businesses without spatial separation of the bakery and the

pastry/cake shop, the minimum requirement is 200 Lux.

If the mixing space, baking room and the workplace for decorating bakedgoods are separate, the following lighting strengths are required:

Mixing space at least 300 Lux

Baking room at least 200 Lux

Work area for decoration at least 500 Lux.

If only the bakery and the pastry/cake shop are spatially separated:

at least 300 Lux for the bakery

at least 500 Lux for the pastry/cake department with decoratingworkplaces.

If there is no spatial separation of the individual work areas:

at least 300 Lux for the whole bakery.

For the lighting installations in the bakery, the planning factor of 1.43 in thesense of point 5.7. NORM O 1040 is to be applied, since there isincreased contamination through flour dust. Annual cleaning of the lightinginstallations is required.

1.2 Safety lighting

Safety lighting is required for the bakery and the escape routes. Storageareas and social areas should be equipped with escape route orientationlighting.Note: VE-EN 2, VE-EN 1838 and TRVB 102 contain correspondingimplementing regulations.


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2. Electrical plant

The electrical plant must generally conform to the implementation for"Installations in Industry and Trade" in accordance with ESV and VE-EN 1.In the bakery and washing-up area, the electrical equipment must conform

to protection category IP 54 in accordance with VE-EN 1.

In new plants, all socket circuits for hand-held machines must beequipped with additional protection in the form of an FI safety switch witha tripping current of 30 mA.

There must be a certificate in accordance with VE-EN 1 21 or (fromOctober 2000) test findings relating to the regular recurring check on theelectrical plant in accordance with ESV 1995, relating to the proper

execution of the electrical plant.

3. General ventilation

Generally, no mechanical ventilation is necessary in the bakery in addition to themeasures described under "Technical measures for reducing flour dust"; and inrelation to the reduction of dust exposure, it can even be counter-productive.

For the ventilation of the other areas, the minimum requirements of thedecree on workplaces - AStV - are sufficient.

With regard to the necessary ventilation measures for reducing flour dust andvapours, see point 6.3.

4. Floors

In accordance with the guideline issued by the employers' liability insuranceassociation (BGR) 181 (code of practice for floors in work rooms with adanger of slipping), the floor coverings (in the case of flat floors) must havethe following evaluation group for slip hazard:

all production areas such as bakery, pastry/cake shop etc. and washing-up area in very small businesses (without mechanical cleaning), at leastR 10

all other businesses, at least R 11 in despatch, store room and side rooms, at least R 9.

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5. The flour silo

Most flour/air mixtures can form an atmosphere capable of explosion.

With regard to explosion protection, flour silos must be set up in accordance withthe stipulations of the decree on explosive atmospheres (VEXAT). In mostcases, a permit from the trade inspectorate authority is required.

Justified deviations from the explosion protection measures below, derived fromstatutory regulations, can be envisaged and exceptions can be granted. Thelocal labour inspectorate office can provide information about conditions forchanges and exemptions.

5.1 Primary explosion protection

(Aim: Preventing the formation of explosive atmospheres)

In the case of cleaning, maintenance and repair in the interior of the silo,care must be taken to ensure that any raising of dust is kept low.

Forflour silos with a filter cloth closure, in any case a fill level meterfor monitoring against over-filling must be provided.

5.2 Secondary explosion protection(Aim: Avoiding the ignition of explosive atmospheres)

The interior of the silo and conveyor pipes are to be classed as Zone 20according to VEXAT.

For flour silos with filter cloth closure, the rooms in which they areinstalled must be assessed on the basis of the type of silo as Zone 22according to VEXAT.

For this reason, the electrical equipment in the installation room mustconform to at least group II category 3 D according to ExSV 1996 (atleast protection category IP 54).

A functional equipotential bonding via the earthing of the silo andconveyor pipes must be certified by means of a test record (specialistfirm).

For equipment and protective systems, there must be certification from

the distributors corresponding to the respective zones, in accordancewith ExSV 1996.


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5.3 Tertiary (constructional) explosion protection

(Aim: Weakening the effects of an explosion)

Possible constructional explosion protection measures include

Constructional explosion protection in the case of flour silos

- Blast pressure relief via an adequatelydimensioned pipe conduit to the outdoors,in an area that is not hazardous forworkers, explosion suppression orexplosion-proof method of construction

- If several silos are connected to oneanother, technical explosion de-coupling isnecessary

- It is possible to set up these flour silos inwork rooms

- The silos must withstand blast pressure orreduced blast pressure (proof: silomanufacturer)

or alternatively:

Constructional explosion protection in the installation room (bunker)Flour silos with filter cloth closure without constructional explosionprotection set up in an installation room.

- The installation room must be separated from work rooms

- For the calculation of the pressure relief, the entire volume of the installationroom including the silo volumes with filter cloth closure are decisive, since thereis no technical explosion de-coupling of the individual silos

- Pressure relief of the installation room in accordance with VDI 3673 sheet 1,

wherein the shock resistance of the boundaries of the room must be ensured(proof for pressure relief area and shock resistance through accredited offices,civil engineers)

Exemption from constructional explosion protection

Exemptions from constructional explosion protection for flour silo plants can begranted only if the same level of protection can be achieved through suitablemeasures. This means that technically and organisationally safe avoidance ofeffective ignition sources must be ensured. For concrete assessment, we

recommend that you contact the local labour inspectorate office.

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Flour silo with filter cloth closure


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6. Technical measures for reducing flour dust

6.1 Mixing space

Closed system in flour delivery and indough production.

The transportation air of the flour silo plantmust not be emitted into the work roomvia the cyclone situated in the work room.

Regular cleaning of the dust filter in the case of the cyclone and exclusiveuse of original filters (must be at least filter class L).

Sufficiently long cloth or fabric hose for the flour delivery, and maintenanceof it.

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Closed flour delivery with lid andvacuum extraction


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6.2. Work equipment

Dust protection lid on the kneading machines instead of grilles (if thediameter of the kneader is larger than 510 mm)

The use of automatic flour sprinklers for the individual machines; setthem correctly and carry out regular maintenance.

The exhaust air from the motors of the bakery machines must not be ledover the flour containers.

Access guards in roll or bread plants, through closed components orcorresponding grilles (closed coverings or cladding are preferable togrilles, on account of the better protection they offer against dust).

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Open flour delivery, rotary armkneading machine with grille cover,workplace-related dust extraction

carried out flexibly, can be used for

the flour delivery and the twokneading machines.

Poor - the exhaust air from the motoris led directly over the flour container

Good - automatic de-dusting reducesdust exposure


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6.3. Technical ventilation plant for reducing hazardous

substances

Essentially, the technical ventilation measures are restricted to dust extractionand vapour traps. With regard to the requirements of dust extraction equipment,we also refer to point 8, "Observing the maximum workplace concentration valueand carrying out measurements".

Depending on the quantity (volume flow) of the extracted air, mechanicalprovision of incoming air is necessary. What is important is that all ventilationcomponents are based on an overall concept.

Minimum requirements made of the ventilation plant:

Vapour traps over bakery ovens and fat-frying devices

In the case of businesses that are to be newly established, within theproject one must take account of the possibility of vacuum extraction atthe work surface and at the mixing space, designed similar to flexible"welding smoke extraction". *)

*) (But also applies to existing businesses, regardless of when they were setup, as well as to businesses regardless of the annual flour consumption if,despite changed working practices and technical measures taken, the limitvalue for flour dust in the air that is breathed is noticeably exceeded!)

Mechanical supply of incoming air, where the extracted air volumeexceeds twice the room content per hour or, with favourablearrangement of the incoming air openings, a maximum of four times theroom content.

Overall concept that takes account of all existing and planned ventilationcomponents, such as e.g.- vapour traps over the bakery ovens and fat-frying devices

- spot flour dust extraction in the case of bread tin dusting and in thecase of individual processing machines that produce large amounts ofdust

- vapour traps over the bakery ovens and fat-frying devices- mechanical supply of incoming air- mechanical extraction of general waste air (if necessary)- free flowing ventilation openings capable of being regulated- free flowing ventilation openings not capable of being regulated, due to

production circumstances (gates at despatch)

For the flour dust extraction plant, corresponding dust explosion protection isnecessary (in the plant interior, at least a design that is free of ignition sources).

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Example illustration of a technical ventilation plant

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1 . . . Pressurised water for cleaning purposes

2 . . . Dough kneaders with stationary vacuum cleaners connected to them

3 . . . Mini-extractor over the weighing table, connected to the filter box system

4 . . . Filter box with self-cleaning filters, connected to waste air duct system that isinstalled in a fixed manner

5 . . . High-vacuum filter system

6 . . . Vacuum conduit with connection points

7 . . . Extractor over the work table, connected to the filter box system

8 . . . Variable suction extraction arm, can easily be applied to different dustsources


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7. Working practices for reducing flour dust

Through changes in working practices, flour dust development can be reducedconsiderably.

Applying the separating flour on the work surface by sprinkling, rubbingin or with a sieve, instead of by throwing flour (fine dust technique)

Gently sweeping the excess separating flour on the work surface into asuitable container, instead of casting it onto the flour

Using closed containers for storing flour

When using goods in sacks, adding a second pressure-relieving cut (onthe underside of the sack) when emptying

Furthermore, where technical production circumstances allow, the use ofsubstitutes as separating agents (oil, low-dust flours) and dusting bread tins witha sieve instead of a dust bag are recommended.


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8. Keeping to the limit value and carrying out

measurements

The following measures for adhering to the limit value must (based on BG/BIA1025 "Recommendations for monitoring work areas - flour dust in bakeries") be

checked:

A Dust protection lid on kneading machinesB Use of dust-avoiding working practicesC Use of substitutes as separating agentsD Use of dust-avoiding cleaning methodsE Use of automatic flour sprinklersF Spot vacuum extraction at the points where dust occursG Closed system in the case of flour delivery

If measure A is not fulfilled, it is recommended that measure F is fulfilled

It is recommended that at least one of the measures B or C is fulfilled in full

In addition to the measures A and/or B C, at least one of the measuresD - G should be realised in full, and another one should be largelyrealised.

If these recommendations are not followed, the limit value for flour dust may beexceeded. In this case, a measurement is necessary.

Depending on the degree to which the limit value is exceeded, a phased plan ofthe technical measures that are to be taken must be drawn up and implemented,taking account of the type of production and production quantities, as well as themachinery installed.

Following the successful implementation of the basic measures, usuallymeasurements are no longer necessary.

9. Protective equipment

For silo cleaning and for other heavily dust-laden activities, a fine dustmask, protection grade P2

Heat protection gloves in the case of work with ovens

Skin protection creams

Clothing for protection against the cold for work in refrigerated andfreezer rooms, as well as loading work in winter

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10. Work clothing

Shoes should cover the whole foot and have a heel restraint as well asslip-proof soles.

11. Cleaning

Where the building circumstances allow, floors should be cleaned bymachine.

Machine cleaning should be by vacuuming.

In the case of blowing, experience shows that the limit value for flour dust isexceeded. The high concentration is also bad for the machines, as the dust ispressed into the bearings and the lubrication of the bearings suffers.

Blowing should therefore not be carried out.

Dust explosion protection is necessary for the vacuum cleaners that areused (in the interior of the device, at least a design that is free of ignitionsources; on the outside, at least protection category IP 54 in accordancewith VE-EX 65/1981).

12. Sanitary and social facilities

A shower is required for those employed in the bakery.

Separate storage of baker's clothing and street clothing is likewisenecessary.

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13. Despatch and loading

The loading of goods should take place in separate rooms. If vehicles drive inreverse in these areas, the following principles must be observed:

No despatch work must be carried out in garages.

The precise definition of the work sequence and scope of work must beexplained in the approval project.

Sufficient ventilation, with cross-ventilation of the loading room.

14. Other burdens

In the baking industry, there are other hazards and stresses posed by:

Lifting and carrying

Aerosols in the mechanised use of oil as a separating agent

Hazardous substances that originate from dough preparation and thebaking process, such as carbon monoxide, sulphur dioxide, aldehydes andnitrosamines

Various types of micro-organisms

Stored food pests, such as grain weevils, rice flour beetles, stored foodmites

Pest control substances

With regard to the stresses posed by lifting and carrying, particular attention

must be paid to the ergonomic design of work equipment, such as e.g. liftingaids.

Exposure to other hazardous substances is essentially avoided through theventilation equipment that is necessary for avoiding dust, and through the vapourtraps or steam traps.

Particular attention must be paid to the stresses posed by aerosols, in particularin the case of automatic oiling equipment in combination with metal utensilcleaning machines.

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The burden posed by harmful micro-organisms (mould formation) is considerablyreduced by observing the hygiene regulations in accordance with the decree onfood hygiene, and by implementing the HACCP guidelines (Hazard AnalysisCritical Control Points).

When using pest control measures with toxic or very toxic working materials, the

requirements of TRGS 523 "Pest control" must be observed.

15. Legal foundations

Employee protection act (ASchG),Federal law gazette (BGBl.) No. 450/1994

General decree on employee protection (AAV),Federal law gazette (BGBl.) II No. 164/2000

Decree on work equipment (AM-VO),Federal law gazette (BGBl.) II No. 164/2000

Decree on health monitoring at the workplace (VG),Federal law gazette (BGBl.) II No. 27/1997

Decree on workplaces (AStV),Federal law gazette (BGBl.) II No. 368/1998

Decree on electrical protection 1995 (ESV),Federal law gazette (BGBl.) No. 706/1995 in conjunction with VE-EX 65/1981

Rules of technology: VDI 3673/1995

Decree on limit values 2001 (GKV 2001),

Federal law gazette (BGBl.) II No. 253/2001

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Adresse

Bundesministerium frWirtschaft und ArbeitZentral-Arbeitsinspektorat

Favoritenstrae 71040 Wien

Arbeitsinspektorat fr den1. AufsichtsbezirkFichtegasse 111010 Wien

Arbeitsinspektorat fr den2. AufsichtsbezirkTrunnerstrae 51020 Wien

Arbeitsinspektorat fr den3. AufsichtsbezirkFichtegasse 111010 Wien

Arbeitsinspektorat fr den

4. AufsichtsbezirkLeopoldsgasse 41020 Wien

Arbeitsinspektorat fr den5. AufsichtsbezirkBelvederegasse 321040 Wien

Arbeitsinspektorat fr den6. AufsichtsbezirkFichtegasse 11

1010 Wien

Arbeitsinspektorat Wr. NeustadtEngelbrechtgasse 82700 Wr. Neustadt

Arbeitsinspektorat St. PltenDaniel-Gran-Strae 103100 St. Plten

Arbeitsinspektorat LinzPillweinstrae 23

4021 Linz

Name, e-mail

Dr. Elsbeth HUBER (Leitung)[email protected]

Angelika [email protected]

Dipl.Ing. Josef [email protected]

Dr. Susanne [email protected]. Helmut [email protected]

Ernst [email protected]

Ing. Barbara [email protected]

Harald FRIMMEL

[email protected]

Adolf HEINRICHIng. Wilhelm PAMMERIng. Franz [email protected]

Ing. Wolfgang [email protected]

Ing. Hans MLLNERIng. Hermann [email protected]

Ing. Harald [email protected]

Walter HOFSTTTERIng. Wolfgang WIESAUER

[email protected]

Telefon, Fax

Tel.: (01) 711 00-6381

Tel.: (01) 711 00-2191

Tel.: (01) 711 00-2182Fax: (01) 711 00-2190

Tel.: (01) 714 0450Fax: (01) 714 0450-469

Tel.: (01) 212 7795Fax: (01) 212 7795-40

Tel.: (01) 714 0456Fax: (01) 714 0456-477

Tel.: (01) 214 9525

Fax: (01) 214 9525-20

Tel.: (01) 505 1795Fax: (01) 505 1795-22

Tel.: (01) 714 0462Fax: (01) 714 0462-475

Tel.: (02622) 23 172Fax: (02622) 23 172-14

Tel.: (02742) 363 225Fax: (02742) 363 225-411

Tel.: (0732) 603 880Fax: (0732) 603 890

Contacts for the bakers' campaign


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Adresse

Arbeitsinspektorat SalzburgAuerspergstrae 695027 Salzburg

Arbeitsinspektorat GrazLiebenauer Hauptstrae 2-68041 Graz

Arbeitsinspektorat LeobenErzherzog-Johann-Strae 68700 Leoben

Arbeitsinspektorat KrntenBurggasse 129010 Klagenfurt

Arbeitsinspektorat InnsbruckArzler Strae 43a6020 Innsbruck

Arbeitsinspektorat BregenzRheinstrae 576900 Bregenz

Arbeitsinspektorat EisenstadtFranz Schubert-Platz 27000 Eisenstadt

Arbeitsinspektorat KremsDonaulnde 493504 Krems-Stein

Arbeitsinspektorat VcklabruckFerdinand-ttl-Strae 124840 Vcklabruck

Arbeitsinspektorat WelsEdisonstrae 24600 Wels

Name, e-mail

Heribert JANSERErich [email protected]

Ing. Martin FELDBACHERDr. Friederike [email protected]

Ing. Harald CAVALAROtto [email protected]

Dr. Christa MOLDERINGSIng. Robert [email protected]

Dr. Gerhild WACHTERAndreas [email protected]

Franz-Josef [email protected]

Ing. Reinhard [email protected]

Ing. Heinz POLLERUSDipl.Ing. Franz [email protected]

Horst [email protected]

Gnther BUCHNERIng. Franz [email protected]

Telefon, Fax

Tel.: (0662) 886 686Fax: (0662) 886 686-428

Tel.: (0316) 48 2040Fax: (0316) 482 040-77

Tel.: (03842) 42 265Fax: (03842) 43 366

Tel.: (0463) 56 506Fax: (0463) 56 506-300

Tel.: (0512) 24 904Fax: (0512) 24 904-76

Tel.: (05574) 78 601Fax: (05574) 78 601-7

Tel.: (02682) 64 506Fax: (02682) 64 506-24

Tel.: (02732) 83 156Fax: (02732) 76 926

Tel.: (07672) 72 769Fax: (07672) 74 973

Tel.: (07242) 68 647Fax: (07242) 68 64 74

Contacts for the bakers' campaign


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Notes

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Notes

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Published by: Federal Ministry for Economics and Labour,labour law and labour inspection section, A 1040 Wien, Favoritenstrae 7

Participation: The Baker Project Team

A product from

No claim is made to completeness.

Your competent labour inspectorate

office will be pleased to advise you.

Further copies of this leaflet can be obtained free of charge from your competentlabour inspectorate office or from the Federal Ministry for Economics and

Labour, labour law and labour inspection section,

or as a download version fromwww.arbeitsinspektion.gv.at/AI/Service/Publikationen

Basics for a Bakery

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