Grejikebe Bakery Employee Safety Handbook

OVERVIEW 0

March 31st, 2013

Grejikebe Bakery

Employee Safety Handbook

March 31st, 2013

Developed by Hapapelo Creative:

Lorelei Betke

Harmeet Grewal

Paula Jiles

Peter Kehoe

Grejikebe Bakery Employee Safety Handbook

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

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

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

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

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

2.5 Fire .............................................................................................................................................. 15

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

2.6 Noise ........................................................................................................................................... 15

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

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

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

3.1 Introduction ................................................................................................................................ 20

3.2 Ingredients .................................................................................................................................. 20

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

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

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

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

4.1 Introduction ................................................................................................................................ 29


4.2 Ergonomics .................................................................................................................................. 29

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

4.3 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 Control Methods ................................................................................................................. 36

5.3 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

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: [email protected]

Standard mail: #124, 11222-40 Ave., Edmonton, AB, T4J 9K9


Chapter 1: Hazard Assessment and Control

HAZARD ASSESSMENT AND CONTROL 3


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.



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



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



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.

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.

Figure 1.3 Personal Protective Equipment



Key Safety Concepts:

Hazard assessments are required by law.

Hazard assessments outline specific risks and control measures.

Controls can be administrative, engineering, or PPE.


Chapter 2: Physical Hazards

PHYSICAL HAZARDS 9


2.1 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.

PHYSICAL HAZARDS 10


2.2 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 1 x 20L

Degreasing solution (for oil and grease spills) 2L

Mop 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

PHYSICAL HAZARDS 11


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.

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.


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.

Figure 2.2 Slip-Resistant Work Shoes

PHYSICAL HAZARDS 12


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.

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

Figure 2.3 Lock and Tag Assembly

PHYSICAL HAZARDS 13


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.

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 2.4 Mixer with safeguard

Figure 2.5 Emergency Stop Device

PHYSICAL HAZARDS 14


2.4 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.


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 closed-

toe shoes to minimize injuries caused by contact with hot

surfaces.

Figure 2.6 Hazard label

Figure 2.7 Heat-

Resistant Mitts

PHYSICAL HAZARDS 15


2.5 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.


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 cut-

off 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.

PHYSICAL HAZARDS 16



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.

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.

Figure 2.8 Hearing Protection

PHYSICAL HAZARDS 17


Table 2.2 First Aid Kit Contents

Quantity Item

10 antiseptic cleansing towelettes, individually packaged

25 sterile adhesive dressings, individually packaged 10 10 centimetres x 10 centimetres sterile gauze pads, individually packaged 2 10 centimetres x 10 centimetres sterile compress dressings, with ties,

individually packaged 2 15 centimetres x 15 centimetres sterile compress dressings, with ties,

individually packaged 2 conform gauze bandages — 75 millimetres wide 3 cotton triangular bandages 5 safety pins — assorted sizes 1 pair of scissors 1 pair of tweezers 1 25 millimetres x 4.5 metres of adhesive tape 1 crepe tension bandage — 75 millimetres wide 1 resuscitation barrier device with a one‐way valve 4 pairs of disposable surgical gloves 1 first aid instruction manual (condensed) 1 inventory of kit contents 1 waterproof waste bag

10 antiseptic cleansing towelettes, individually packaged

PHYSICAL HAZARDS 18



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.


Chapter 3: Occupational Exposure

OCCUPATIONAL EXPOSURE 20


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



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”).


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

Safety”).

Daily Cleaning

Dividers: cleaned with water and a towel/cloth.

Drains: cleaned with degreaser.

Floors: cleaned with floor cleaner and sanitizer.

Figure 3.1 High Efficiency Vacuum Cleaner



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

Figure 3.2 Employee wiping down

showcases with glass cleaner



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



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”).

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.


The following methods will be used in order to avoid exposure to harmful

chemicals:

Figure 3.4 Food handling gloves



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

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

Figure 3.5 Poison

Label



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




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.


Chapter 4: Other Hazards

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


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.

OTHER HAZARDS 30


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.

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 4.1 Proper stance when lifting

Figure 4.2 Proper positioning when loading a pan

OTHER HAZARDS 31


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.

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

Figure 4.3 Trays for easy transport of glassware

OTHER HAZARDS 32


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).

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

Figure 4.5 Stand for Ingredients

OTHER HAZARDS 33


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.


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).

OTHER HAZARDS 34



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.

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.


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

PERSONAL HYGIENE 37


equipment, all bakery personnel must carefully wash their hands (Figure 5.1 shows

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).

Figure 5.1 Proper Hand-washing Technique

PERSONAL HYGIENE 38


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.

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

Figure 5.2 Latex Gloves

PERSONAL HYGIENE 39


fundamental; expiration logs will be updated and posted to keep these procedures and

protocols current, comprehensive and in compliance with safety standards.


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.

PERSONAL HYGIENE 40


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 5.3 Cleaners

Figure 5.4 Quality Ingredients

PERSONAL HYGIENE 41



Wash hands frequently and thoroughly.

Maintain the sanitation of surfaces, utensils, appliances etc.

Maintain quality ingredients by employing proper storage and logging techniques.

Chapter 6: Emergency Procedures

EMERGENCY PROCEDURES 43


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 shut-

offs. 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




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.

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

Figure 6.2 Exit sign



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



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.




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.

APPENDIX 1 48


Appendix 1: Workplace Hazard Assessment Form

Wo

rk Area

Hazard

Cate

gory

(ph

ysical/chem

ical/b

iolo

gical/ ergo

no

mic/o

ther)

Iden

tified

Hazard

s

Probability

(1-4) Asse

ssmen

t

Frequency (1-

3)

Severity (0-5)

Trainin

g R

equ

ired

Co

ntro

ls in

Place

APPENDIX 2 49


Appendix 2: Grejikebe Bakery Evacuation Plan

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

GLOSSARY 51


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

http://en.wikipedia.org/wiki/Clothing

http://en.wikipedia.org/wiki/Helmets

http://en.wikipedia.org/wiki/Goggles

GLOSSARY 52


Sanitation The application of measures and means to protect public

health and prevent contact with hazardous materials.

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 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

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 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

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.

REFERENCES 55


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

Meeting Guide.

Grejikebe Bakery Employee Safety Handbook

Documents

Transcript of Grejikebe Bakery Employee Safety Handbook