OSHA convened small business employers regarding proposed rules on exposure to diacetyl, a potentially harmful substance found in food flavorings.  The goal is for the employers to review the proposal before OSHA publishes the rules.

Prior to this convening, there have already been cases of workers’ deaths due to respiratory problems reportedly caused by prolonged exposure to diacetyl.

Why these deaths?  If diacetyl exposure causes death, does ingestion of it also cause the same?

The chemical diacetyl is responsible for the butter-like flavor in several food products.  It is found in dairy products, coffee, brandy and rum.  Artificially, it is used as flavoring in popcorns, baked goods, cake mixes and even in pet foods.  Yes, frequent and repeated inhaling of its vapors in high concentrations may lead to lung problems; however, ingestion does not since it is classified as “Generally Recognized as Safe” (GRAS) for consumption by the Food and Drug Administration.

Aside from lung problems, diacetyl purportedly causes skin, eye, nasal and upper respiratory burns too.

For workers assigned in flavor-making plants or in facilities that coat food products like popcorns with flavorings that contain diacetyl, extreme caution is therefore important.  Here are exposure control methods that must be followed.

1. Know your health condition.  If you have sensitive lungs, ask your employer if you can be assigned to tasks that will limit or not expose you to diacetyl vapors.
2. Be properly trained – in detecting the release of diacetyl, its physical and health hazards, and the control measures necessary such as work practices, emergency procedures, and the use and maintenance of PPE.  Training should be done as often as necessary.
3. Read the Material Safety Data Sheets or MSDS of diacetyl before you use them.
4. Take note that diacetyl is flammable so keep it away from fire or any source of spark.
5. Wash your hands thoroughly with soap and warm water after working with diacetyl.
6. Clean up spills and leaks immediately.
7. Ensure safety when cleaning and maintaining tanks and other containers.  Make sure that the cleaning areas are isolated.  Rinse tanks and containers with cold water first; do not use compressed air in cleaning powdered butter-flavoring chemicals.  If you need to enter tanks and containers, make sure that you comply with confined space entry requirements.
8. Implement engineering controls:

• Close or cover mixing tanks.  Provide local exhaust ventilation from the mixing and holding tank to the outside of the facility.  Make sure that you comply with environmental regulations when doing this.
• For transferring purposes, utilize pumping system instead of manual transfer to minimize exposure.  Provide a separate room or enclose a room used for butter flavored popcorns.  Make sure that there is negative air pressure in the mixing room in relation to the rest of the facility.
• Use the appropriate PPE.  If you operate or work inside the mixing room, make sure that you use the proper respirator.  In choosing the proper respirator, consider your operations, the working condition, and other factors.  For microwave popcorn facilities, a NIOSH-certified air-purifying respirator with organic vapor cartridges may be used.  In hot mixing rooms, another kind of respirator called powered air-purifying respirator or PAPRs may be considered.
• Aside from the respirator, you may also need to wear eye protection as the vapors may also irritate your eyes; gloves and apron made of butyl rubber to prevent skin irritation; and chemical-resistant gloves or sleeves to avoid dermal injury.
• Keep your workplace well-ventilated.  When using ventilation, make sure that the other areas of the facility do not get contaminated.

These are important control methods from OSHA that you must follow if you want to have a safe working environment.  Be fit, healthy and safe at all times!