The food and beverage industry can be highly volatile and to stay on top you must stay one step ahead of the competition. Expanding your food and beverage manufacturing facility can help you produce and process more which translates into increased sales and a larger market share. Besides ensuring the construction meets local building codes and suits your needs, you also have to make sure that the installation of OSHA-compliant fall protection equipment is part of your overall expansion plans. This will ensure a safe workplace and maintain your company’s compliance with OSHA fall protection rules.
Your Fall Protection Obligations Under OSHA
According to OSHA 1910.28(b)(1)(i) “The employer must ensure that each employee on a walking-working surface with an unprotected side or edge that is 4 feet (1.2 m) or more above a lower level is protected from falling by one or more forms of fall protection.”
OSHA does not tell employers which type of equipment they must use to protect workers from falls. You may choose a modular guardrail system and a mezzanine gate to protect workers on elevated work surfaces. Or you may recognize that employees face fall hazards at the loading dock, so installing loading dock safety gates is the right solution. Regardless of the type of fall protection you use, it must meet the guidelines in OSHA 1910.29.
The Need for Fall Protection Equipment in Food and Beverage Facilities
People who work in food and beverage processing and packaging facilities face a host of safety hazards and challenges that don’t necessarily exist in other industries. It’s up to you to eliminate as many hazards as you can and to protect workers from those you can’t. Keeping workers safe from falls means paying close attention to the fall hazards and conditions that exist in your facility and adjusting accordingly.
Here are some of the most common fall hazards / areas in a Food & Beverage Processing Facility:
Spills and Overflows
Oil, grease, water, powders, and a variety of other ingredients that are used in food and beverage manufacturing can cause slippery surfaces. Many times, the substance is clear, making it particularly difficult to see or avoid.
Freezing Temperatures
In some areas of a food and beverage facility, there is a need for refrigeration or freezing. When water or other liquids spill, they can freeze to the floor making it slippery and dangerous. Oftentimes, this type of spill is hard to spot and difficult to avoid.
Smooth, Slippery Surfaces
To protect against contamination, stainless steel is a popular material for surfaces throughout food and beverage manufacturing facilities. When this material is coated in a slippery substance, it’s a serious fall hazard for workers.
Elevated Working Surfaces
Whenever employees work on an elevated surface that’s more than 4 feet above another level, you must keep them safe with a modular guardrail system or equivalent around the exposed edge. Guardrails are extremely versatile and can be used for fall protection as well as falling object protection on elevated surfaces.
Access to Elevated Surfaces
It’s essential for there to be an opening in the guardrails for workers to access a mezzanine or other elevated surface. Once workers are in the area, the access point needs to be closed off to keep everyone safe. A self-closing mezzanine gate will protect workers as they enter and exit the mezzanine.
Stairways and Fixed Ladders
Accessing the mezzanine level requires workers to climb a stairway or to use a fixed ladder. Stairways have to be equipped with handrail that meets the requirements set forth in OSHA 1910.29(f). Employees must be instructed on the proper use of the handrail which is one hand on the rail at all times to minimize risks. Fixed ladders must be equipped with a ladder safety system to be OSHA compliant.
Dangerous Machinery and Equipment
Food and beverage processing and packaging equipment can be dangerous for employees in several ways. Slip and fall accidents can happen due to oily or wet conditions around the machines. Getting too close to some equipment can result in injuries or damage to the machine. Protect processing and packaging equipment with a modular guardrail system around its perimeter along with a self-closing safety gate.
Moist Conditions and Puddled Moisture
The environment inside a food and beverage manufacturing facility can often be humid, wet, and slippery. Puddles of water or other slippery liquids can accumulate. When these conditions exist, it puts workers at greater risk of falls. Good housekeeping is essential. Keep surfaces clean and dry as much as possible. When cleanup isn’t possible incorporate personal fall protection devices and non-slip footwear to mitigate fall hazards.
Busy Loading Docks
Expanding your food and beverage manufacturing facility will likely result in needing additional loading docks to keep up with increased production. Installing warning lights and alarms and painting edges with high-contrast paint help warn loading dock workers of fall hazards. Loading dock safety gates provide a barrier that keeps workers from getting too close to the edge as they carry out their duties.
What Fall Protection Equipment Is Appropriate for Your Facility?
As mentioned previously, OSHA doesn’t specify that you have to use any particular type of fall protection equipment. It’s really up to you and your safety team to determine where the fall hazards will be in your facility and how best to eliminate or mitigate them. Consider the most common forms of fall protection and discuss each with your safety specialist before making a final choice:
- Modular Guardrail System – This is a versatile form of fall protection that can be used in nearly any setting. A modular guardrail system has to meet the criteria in OSHA 1910.29 (b) to be considered OSHA-compliant.
- Self-Closing Safety Gates – When there is an opening in the guardrail system on a stairwell, by a ladder entrance, or on an elevated platform, a self-closing safety gate or mezzanine gate is essential to protect workers from falls. And loading dock safety gates are vital to protect workers when loading and unloading at the dock.
- Handrails and Ladder Safety – If workers have to climb stairs to get to an upper level, a handrail that meets OSHA 1910.29(f) guidelines must be installed. Ladder safety systems are required for all fixed ladders 24 feet or more above the lower level.
- Personal Fall Protection – In some cases, the use of guardrails and gates are inadequate or not feasible. When this happens, personal fall protection equipment such as a harness, lanyard, and lifeline may be incorporated to protect workers from falls.
Make Fall Protection Part of Your Expansion Plan
There are endless decisions that need to be made when planning out the expansion of your food and beverage facility. Do you build vertically, horizontally, or both? If you’re adding vertical space, are your employees going to be traversing elevated catwalks and working on mezzanines? Will dangerous equipment be operating below? Would loading dock safety gates keep workers safer during busy seasons? Contact us to talk to one of our qualified safety experts to learn how every aspect of your expansion affects the future safety and well-being of your workers.
