gasses to slippery surface hazards

Risks Associated with Gases in the Brewery

Types of Gases Used

• Compressed air and oxygen cylinders are commonly utilized.

• Carbon dioxide (CO2) is produced during fermentation, used for:

  • Counter-pressuring

  • Maturation

  • Carbonation during kegging, bottling, and canning processes.

• Larger breweries may utilize:

  • Cylinders

  • Large external tanks

  • CO2 recovery systems.

• Nitrogen is selectively used, typically mixed with CO2 for various beer styles.

• Miscellaneous gas cylinders may be present for:

  • Maintenance (e.g., welding)

  • Laboratory activities.

• Ammonia handling is a significant risk especially in larger operations.

Health Risks from CO2

• Carbon dioxide is colorless and odorless, displacing oxygen in enclosed spaces.

• Accumulation of CO2 can lead to:

  • Dizziness

  • Loss of consciousness

  • Asphyxiation.

• Exposure levels:

  • 3-5%: moderate; symptoms such as dizziness, headache, shortness of breath.

  • 5-6%: rapid onset of fuzzy feeling; lightheadedness.

  • 6-7%: intoxication-like symptoms; loss of motor and cognitive functions.

  • Above 7%: risk of immediate unconsciousness leading to death without assistance.

• Pure nitrogen also poses asphyxiation risks:

  • Colorless and odorless, reducing oxygen in work environments.

Risks of Explosions and Fires

• Gases used in maintenance may trigger explosions or fires.

• High-pressure storage can become a source of injuries when rupture occurs.

Safety Measures and Preventive Actions

• In areas where CO2 may accumulate:

  • Implement active ventilation to disperse CO2.

  • Conduct regular leak checks.

  • Maintain awareness of personnel locations.

  • Clear instructions for emergency responses should be established:

    • Evacuate

    • Raise alarms

    • Seek fresh air.

• Personnel involved in emergencies must wear proper protective gear such as SCBA (self-contained breathing apparatus).

• Design considerations for craft breweries:

  • Ensure adequate ventilation and installation of reliable sensors that trigger alarms for unsafe CO2 levels.

  • Availability of protective and response equipment is vital.

  • Education and awareness for all personnel, including office staff, is crucial due to the potential impact of CO2 leaks.

  • Establish a preventive maintenance program for all systems related to CO2 handling, with regular audits planned.

Risks Involving Vessels

Potential Vessel Failures

• Cases of vessel ruptures in craft breweries due to:

  • High pressure when safety valves fail.

• All vessels are designed for specific working pressures, exceeding these can lead to:

  • Complete failure of the tank

  • Damage to adjacent tanks and potential injuries.

• Keg explosions: particularly concerning with plastic kegs.

• Tanks can also collapse due to vacuum conditions arising from:

  • Sudden temperature drops

  • Improper use of cleaners.

Preventive Measures for Vessel Risks

• Develop safe operating procedures that are well-documented and integrated into training programs.

• Regularly verify the functionality of safety valves through preventive maintenance.

• Routine inspection and cleaning of pressure/vacuum release valves, especially after fermentation:

  • Cleaning can prevent blockages from residues that compromise functionality.

• Modern systems can utilize analog devices to prevent pressure build-up or escalating vacuum conditions.

Slippery Surfaces and Related Hazards

Causes and Consequences

• Slippery surfaces often result from:

  • Poor design

  • Poor housekeeping.

• Common areas affected include:

  • Brewhouse

  • Filtration areas

  • Packaging zones.

• Slippery surfaces can result in:

  • Injuries such as fractures

  • Lost time accidents

  • Production losses.

• In warehouses, conditions can affect forklift operations, making control difficult.

• Poor housekeeping leads to increased microbial growth, resulting in:

  • Product contamination

  • Higher bacteria/wild yeast incidence in packaged products.