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Evaluation of exposures and respiratory health at a coffee roasting and packaging facility [HHE-2016-0164-3341]
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2019/03/01
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Source: Morgantown, WV: U.S. Department of Health and Human Services, Public Health Service, Centers for Disease Control and Prevention, National Institute for Occupational Safety and Health, HHE 2016-0164-3341, 2019 Mar; :1-60
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Description:In May 2016, the National Institute for Occupational Safety and Health's (NIOSH) Health Hazard Evaluation Program received a request from management of a coffee roasting and packaging facility regarding concerns about exposures to and health effects from diacetyl and 2,3-pentanedione during coffee roasting, grinding, and flavoring. In July 2016, we conducted an industrial hygiene survey and ventilation assessment at the facility. The industrial hygiene survey consisted of collection of air samples and bulk samples of coffee for analysis of diacetyl, 2,3-pentanedione, and 2,3-hexanedione. Continuous monitoring instruments were used to monitor total volatile organic compounds, carbon monoxide, carbon dioxide, temperature, and relative humidity in specific areas and during tasks. We also measured levels of carbon monoxide in employees' exhaled breath and conducted a ventilation assessment. In August 2016, we conducted a medical evaluation of employees that consisted of a health questionnaire and breathing tests. In February 2017, we returned to conduct an industrial hygiene survey of the finished goods warehouse All personal full-shift samples collected during the industrial hygiene survey exceeded the NIOSH recommended exposure limit for diacetyl of 5.0 parts per billion, with a maximum concentration of 420.9 parts per billion. Thirty-six of the 37 full-shift samples exceeded the NIOSH recommended exposure limit for 2,3-pentanedione of 9.3 ppb, with a maximum of 275.9 parts per billion. We identified work tasks that resulted in higher air concentrations of diacetyl and 2,3-pentanedione than other tasks. Specifically, flavoring coffee, grinding roasted coffee beans, roasting coffee beans, packaging roasted coffee, and cleaning equipment were associated with higher diacetyl levels. We observed high instantaneous levels of diacetyl and 2,3-pentanedione during flavoring, grinding, and packaging. Air levels of carbon monoxide collected on employees with duties that included flavoring and grinding coffee exceeded the NIOSH ceiling limit of 200 parts per million. Carbon dioxide levels were low throughout most of the facility. The most commonly reported symptoms were nose and eye symptoms. Some employees reported these nose and eye symptoms were caused or aggravated by green bean coffee burlap bags, green bean and roasted coffee dust, smoke, flavorings, or roasting coffee Wheezing or whistling in the chest was the most commonly reported lower respiratory symptom. Some employees reported their lower respiratory symptoms were caused or aggravated by grinding and flavoring, heat, or stress. Six (6%) of 99 participants had abnormal spirometry. Eight (8%) participants had high exhaled nitric oxide, a marker of allergic airways inflammation. Employees who reported grinding or flavoring had higher odds of waking up with chest tightness and episodes of flu-like achiness or achy joints in the last 12 months, and had lower lung function parameters, although these were not statistically significant. One participant with abnormal spirometry and work-related respiratory symptoms was referred to a pulmonologist and subsequently received a clinical diagnosis of obliterative bronchiolitis associated with occupational exposure to flavorings In response to our evaluation, the company implemented engineering controls and made administrative changes to reduce employees' exposure to diacetyl and 2,3-pentanedione. The company installed additional general exhaust ventilation in administrative and production areas, local exhaust ventilation in production areas where sources of high exposures to diacetyl and 2,3-pentanedione were documented, and equipment to monitor pressure differentials between production and administrative spaces. The company also enclosed the grinding area. Personal protective equipment requirements were implemented and included powered air-purifying respirators for employees in the flavoring room and grinding area, and half-face respirators for employees in other areas of the facility until exposures could be reduced and verified by additional air sampling. The company also instituted a medical surveillance program that included repeating spirometry every six months to identify employees who might be developing work-related lung disease (e.g., asthma, flavoring related lung disease). Of 53 employees who underwent spirometry testing conducted by NIOSH in 2016 and the coffee facility s occupational health provider in 2017, six (11%) had 15% or more decrease in lung function between tests, which is more than expected because of aging. One employee had 15% or more decrease between two occupational health provider spirometry tests conducted in 2017. We recommend follow-up air sampling to confirm the effectiveness of engineering controls and consulting with a ventilation engineer to install additional engineering controls near point sources. Additional engineering controls might be designed to capture diacetyl and 2,3-pentanedione in specific locations at sources where elevated levels of diacetyl and 2,3-pentanedione were measured. We recommend the company continue to train employees about potential workplace hazards, and continue to administer the medical surveillance program.
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Pages in Document:71 pdf pages
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Contributor:Beaty, Mike;Boylstein, Randy;Burns, Dru A.;Edwards, Nicole;Fedan, Kathleen;Hatcher, Kyle;Humann, Michael;LeBouf, Ryan;McClelland, Tia;Mugford, Chris;Ranpara, Anand;Tift, Brian;
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NIOSHTIC Number:20055133
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NTIS Accession Number:PB2019-100535
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Citation:NIOSH [2018]. Health hazard evaluation report: Evaluation of exposures and;respiratory health at a coffee roasting and packaging facility. By Harvey RR,;Hawley B, Martin SB, Stanton ML. Morgantown, WV: U.S. Department of Health and;Human Services, Centers for Disease Control and Prevention, National Institute for;Occupational Safety and Health, NIOSH HHE Report No. 2016-0164-3341,;
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Federal Fiscal Year:2019
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Peer Reviewed:False
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Resource Number:HHE-2016-0164-3341
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[PDF-1.02 MB]
