Basic requirements for

bakeries

Information from the labour inspectorate

A R B E IT S

IN S P E K T IO N

Table of contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1. 2. 3. 4. 5. Lighting, safety lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Electrical plant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 General ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Floors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 The flour silo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5.1 Primary explosion protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 5.2 Secondary explosion protection. . . . . . . . . . . . . . . . . . . . . . . . . . . 8 5.3 Tertiary (constructional) explosion protection . . . . . . . . . . . . . . . . 9 6. Technical measures for reducing flour dust . . . . . . . . . . . . . . . . . 10 6.1 Mixing space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 6.2 Work equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 6.3 Technical ventilation plant for reducing hazardous substances. . 12 7. 8. 9. 11. Working practices for reducing flour dust . . . . . . . . . . . . . . . . . . . 14 Keeping to the limit value and carrying out measurements . . . . . 15 Protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

10. Work clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 12. Sanitary and social facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 13. Despatch and loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 14. Other burdens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 15. Legal foundations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Contacts for the bakers' campaign . . . . . . . . . . . . . . . . . . . . . . . . 19

Introduction
This leaflet represents a working document within the framework of the "Campaign for health and safety protection in bakeries". This leaflet is intended to provide ideas for measures to reduce flour dust, and to provide information and advice about possible measures. At the same time, it represents an aid when assessing evaluation measures, and thus also forms a guide for the production of the health and safety protection document. The recommendations (marked in yellow as minimum standards) which should be implemented by all Austrian bakery businesses by the end of 2005 have been laid down depending on the size of the business and the production quantities, as well as taking into account the prevailing conditions of workplaces that have evolved over time, and work equipment that is already present. A distinction has been made here between firms with an average annual flour consumption of less than 100 tonnes (small and very small businesses), and firms with a flour consumption of more than 100 tonnes. Account was also taken of whether the firm was an old, existing firm that was approved by the trade inspectorate authorities, whether it involved building conversions or additions that had been carried out, whether new machinery had been acquired, or the business had been set up completely new. As far as possible, in the structure of the leaflet we have taken into account the production sequence in bakeries: General outline conditions relating to the workplace, such as lighting, escape route lighting etc., Requirements made of flour silos, The supply, mixing and working of dough by means of machines - technical measures to be taken, Changing working practices, Cleaning, Ventilation equipment for reducing flour dust, and Measuring the dust limit value.

The measures that are described and recommended in the leaflet, and are to some extent obligatory, are based on Experience from the EU project "Let's bake it", Experience from the implementation of this EU project in Austria, Statutory minimum standards of employee protection, and International and European standards and norms. All the measures were successfully trialled within the framework of the Upper Austrian project, including the provincial guild of bakers, the vocational school, representatives of bakery firms, machine manufacturers, the accident insurance agency and scientific institutions. The leaflet is aimed at bakers, project workers, qualified safety staff, manual workers, such as e.g. electricians, silo manufacturers.

The colour coding used in the leaflet is intended to help make it easier to find the required minimum standard that is applicable to the concrete situation in each case. Those portions of text that are not colour-coded are general recommendations and measures.
Minimum standard for all bakery businesses Businesses with an average annual consumption of more than 100 tonnes of flour Newly-established business, or additional building or building conversion for a bakery business, purchase of new machines, setting up of a flour silo plant, and an average annual consumption of less than 100 tonnes of flour *) Newly-established business, or additional building or building conversion for a bakery business, purchase of new machines, setting up of a flour silo plant, and an average annual consumption of more than 100 tonnes of flour *)
*)

The increased requirements apply only to the new machines and to those areas that are newly built or converted.

1. Lighting, safety lighting

1.1 Lighting
For existing businesses without spatial separation of the bakery and the pastry/cake shop, the minimum requirement is 200 Lux. If the mixing space, baking room and the workplace for decorating baked goods are separate, the following lighting strengths are required: Mixing space at least 300 Lux Baking room at least 200 Lux Work area for decoration at least 500 Lux. If only the bakery and the pastry/cake shop are spatially separated: at least 300 Lux for the bakery at least 500 Lux for the pastry/cake department with decorating workplaces. If there is no spatial separation of the individual work areas: at least 300 Lux for the whole bakery. For the lighting installations in the bakery, the planning factor of 1.43 in the sense of point 5.7. NORM O 1040 is to be applied, since there is increased contamination through flour dust. Annual cleaning of the lighting installations is required.

1.2 Safety lighting

Safety lighting is required for the bakery and the escape routes. Storage areas and social areas should be equipped with escape route orientation lighting. Note: VE-EN 2, VE-EN 1838 and TRVB 102 contain corresponding implementing regulations.

2. Electrical plant
The electrical plant must generally conform to the implementation for "Installations in Industry and Trade" in accordance with ESV and VE-EN 1. In the bakery and washing-up area, the electrical equipment must conform to protection category IP 54 in accordance with VE-EN 1. In new plants, all socket circuits for hand-held machines must be equipped with additional protection in the form of an FI safety switch with a tripping current of 30 mA. There must be a certificate in accordance with VE-EN 1 21 or (from October 2000) test findings relating to the regular recurring check on the electrical plant in accordance with ESV 1995, relating to the proper execution of the electrical plant.

3. General ventilation
Generally, no mechanical ventilation is necessary in the bakery in addition to the measures described under "Technical measures for reducing flour dust"; and in relation to the reduction of dust exposure, it can even be counter-productive. For the ventilation of the other areas, the minimum requirements of the decree on workplaces - AStV - are sufficient. With regard to the necessary ventilation measures for reducing flour dust and vapours, see point 6.3.

4. Floors
In accordance with the guideline issued by the employers' liability insurance association (BGR) 181 (code of practice for floors in work rooms with a danger of slipping), the floor coverings (in the case of flat floors) must have the following evaluation group for slip hazard: all production areas such as bakery, pastry/cake shop etc. and washingup area in very small businesses (without mechanical cleaning), at least R 10 all other businesses, at least R 11 in despatch, store room and side rooms, at least R 9.

5. The flour silo

Most flour/air mixtures can form an atmosphere capable of explosion. With regard to explosion protection, flour silos must be set up in accordance with the stipulations of the decree on explosive atmospheres (VEXAT). In most cases, a permit from the trade inspectorate authority is required. Justified deviations from the explosion protection measures below, derived from statutory regulations, can be envisaged and exceptions can be granted. The local labour inspectorate office can provide information about conditions for changes and exemptions.

5.1 Primary explosion protection

(Aim: Preventing the formation of explosive atmospheres) In the case of cleaning, maintenance and repair in the interior of the silo, care must be taken to ensure that any raising of dust is kept low. For flour silos with a filter cloth closure, in any case a fill level meter for monitoring against over-filling must be provided.

5.2 Secondary explosion protection

(Aim: Avoiding the ignition of explosive atmospheres) The interior of the silo and conveyor pipes are to be classed as Zone 20 according to VEXAT. For flour silos with filter cloth closure, the rooms in which they are installed must be assessed on the basis of the type of silo as Zone 22 according to VEXAT. For this reason, the electrical equipment in the installation room must conform to at least group II category 3 D according to ExSV 1996 (at least protection category IP 54). A functional equipotential bonding via the earthing of the silo and conveyor pipes must be certified by means of a test record (specialist firm). For equipment and protective systems, there must be certification from the distributors corresponding to the respective zones, in accordance with ExSV 1996.

5.3 Tertiary (constructional) explosion protection

(Aim: Weakening the effects of an explosion) Possible constructional explosion protection measures include Constructional explosion protection in the case of flour silos
- Blast pressure relief via an adequately dimensioned pipe conduit to the outdoors, in an area that is not hazardous for workers, explosion suppression or explosion-proof method of construction - If several silos are connected to one another, technical explosion de-coupling is necessary - It is possible to set up these flour silos in work rooms - The silos must withstand blast pressure or reduced blast pressure (proof: silo manufacturer)

Flour silo with filter cloth closure

or alternatively: Constructional explosion protection in the installation room (bunker) Flour silos with filter cloth closure without constructional explosion protection set up in an installation room.
- The installation room must be separated from work rooms - For the calculation of the pressure relief, the entire volume of the installation room including the silo volumes with filter cloth closure are decisive, since there is no technical explosion de-coupling of the individual silos - Pressure relief of the installation room in accordance with VDI 3673 sheet 1, wherein the shock resistance of the boundaries of the room must be ensured (proof for pressure relief area and shock resistance through accredited offices, civil engineers)

Exemption from constructional explosion protection Exemptions from constructional explosion protection for flour silo plants can be granted only if the same level of protection can be achieved through suitable measures. This means that technically and organisationally safe avoidance of effective ignition sources must be ensured. For concrete assessment, we recommend that you contact the local labour inspectorate office.

6. Technical measures for reducing flour dust

6.1 Mixing space
Closed system in flour delivery and in dough production. The transportation air of the flour silo plant must not be emitted into the work room via the cyclone situated in the work room.

Closed flour delivery with lid and vacuum extraction

Regular cleaning of the dust filter in the case of the cyclone and exclusive use of original filters (must be at least filter class L). Sufficiently long cloth or fabric hose for the flour delivery, and maintenance of it.

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6.2. Work equipment

Dust protection lid on the kneading machines instead of grilles (if the diameter of the kneader is larger than 510 mm)

Open flour delivery, rotary arm kneading machine with grille cover, workplace-related dust extraction carried out flexibly, can be used for the flour delivery and the two kneading machines.

The use of automatic flour sprinklers for the individual machines; set them correctly and carry out regular maintenance. The exhaust air from the motors of the bakery machines must not be led over the flour containers.

Poor - the exhaust air from the motor is led directly over the flour container

Good - automatic de-dusting reduces dust exposure

Access guards in roll or bread plants, through closed components or corresponding grilles (closed coverings or cladding are preferable to grilles, on account of the better protection they offer against dust).

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6.3. Technical ventilation plant for reducing hazardous substances

Essentially, the technical ventilation measures are restricted to dust extraction and vapour traps. With regard to the requirements of dust extraction equipment, we also refer to point 8, "Observing the maximum workplace concentration value and carrying out measurements". Depending on the quantity (volume flow) of the extracted air, mechanical provision of incoming air is necessary. What is important is that all ventilation components are based on an overall concept. Minimum requirements made of the ventilation plant: Vapour traps over bakery ovens and fat-frying devices In the case of businesses that are to be newly established, within the project one must take account of the possibility of vacuum extraction at the work surface and at the mixing space, designed similar to flexible "welding smoke extraction". *)
*)

(But also applies to existing businesses, regardless of when they were set up, as well as to businesses regardless of the annual flour consumption if, despite changed working practices and technical measures taken, the limit value for flour dust in the air that is breathed is noticeably exceeded!) Mechanical supply of incoming air, where the extracted air volume exceeds twice the room content per hour or, with favourable arrangement of the incoming air openings, a maximum of four times the room content. Overall concept that takes account of all existing and planned ventilation components, such as e.g. - vapour traps over the bakery ovens and fat-frying devices - spot flour dust extraction in the case of bread tin dusting and in the case of individual processing machines that produce large amounts of dust - vapour traps over the bakery ovens and fat-frying devices - mechanical supply of incoming air - mechanical extraction of general waste air (if necessary) - free flowing ventilation openings capable of being regulated - free flowing ventilation openings not capable of being regulated, due to production circumstances (gates at despatch)

For the flour dust extraction plant, corresponding dust explosion protection is necessary (in the plant interior, at least a design that is free of ignition sources).

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Example illustration of a technical ventilation plant

1 2 3 4 5 6 7 8

. . . Pressurised water for cleaning purposes . . . Dough kneaders with stationary vacuum cleaners connected to them . . . Mini-extractor over the weighing table, connected to the filter box system . . . Filter box with self-cleaning filters, connected to waste air duct system that is installed in a fixed manner . . . High-vacuum filter system . . . Vacuum conduit with connection points . . . Extractor over the work table, connected to the filter box system . . . Variable suction extraction arm, can easily be applied to different dust sources

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7. Working practices for reducing flour dust

Through changes in working practices, flour dust development can be reduced considerably. Applying the separating flour on the work surface by sprinkling, rubbing in or with a sieve, instead of by throwing flour (fine dust technique)

Gently sweeping the excess separating flour on the work surface into a suitable container, instead of casting it onto the flour Using closed containers for storing flour When using goods in sacks, adding a second pressure-relieving cut (on the underside of the sack) when emptying

Furthermore, where technical production circumstances allow, the use of substitutes as separating agents (oil, low-dust flours) and dusting bread tins with a sieve instead of a dust bag are recommended.

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8. Keeping to the limit value and carrying out measurements

The following measures for adhering to the limit value must (based on BG/BIA 1025 "Recommendations for monitoring work areas - flour dust in bakeries") be checked: A B C D E F G Dust protection lid on kneading machines Use of dust-avoiding working practices Use of substitutes as separating agents Use of dust-avoiding cleaning methods Use of automatic flour sprinklers Spot vacuum extraction at the points where dust occurs Closed system in the case of flour delivery

If measure A is not fulfilled, it is recommended that measure F is fulfilled It is recommended that at least one of the measures B or C is fulfilled in full In addition to the measures A and/or B C, at least one of the measures D - G should be realised in full, and another one should be largely realised. If these recommendations are not followed, the limit value for flour dust may be exceeded. In this case, a measurement is necessary. Depending on the degree to which the limit value is exceeded, a phased plan of the technical measures that are to be taken must be drawn up and implemented, taking account of the type of production and production quantities, as well as the machinery installed. Following the successful implementation of the basic measures, usually measurements are no longer necessary.

9. Protective equipment
For silo cleaning and for other heavily dust-laden activities, a fine dust mask, protection grade P2 Heat protection gloves in the case of work with ovens Skin protection creams Clothing for protection against the cold for work in refrigerated and freezer rooms, as well as loading work in winter

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10. Work clothing

Shoes should cover the whole foot and have a heel restraint as well as slip-proof soles.

11. Cleaning
Where the building circumstances allow, floors should be cleaned by machine. Machine cleaning should be by vacuuming.

In the case of blowing, experience shows that the limit value for flour dust is exceeded. The high concentration is also bad for the machines, as the dust is pressed into the bearings and the lubrication of the bearings suffers. Blowing should therefore not be carried out. Dust explosion protection is necessary for the vacuum cleaners that are used (in the interior of the device, at least a design that is free of ignition sources; on the outside, at least protection category IP 54 in accordance with VE-EX 65/1981).

12. Sanitary and social facilities

A shower is required for those employed in the bakery. Separate storage of baker's clothing and street clothing is likewise necessary.

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13. Despatch and loading

The loading of goods should take place in separate rooms. If vehicles drive in reverse in these areas, the following principles must be observed: No despatch work must be carried out in garages. The precise definition of the work sequence and scope of work must be explained in the approval project. Sufficient ventilation, with cross-ventilation of the loading room.

14. Other burdens

In the baking industry, there are other hazards and stresses posed by: Lifting and carrying Aerosols in the mechanised use of oil as a separating agent Hazardous substances that originate from dough preparation and the baking process, such as carbon monoxide, sulphur dioxide, aldehydes and nitrosamines Various types of micro-organisms Stored food pests, such as grain weevils, rice flour beetles, stored food mites Pest control substances

With regard to the stresses posed by lifting and carrying, particular attention must be paid to the ergonomic design of work equipment, such as e.g. lifting aids. Exposure to other hazardous substances is essentially avoided through the ventilation equipment that is necessary for avoiding dust, and through the vapour traps or steam traps. Particular attention must be paid to the stresses posed by aerosols, in particular in the case of automatic oiling equipment in combination with metal utensil cleaning machines.

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The burden posed by harmful micro-organisms (mould formation) is considerably reduced by observing the hygiene regulations in accordance with the decree on food hygiene, and by implementing the HACCP guidelines (Hazard Analysis Critical Control Points). When using pest control measures with toxic or very toxic working materials, the requirements of TRGS 523 "Pest control" must be observed.

15. Legal foundations

Employee protection act (ASchG), Federal law gazette (BGBl.) No. 450/1994 General decree on employee protection (AAV), Federal law gazette (BGBl.) II No. 164/2000 Decree on work equipment (AM-VO), Federal law gazette (BGBl.) II No. 164/2000 Decree on health monitoring at the workplace (VG), Federal law gazette (BGBl.) II No. 27/1997 Decree on workplaces (AStV), Federal law gazette (BGBl.) II No. 368/1998 Decree on electrical protection 1995 (ESV), Federal law gazette (BGBl.) No. 706/1995 in conjunction with VE-EX 65/1981 Rules of technology: VDI 3673/1995 Decree on limit values 2001 (GKV 2001), Federal law gazette (BGBl.) II No. 253/2001

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Contacts for the bakers' campaign

Adresse Bundesministerium fr Wirtschaft und Arbeit Zentral-Arbeitsinspektorat Favoritenstrae 7 1040 Wien Name, e-mail Dr. Elsbeth HUBER (Leitung) elsbeth.huber@bmwa.gv.at Angelika ZAPFEL angelika.zapfel@bmwa.gv.at Dipl.Ing. Josef KERSCHHAGL josef.kerschhagl@bmwa.gv.at Arbeitsinspektorat fr den 1. Aufsichtsbezirk Fichtegasse 11 1010 Wien Arbeitsinspektorat fr den 2. Aufsichtsbezirk Trunnerstrae 5 1020 Wien Arbeitsinspektorat fr den 3. Aufsichtsbezirk Fichtegasse 11 1010 Wien Arbeitsinspektorat fr den 4. Aufsichtsbezirk Leopoldsgasse 4 1020 Wien Arbeitsinspektorat fr den 5. Aufsichtsbezirk Belvederegasse 32 1040 Wien Arbeitsinspektorat fr den 6. Aufsichtsbezirk Fichtegasse 11 1010 Wien Arbeitsinspektorat Wr. Neustadt Engelbrechtgasse 8 2700 Wr. Neustadt Arbeitsinspektorat St. Plten Daniel-Gran-Strae 10 3100 St. Plten Arbeitsinspektorat Linz Pillweinstrae 23 4021 Linz Dr. Susanne PINSGER post.ai1.arzt@arbeitsinspektion.gv.at Dipl.Ing. Helmut SCHORN post.ai1@arbeitsinspektion.gv.at Ernst BADER post.ai2@arbeitsinspektion.gv.at Telefon, Fax Tel.: (01) 711 00-6381 Tel.: (01) 711 00-2191 Tel.: (01) 711 00-2182 Fax: (01) 711 00-2190 Tel.: (01) 714 0450 Fax: (01) 714 0450-469

Tel.: (01) 212 7795 Fax: (01) 212 7795-40

Ing. Barbara THIERER post.ai3@arbeitsinspektion.gv.at

Tel.: (01) 714 0456 Fax: (01) 714 0456-477

Harald FRIMMEL post.ai4@arbeitsinspektion.gv.at

Tel.: (01) 214 9525 Fax: (01) 214 9525-20

Adolf HEINRICH Ing. Wilhelm PAMMER Ing. Franz STROBL post.ai5@arbeitsinspektion.gv.at Ing. Wolfgang ZEILER post.ai6@arbeitsinspektion.gv.at

Tel.: (01) 505 1795 Fax: (01) 505 1795-22

Tel.: (01) 714 0462 Fax: (01) 714 0462-475

Ing. Hans MLLNER Ing. Hermann GREMEL post.ai7@arbeitsinspektion.gv.at Ing. Harald SIMHANDL post.ai8@arbeitsinspektion.gv.at Walter HOFSTTTER Ing. Wolfgang WIESAUER post.ai9@arbeitsinspektion.gv.at

Tel.: (02622) 23 172 Fax: (02622) 23 172-14 Tel.: (02742) 363 225 Fax: (02742) 363 225-411 Tel.: (0732) 603 880 Fax: (0732) 603 890

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Contacts for the bakers' campaign

Adresse Arbeitsinspektorat Salzburg Auerspergstrae 69 5027 Salzburg Arbeitsinspektorat Graz Liebenauer Hauptstrae 2-6 8041 Graz Arbeitsinspektorat Leoben Erzherzog-Johann-Strae 6 8700 Leoben Arbeitsinspektorat Krnten Burggasse 12 9010 Klagenfurt Arbeitsinspektorat Innsbruck Arzler Strae 43a 6020 Innsbruck Arbeitsinspektorat Bregenz Rheinstrae 57 6900 Bregenz Arbeitsinspektorat Eisenstadt Franz Schubert-Platz 2 7000 Eisenstadt Arbeitsinspektorat Krems Donaulnde 49 3504 Krems-Stein Arbeitsinspektorat Vcklabruck Ferdinand-ttl-Strae 12 4840 Vcklabruck Arbeitsinspektorat Wels Edisonstrae 2 4600 Wels Name, e-mail Heribert JANSER Erich STADLER post.ai10@arbeitsinspektion.gv.at Ing. Martin FELDBACHER
Dr. Friederike SACHORNIG-TUMLIRZ

Telefon, Fax Tel.: (0662) 886 686 Fax: (0662) 886 686-428 Tel.: (0316) 48 2040 Fax: (0316) 482 040-77 Tel.: (03842) 42 265 Fax: (03842) 43 366 Tel.: (0463) 56 506 Fax: (0463) 56 506-300 Tel.: (0512) 24 904 Fax: (0512) 24 904-76 Tel.: (05574) 78 601 Fax: (05574) 78 601-7 Tel.: (02682) 64 506 Fax: (02682) 64 506-24 Tel.: (02732) 83 156 Fax: (02732) 76 926 Tel.: (07672) 72 769 Fax: (07672) 74 973 Tel.: (07242) 68 647 Fax: (07242) 68 64 74

post.ai11@arbeitsinspektion.gv.at Ing. Harald CAVALAR Otto EBNER post.ai12@arbeitsinspektion.gv.at Dr. Christa MOLDERINGS Ing. Robert DEMARLE post.ai13@arbeitsinspektion.gv.at Dr. Gerhild WACHTER Andreas SCHMIEDHOFER post.ai14@arbeitsinspektion.gv.at Franz-Josef NETZER post.ai15@arbeitsinspektion.gv.at Ing. Reinhard STEINER post.ai16@arbeitsinspektion.gv.at Ing. Heinz POLLERUS Dipl.Ing. Franz JGER post.ai17@arbeitsinspektion.gv.at Horst WOLFSGRUBER post.ai18@arbeitsinspektion.gv.at Gnther BUCHNER Ing. Franz WOLF post.ai19@arbeitsinspektion.gv.at

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Notes

21

Notes

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Further copies of this leaflet can be obtained free of charge from your competent labour inspectorate office or from the Federal Ministry for Economics and Labour, labour law and labour inspection section, or as a download version from www.arbeitsinspektion.gv.at/AI/Service/Publikationen

Your competent labour inspectorate office will be pleased to advise you.

Published by: Federal Ministry for Economics and Labour, labour law and labour inspection section, A 1040 Wien, Favoritenstrae 7 Participation: The Baker Project Team A product from No claim is made to completeness. Version: January 2005