Brewers of all sizes should uphold the value of safety alongside their edgy brands and creative and carefully crafted beers and other beverages. It’s the responsibility of all brewery employees to assess hazards, learn how to control or eliminate them, and to document and train each other on the safest ways to perform tasks. It’s not just about government regulation, but it is also about making your brewery the best brewery possible—for your beer, your staff, and your visitors.

Breweries face hazards that can be divided into physical, chemical, biological, ergonomic, and psychosocial hazards. Learning to address these aspects of safety to ensure a safe product and working environment is paramount. From physical trauma to chemical irritations, biological hazards to psychosocial hazards, Brewery Safety explores in-depth how to think about and avoid these hazards. Brewers will learn to evaluate, educate, and execute safety conscious measures to ensure that the working environment, welfare of staff, and the quality of the product are first and foremost.

Brewery Safety: Principles, Processes, and People

Foreword
Acknowledgments

INTRODUCTION TO SECTION I: PRINCIPLES

Chapter 1—Safety is a Value

Safety Evolves
Safety is a Team Effort

Chapter 2—Understanding OSHA

The Big Picture
OSHA Regulations in the Legal Code
Core Concepts in OSHA Standards

Prescriptive versus Performance-Oriented Regulations
Program versus Plan
The Rebuttable Presumption

Classifying Your Business
Injury and Illness Recordkeeping and Reporting

Reporting a Severe Injury or Fatality
The 300 Forms

Chapter 3—Hazard Classification and Identification

Hazards and Outcomes

Classifying Hazards
Outcomes

Identifying Hazards

Process Knowledge
Measuring and Monitoring

Chapter 4—Hazard Controls

What Are Hazard Controls?
Selection of Controls

Prevention and Protection
Hierarchies of Control

Hazard Control Strategies

Thoughts and Actions
Administrative Controls
Engineering Controls
Personal Protective Equipment

How to Improve Hazard Control Effectiveness

Include Others
Gather Information
Prioritize Hazard Assessments
Use Multiple Controls for Optimal Safety
Systematize and Regularly Review

Chapter 5—Hazard Assessment

Versions of Hazard Assessment
Hazard Assessment Process

1. Outline the Task Step by Step
2. Identify Potential Hazards
3. Determine Best Hazard Controls
4. Document the Safe Task Procedure

Documentation Best Practices

INTRODUCTION TO SECTION II: PROCESSES

Section II Organization

Systemic Hazards
Situational Hazards

Other Uses of This Section

Chapter 6—How Hazards Cause Injury

Acute versus Chronic Injury
Disease
Local versus Systemic Injury
Routes of Entry

Respiratory Route of Entry
Ingestion Route of Entry
Dermal Absorption and Skin Penetration Routes of Entry

Chapter 7—Hazards are an Exchange of Energy

Energy—The Basics
Forms of Energy

Chapter 8—Systemic Workplace Conditions

Intention to Create a Safe Workplace
Housekeeping
Walking and Working Surfaces
Hoses and Cords
Tools and Parts
Sanitary Considerations
Combustible Materials
When Not to Perform Housekeeping
Applicable Standards
Emergency Planning and Signage
Emergency Action Planning

Emergency Action Plan
Fire Prevention Plan
Spill Prevention Plan
Medical Services and First Aid

Preparing for Extraordinary Events

Building Infrastructure
Natural Disasters
Hostile Persons

Hazard Signage

Emergency Exits
Hazard Areas
Process Signage and Floor Markings
Labor Law Poster and Public Safety Postings

Applicable Standards
Repair and Maintenance
General
Building Systems
Applicable Standards

Chapter 9—Personal Protective Equipment

Personal Protective Equipment
General Requirements
Eye Protection

Chemical Exposure Protection
Foreign Matter and Physical Trauma
Eye Strain
Hazardous Light
Vision Correction

Head Protection
Foot and Leg Protection
Hand Protection
Hearing Protection
Respiratory Protection

Voluntary Protection
Respiratory Protection Program

Protection from Other Types of Bodily Injury
Sensible Work Clothes
Applicable Standards

Chapter 10—Environmental, Ergonomic, and Trip/Fall Hazards

Noise and Hearing Protection
Occupational Noise

Onset of Hearing Loss
Brewery Noise Sources and Controls

Hearing Conservation Program

Brewery Noise Monitoring
Audiometric Testing

Applicable Standards
Lacerations, Abrasions, Punctures, Avulsions, and Amputations
Types of Tissue Injuries

Lacerations
Abrasions and Rashes
Punctures
Avulsions
Amputation

Systemic Laceration Hazards

Unprotected Surfaces, Edges, and Protrusions
Cutting Tools and Knives
Broken Glass

Applicable Standards
Musculoskeletal Disorders
Types of Musculoskeletal Injuries

Sprains, Strains, and Contusions (Soft Tissue Injuries)
Back Injury and Lifting
Repetitive Motion
Posture
Arthritis
Hernia

Applicable Standards
Slips, Trips, and Falls from Ground Level
Surface Texture and Adhesion
Change in Pitch or Gate
Raised or Depressed Obstacles and Clutter
Applicable Standards
Falls from Height and Falling Objects
Working at Heights

Stairways
Ladders
Fall Protection and Fall PPE
Falling Objects

Applicable Standards

Chapter 11—Materials Handling and Motion Hazards

Manual Materials Handling
Clearance
Housekeeping
Storage
Guarding
Applicable Standards
Engulfment and Grain Handling
Grain Storage and Handling

Silos
Bulk Bags and Unloaders

Grain Conveyance in Production
Milling
Spent Grain Handling
Applicable Standards
General
Portable Powered Lifts and Trucks
Powered Industrial Trucks

Fuel Types and Classes
Seated Operation
Standing Operation

Operator Certification
Safe Use of Powered Lifts and Trucks

Pre-Operation
Driving and Maneuvering
Handling Loads
Equipment Limitations
Stability Triangle

Mobile Elevated Work Platforms
Applicable Standards
Motion Hazards: Machinery, Vehicles, and Flying Objects
Machinery Design and Installation
Safe Work Practices
Administrative Controls
Personal Protection
Applicable Standards

Chapter 12—Pressure Hazards: Compressed Gases, Pneumatics, and Hydraulics

Pressure Hazards: Compressed Gases, Pneumatics, and Hydraulics
Pressurized Fluids and Gases
Compressed Gases and Air

Compressed Gas Cylinders
Cryogenic Bulk Tanks
On-Site Gas Generation and Capture
Compressed Air and Pneumatic Control Systems
Beer Vessels Under Pressure

Controls for Pressure Hazards

Proper Fittings and Tubing
Valves
Automated Valves
Self-Actuated Pressure Relief Valves
Process Labeling

Applicable Standards

Chapter 13—Flammable and Explosive Hazards

Flammability and Explosivity
Things That Can Catch Fire

Building Materials and Supplies
Petroleum Fuels and Solvents
Flammable Liquids and Vapors

Ignition Sources

Electrical Systems
Heat Producing Appliances
Open Flames
Other Ignition Sources
Grounding and Bonding

Applicable Standards

Chapter 14—Extreme Temperature Hazards

Thermal Burns and Heat Disorders
Thermal Burns

Burn Physiology
Direct Contact with Hot Liquids
Exposure to Steam
Contact with Hot Surfaces

Heat Disorders

Heat Stress
Hypothermia and Frostbite

Applicable Standards

Chapter 15—Other High-Energy Source Hazards

Electrical Hazards: Shock, Electrocution, Arc Flash
Electrical Hazards

Shock and Electrocution
The Nature of Electricity
Conductors and Insulators

Electrical Systems

Electric Distribution to and into the Brewery
Grounding
Load Controls

Applicable Standards
Electromagnetic Energy: Non-Ionizing and Ionizing Radiation
Electromagnetic Fields

Non-Ionizing Radiation
Hazardous Light Energy
Ionizing Radiation

Applicable Standards

Chapter 16—Chemical Hazards

Hazard Communication
HazCom Requirements

Worker Notice
Labels
PPE and Training
Chemical Inventory
Safety Data Sheet
Exemptions Under HazCom

Physical Properties of Chemicals

Physical States of Matter
Gases and Vapors
Appearance of Liquids and Solids
Liquids and Solids

Applicable Standards
Corrosive Chemicals
The pH Scale
Buffers
Acids

Mineral Acids
Organic Acids

Bases
Boiler Additives
Oxidizers
Not All Oxidizers Contain Oxygen
Inorganic Oxidizers
Organic Peroxides
Non-Oxidizer Disinfectants, Sanitizers, and Cleaners
Disinfectants versus Sanitizers
Understanding and Selecting Cleaners
Detergents and Inorganic Cleaners
Solvents

Polar Solvents
Non-Polar Solvents

Selection and Controls
Other Chemical Hazards
Front of House and Kitchen Chemicals
Pest Control and Groundskeeping Chemicals

Pest Control
Groundskeeping Chemicals

Chapter 17—Biological Hazards

Human and Food Transmitted Illnesses
Human and Foodborne Illnesses in the Workplace

Airborne and Direct Contact Illnesses
Illnesses from Blood and Bodily Fluids
Illnesses from Contaminated Food, Water, or Feces
Toxins Resulting from Contaminated Food

Applicable Standards
Hazard Controls for Human Disease Hazards

Bloodborne Pathogen Controls
Surface Disinfection Controls
Food Contamination Controls
Destruction of Bacterial and Fungal Spores

Illnesses and Allergies Caused by Animals, Plants, and Consumables
Illnesses Related to Pests

Vermin
Venomous Native Animals
Irritating Native Plants
Fungal Spores

Allergens

Food Allergens
Medications and Cosmetics

Drugs and Alcohol
Hazard Controls

Hazard Controls for Animal and Plant Pests
Avoiding and Responding to Allergic Response
Hazard Controls for Alcohol and Drugs in the Workplace

Chapter 18—Psychosocial Hazards

Alarm and Adaptation

Alarm Reaction and Outcomes
Adaptation

Biosocial and Situational Interactions
Social Modeling Behaviors

Normalization and Habituation
Perceived and Assumed Risk
Social Proof and Peer Influence
Cognitive Dissonance

Worker-to-Worker Interactions
Identifying and Resolving Biosocial and Situational Interactions
Biosocial and Situational Interactions
Harmful Self-Narratives, Anxieties, and Discontent
Neurodiversity
Substance Use

Casual Substance Use
Substance Use Disorder
Substance Use Disorder Interventions

Identifying and Managing Individual Psychological Stressors
Employment Setting

Work Design
Management Behaviors
Toxic Workplace Culture

Workforce Characteristics

Job Position and Tenure
Age, Gender, and Experience
Socioeconomic Status

Identifying and Managing Employment Setting Stressors

Chapter 19—Combined Hazards

Confined Spaces
What Is a Confined Space?
Permit-Required Confined Space

Actual or Potential Hazardous Atmosphere
Engulfment
Sloping or Converging Walls or Floors
Any Other Serious Safety or Health Hazard

Special Requirements for Permit-Required Confined Spaces

Reclassified Confined Space
Alternate Procedures Confined Space

Written Permit-Required Confined Space Program

Control Entry to Spaces
Develop Entry Procedures
Inventory and Site Plan
Provide Equipment
Designated Roles and Responsibilities
Entry Permit
Evaluate the Space Prior to Entry
Managing Changing Conditions and Emergencies
Program Review
Training

Typical Brewery Confined Spaces and Their Treatment

Grain Silos, Baghouses, Grist Cases, and Spent Grain Storage
Brewhouse Vessels
Cellar and Packaging Vessels
Wastewater Systems
Utility Vaults
Boilers and Furnaces
Non-Confined Spaces with Hazards

Applicable Standards
Control of Hazardous Energy (Lockout/Tagout)
Nuances in Applying Lockout/Tagout

Lockout/Tagout Exemptions
Conservative View of Lockout/Tagout

Energy Control Program

Lockout Versus Tagout
Energy Control Procedures
Energy Control Devices
Periodic Inspection
Training and Communication

Applicable Standards

INTRODUCTION TO SECTION Ill: PEOPLE

Chapter 20—Safety Culture

Culture Connects Experience to Action

Safe Behavior is Working Safely
Culture is a Complicated Collection
Experience and Socialization

Drivers of Safety CuIture

Expressed Management Values
Communication
Accountability
lnclusivity
Competence

Chapter 21—Measuring Progress

Key Performance Indicators
KPI Variables

Leading versus Lagging
Quantitative versus Qualitative
Inward versus Outward
Business as Usual versus Attaining New Objectives

KPI AppIications

Management Engagement
Communication
Accountability
Inclusion
Competence
Hazard Assessment and Control

KPI Tips for Success

Data Reliability
Data Sufficiency
Data Collection Design

Chapter 22—Safety Management Systems

Safety Management Systems Background

Early Safety Management and Behavioral Safety
Modern Systems Management
Continuous Improvement

Safety Management Systems

Safety Management Systems Consensus Standards

Safety Management Systems for a Small Brewery

Safety Mission Statement
Hazard Assessment and Hazard Control
Communication and Training
Review and Improvement

Appendix—Job Activity Hazards Index
Bibliography
Index

Publish Date: 2023
Format: 8.375” x 10.875” softcover
Pages: 368
Publication Weight: 2 lbs