Brewery Safety Infographic

Breweries host numerous hazards that can create havoc for workers and visitors alike. Hot liquids, wet floors, and forklifts are just some of the hazards present in breweries throughout the United States.

This helpful infographic encapsulates those hazards and offers numerous resources for maintaining a safe brewery. It shares some of the industry’s safety statistics, outlines OSHA standards and guidelines, and provides tips for ensuring a safe, efficient brewery.

The following is a transcript of the Brewery Safety Infographic:

Brewery Safety

Hot liquids, pressurized tanks, wet floors, and forklifts are just some of the hazards present in breweries around the country. Brewing is considered a highly-hazardous industry, given the dangerous nature of the work. As the country's beer market grows, employers should remain vigilant of these hazards and take steps to keep workers safe.

Overall Beer Market

In 2015: 105.9 billion

In 2015: Craft beer market 22.3 billion

196,701,792 barrels of beer produced in 2015.

4,269 breweries in the United States. Highest number since 1873. 17.9% increase since 2014.

Craft Beer Market

5,832,682 barrels of beer produced in 2004.

24,076,864 barrels of beer produced in 2015. 313% increase.

Risks Brewers Face on the Job

Toxic Chemical Inhalation: Brewers may inhale chemicals and pathogens while working in confined spaces and if HazCom 2012 regulations aren't followed.

Burns & Electrocutions: Employees may be burned or electrocuted if proper lockout/tagout procedures aren't observed.

Collisions: Employees must be trained to drive forklifts, and all aisles should be properly marked. Failure to do so may lead to collisions between employees and forklifts.

Chemical Exposure: Without a process hazard analysis or written program for the emergency use of refrigeration systems, employees may be exposed to toxic, reactive, flammable, or explosive chemicals. 

Ergonomic Injuries: Employees should practice ergonomic safety when lifting heavy objects, such as kegs, or performing repetitive tasks; failure to do so may result in musculoskeletal pain or Carpal Tunnel Syndrome.

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Common Injuries & Illnesses in Breweries

Overexertion & Bodily Reaction:

• 2014: 220
• 2013: 80
• 2012: 110
• 2011: 40
• 2010: 60

Musculoskeletal Disorders:

• 2014: 200
• 2013: 80
• 2012: 110
• 2011: 40
• 2010: N/A

Strains, Sprains, & Tears

• 2014: 150
• 2013: 80
• 2012: 80
• 2011: 50
• 2010: 60

Exposure to Harmful Substances & Environments

• 2014: 110
• 2013: 0
• 2012: 20
• 2011: 20
• 2010: N/A

Struck by an Object or Equipment

• 2014: 110
• 2013: 60
• 2012: 20
• 2011: 40
• 2010: N/A

Slips, Trips, & Falls

• 2014: 60
• 2013: 80
• 2012: 30
• 2011: 30
• 2010: N/A

Injuries to the Lower Body

• 2014: 170
• 2013: 100
• 2012: 70
• 2011: 30
• 2010: 70

Injuries to the Upper Body

• 2014: 150
• 2013: 80
• 2012: 30
• 2011: 80
• 2010: 30

Injury & Incident Rates in Breweries

Total Recordable Cases of Nonfatal Injuries & Illnesses (Per 100 full-time employees)

• 2014: 5.8
• 2013: 3.8
• 2012: 4.1
• 2011: 3.8
• 2010: 3.7

Cases with Days Away From Work, Job Transfer, or Restriction (per 100 full-time employees)

• 2014: 2.2
• 2013: 2.4
• 2012: 1.9
• 2011: 1.6
• 2010: 1.6

Federal Brewery Citations & Fines

Total Federal Brewery Citations

• 2015: 174
• 2014: 146
• 2013: 80
• 2012: 90
• 2011: 81
• 2010: 85

Federal OSHA Fines Issued to Breweries

October 2014-September 2015: $41,395

of that total:

• Process safety management of highly hazardous chemicals: $13,750
• Powered industrial trucks: $8,750
• Control of hazardous energy (lockout/tagout): $7,500
• Permit-required confined spaces: $3,700
• Medical services and first aid: $2,270
• Hazard communications: $1,550
• Protection around floor openings: $850
• General Duty Clause violations: $850
• Electrical requirements concerning hazardous materials: $800
• Respiratory protection: $720
• Work-related illness and injury recordkeeping: $655

Fines by State

October 2014-September 2015

• Minnesota: $15,760
• Hawaii: $10,500
• California: $6,705
• Maryland: $2,535
• Washington: $2,200
• Oregon: $1,770
• North Carolina: $1,650
• Michigan: $200 

Brewers' Best Practice Checklist

Have you taken necessary precautions before working in a confined space (such as inside a fermenter or mash tun)?

Is the employee outfitted with a respirator?

Has the entry supervisor provided a signed permit, if necessary?

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Have employees received training to operate forklifts?

29 CFR 1910.178(I)(1)(i) stipulates that employers must train and evaluate all employees using forklifts and powered trucks. 

Do employees have PPE for the head, eyes, face, body, hands, and feet?

HELMETS can prevent injuries in the event of flying objects or collisions with workplace items.

RESPIRATORS can prevent employees from inhaling toxic chemicals, air contaminants, and hazardous vapors while working in confined spaces.

GLOVES can help around hot surfaces, chemicals, boiling liquids, and more. Be sure to choose the most appropriate glove for each hazard, and be sure to check how long gloves can be used and if they can be reused. 

EYEWEAR such as safety glasses and safety goggles prevents injuries caused by splashes from cleaning chemicals or boiling liquids. All eyewear should conform to the ANSI Z87.1-2003-6.2.1 standard.

HEARING PROTECTION can mitigate hazards posed by loud machinery.

SAFETY VESTS can protect the torso against splashes from hot liquids and toxic chemicals.

SAFETY SHOES AND BOOTS can protect against slips, trips, and falls; corrosive materials; and physical injuries.

Cleaning & Maintenance

All PPE should be regularly inspected, cleaned, maintained, and sanitized in accordance with 29 CFR 1910.132 (a) and (b).

• A - Reflect
• B - Heavy Duty
• C - Tread
• D - Glow
• E - Print
• F - Floor Signs

Are aisles clearly marked and signs posted where forklifts may move throughout the brewery or around loading docks?

29 CFR 1910.22 outlines the need for floor marking; another OSHA interpretation expanded on the requirement with recommendations that aisle markers can be any color, should be 2'' to 6'' wide, and that aisles should be 3' wider than the largest equipment used (or a minimum of 4').

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Have employees followed all lockout/tagout procedures while performing maintenance on energized equipment (such as bottling lines), as outlined in 29 CFR 1910.147?

Are all pipes properly labeled, in conjunction with the ANSI/ASME A13.1 standard or, when ammonia refrigeration is present, the Institute of Ammonia Refrigeration (IIAR) Bulletin No. 114 standard?

Does the brewery have safety data sheets for all relevant cleaners, sanitizers, and additives—as required in 29 CFR 1910. 1200(b)(3)(ii)? Are all chemicals properly labeled?

Has a process analysis been established in accordance with 29 CFR 1910.119, OSHA's regulation for preventing or minimizing the release of toxic, reactive, flammable, or explosive chemicals?

Sources: OSHA.gov, BLS.gov, BrewersAssociation.org