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Health and Safety Executive
A Bakers dozen
Thirteen essentials for health and safety in bakeries
This is a free-to-download, web-friendly version of HSG233 (First edition, published 2003). This version has been adapted for online use from HSEs current printed version.
You can buy the book at www.hsebooks.co.uk and most good bookshops.
ISBN 978 0 7176 2616 8Price 13.50
This comprehensive guide should help you reduce the risk of injuries and occupational ill health in your bakery. Packed with authoritative advice, it includes sections on bakery dust, manual handling, slips and trips, workplace transport, falls from height, machinery, noise and electrical safety.
HSE Books

of 96
Crown copyright 2003
First published 2003
ISBN 978 0 7176 2616 8
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the prior written permission of the copyright owner.
Applications for reproduction should be made in writing to: The Office of Public Sector Information, Information Policy Team, Kew, Richmond, Surrey TW9 4DU or e-mail: [email protected]
This guidance is issued by the Health and Safety Executive. Following the guidance is not compulsory and you are free to take other action. But if you do follow the guidance you will normally be doing enough to comply with the law. Health and safety inspectors seek to secure compliance with the law and may refer to this guidance as illustrating good practice.

A Bakers dozen: Thirteen essentials for health and safety in bakeries Page 3 of 96
ContentsINTRODUCTION 7About this book 7Revitalising Health and Safety 8Baking industry priorities 9The challenge 9
CHAPTER 1MANAGING THE PRIORITIES 10The bakery industry injury rate 10The main causes of injuries and ill health in bakeries 11Major injuries 11Over-3-day absence injuries 12Fatal injuries 12Occupational ill health 13First steps - identifying the hazards 13Risk assessment - how to do it 13Investigating accidents 14Check what happened 14Prevent the accident/incident happening again 14Selection and training of workers and young people 15Selection 15Training 15Young people 15Managing contractors 16Involving workers and safety representatives 16Key steps to successful health and safety management 17Employees have responsibilities too 17
CHAPTER 2 DUST FROM FLOUR AND OTHER INGREDIENTS 18What are the health hazards? 18What the law says 19Exposure limits 19Assessing bakery dust levels and risk 20Controlling dust levels 21Improving plant and equipment 21Improving working practices 22Ten top tips for bakers 22Protective clothing and equipment 23Overalls 23Respirators (respiratory protective equipment) 23Health surveillance for respiratory issues 24Dermatitis 25
CHAPTER 3 MANUAL HANDLING 26Is manual handling really a problem? 26Lifting and carrying 26Repetitive work 26Bakery industry priorities 27What the law says 27Avoiding the risk 27Assessing the risk 27Reducing the risk 28Training and information 28

Reviewing the assessment 28Managing and controlling the risks 28Identification 28Elimination 28Preventive measures 29Reporting of symptoms 29Training and information 29Monitoring 29Supply chain 29Reducing the risks 30
CHAPTER 4SLIPS AND TRIPS 33Why tackle slips and trips in bakeries? 33What the law says 33Preventing slips - environmental factors 33Prevent floor contamination 33Increase the slip-resistance of the existing floor 35Laying a slip-resistant floor with enough surface roughness 35Hygiene considerations 38Stairs 39Preventing slips - organisational factors 39Preventing slips - selecting footwear 39Preventing slips - worker involvement and training 40Preventing trips 41
CHAPTER 5WORKPLACE TRANSPORT 41Is workplace transport really a problem? 41Fork-lift trucks (FLTs) 41Delivery vehicles 41The priorities 42Risk assessment and safety precautions 42Pedestrian safety and pedestrian/vehicle segregation 42Vehicle reversing 43Falls from vehicles 44Tail lifts 44FLT operations 45Training 46Securing contents of delivery vehicles 46
CHAPTER 6 FALLS FROM HEIGHT 47Why tackle falls from height risks? 47Places where falls from height occur in bakeries 47Activities being undertaken when falls occur 47What the law says 48How to prevent falls from height 48Installation of new plant 48Cleaning 49Sampling or checking 49Maintenance 49Falls caused by slipping 50Falls on stairs 50Falls from warehouse racking 51Access onto internal roofs/false ceilings 51Storage in lofts and other elevated areas 51Using fork-lift trucks for access 52

CHAPTER 7 BAKERY AND PACKAGING MACHINERY 52Injuries caused by machinery 52Machines that cause the most accidents 52Bakery equipment 52Conveyors 53Packaging machines 53Power transmission machines 54How most machinery accidents happen 55Buying new machinery 55Machinery already in use on your premises 55Special safety problems with safeguarding food machinery 56Fixed or interlocking guards? 56Fixed guards 56Design of interlocks 57Maintenance of guards and interlocks 57Stored energy 57Unexpected start-up 57Slips 58Hygienic design 58Machinery isolation and lock-off 58Safeguarding standards for machines that cause most accidents 59Conveyors 59Bakery machinery 59Packaging machinery 62Checklist for buying new machinery 64
CHAPTER 8 NOISE 65The risk - hearing loss 65Noise levels in bakeries 65Noise reduction 65What the law says 67Current legislation 67Proposed legislation 67
CHAPTER 9 CONFINED SPACES 68Dangers from confined spaces 68What is a confined space? 68Hazards of confined spaces 68Where are there confined spaces? 68Reducing the risk 68Entry into silos 68Ovens 70Basements 70The law and further guidance 71
CHAPTER 10 CHEMICAL CLEANERS 71Chemical cleaners - hazardous substances 71Risks from chemical cleaners 72COSHH 73Incompatibility of some chemicals 74

CHAPTER 11 FIRE AND EXPLOSION 74The main hazards in bakeries 74Flour and ingredient dust 74Prevention of primary explosions 75Prevention of secondary explosions 75Fuel gas 76Oven fires 77Deep fat fryers 78Hot work 78Fire risk assessment 78
CHAPTER 12 ELECTRICAL SAFETY 79What are the hazards? 79Electricity at Work Regulations 1989 79A safe installation - a good starting point 79Fixed machinery installations - what to look for 79Small machines with flexible cables 79Fuses, protection and earthing 80Water ingress 80Pressure-washers and steam-cleaners 80Maintaining and testing electrical equipment 81
CHAPTER 13ACCIDENTS AND EMERGENCIES 82Reporting injuries, occupational diseases etc 82First aid 83Emergency procedures 83
FURTHER READING 85
USEFUL ADDRESSES 94

IntroductionAbout this book
1 This book is for people who have management, supervisory or other health and safety interests in bakeries. It is intended as an aid to health and safety management, in order to reduce the numbers of injuries and cases of occupational ill health. The information will be of use in:
n plant bakeries;n craft bakeries;n semi-automated craft bakeries;n in-store bakeries;n pizza manufacture;n pastry manufacture; n biscuit manufacture.
Figure 1 Operating a mixer in a craft bakery
2 Although most of the information in the book will apply to the processes in a range of premises, non-plant bakers may discover parts less relevant to them (eg transport), whereas plant bakeries may find they will require additional sources of information (eg on machinery/plant). However, most of the chapters will be of interest to bakeries of all sizes.
3 Approximately 95 000 people work in the UK baking industry. There are about 4500 small craft bakeries, each employing typically between 5 and 25 people, in addition to specialist pizza and pastry producers. At the other end of the scale there are about 150 large plant bakeries, each employing more than 100 workers. In between there is a range of medium-sized bakeries, about 350 in total, each employing 25-100 people.

4 This book has been written by the Health and Safety Executive (HSE), in liaison with the Health and Safety in Bakeries Liaison Committee (HSBLC), to highlight the main causes of injury and occupational ill health in bakeries. The HSBLC is a joint committee that identifies priorities and produces guidance for the bakery industry. It is represented by the following organisations:
n Federation of Bakers;n National Association of Master Bakers;n Scottish Association of Master Bakers;n Association of Bakery Ingredients Manufacturers;n Biscuit, Cake, Chocolate and Confectionery Alliance;n Processing and Packaging Machinery Association;n Bakers, Food and Allied Workers Union;n United Road Transport Union;n Health and Safety Executive.
Figure 2 Bread rolls exiting a tunnel oven
Revitalising Health and Safety
5 In June 2000 the Health and Safety Commission (HSC) and the Department of Environment, Transport and Regions (DETR) launched a strategy statement on Rev

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