Frozen food production can be hazardous to workers. Although nitrogen and carbon dioxide can quickly freeze food products if released into the work area, they can displace oxygen in the air, which can be fatal to workers. Fundamental safety and operational precautions, such as systems to prevent nitrogen and carbon dioxide from entering and accumulating in the work area, alarms to detect low oxygen levels, emergency ventilation, and worker training, are essential for ensuring hazard awareness and employee escape from oxygen-deficient areas.
Background
In food processing, spiral and immersion freezers rapidly freeze food to preserve product quality. Food products are brought into contact with nitrogen or carbon dioxide in solid, liquid, and vapor forms inside flash freezers. If the nitrogen or carbon dioxide spills out of the equipment during operation, high concentrations can accumulate in the work area, replace the oxygen in the air, and asphyxiate workers. OSHA has recently investigated several fatal incidents related to nitrogen and carbon dioxide releases from flash freezers. These releases can be the result of equipment failure, improper equipment operation, or even food product changes. In one case, a release of nitrogen at a flash freezing facility killed six workers and injured others due to equipment failure, inadequate training and procedures, insufficient atmospheric monitoring, and faulty emergency ventilation. Tragically, additional workers were killed in seconds when they entered the room unprotected to rescue the fallen workers.
Protecting Workers from Asphyxiation and Cryogenic Hazards
Employers must always ensure a safe workplace by controlling hazards from flash-freezing operations. As discussed in a prior OSHA Letter of Interpretation, several OSHA standards and guidance relate to protecting workers from the known hazards of nitrogen. Additionally, the General Duty Clause of the Occupational Safety and Health Act requires employers to provide their workers “employment and a place of employment which are free from recognized hazards that are causing or are likely to cause death or serious physical harm.” 29 USC 654(a)(1).
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