HYGIENE, HEALTH & SAFETY

PREFACE

The Flour Milling Industry has always been aware of the need to review and improve its training provision on a regular basis and to
make improvements as necessary

Since 1932 correspondence courses in flour milling leading to City and Guilds of London Institute (CGLI) qualifications and run by
the Incorporated National Association of British and Irish Millers (nabim), on behalf of the industry, have provided part-time study
to meet the needs of new and established employees alike. Today, the courses still attract many hundreds of students both within the
United Kingdom and worldwide.

In 1985. nabim decided to undertake a thorough revision of the longstanding Practice of Flour Milling textbooks and published in
their place a new series of more up-to-date and accessible booklets to function as the main source of information for the courses and a
reference text for the industry.

In 1993, encouraged by the industry to do so, nabim and CGLI agreed a restructuring of the CGLI certificate syllabuses into seven
modules: Hygiene, Health and Safely: Wheat and the Screenroom; Mill Processes and Performance; Product (now Materials)
Handling. Storage and Distribution: Flour; Power and Automation: and Flour Milling Management. Consequently, the decision was
taken to produce a series of new textbooks, revised, updated and reflecting the new modular structure. These new booklets are of
standard format and colour-coded. It is clear that the new modules and textbooks are proving popular and are being used throughout
the industry in training, not only towards the CGLI qualifications but also towards meeting the standards of knowledge,
understanding and ability required in other qualifications.

The Flour Milling Industry would like to offer its thanks to all those individuals who gave voluntarily and generously of their time to
the production of this module and to those organisations, notably the milling engineers and Wheat Boards, which provided valuable
assistance in the whole project.

ONE TEAM – ONE VISION Page 1

HYGIENE, HEALTH & SAFETY

OBJECTIVES

On completing the module, students should be able to:

• Detail the priority hazards to health and safety in the flour milling industry.

• Describe means by which each of these hazards can be adequately controlled in order to minimize the risk to health and safety.

• Describe the factors necessary for a dust explosion to occur and explain precautions necessary to prevent such an explosion.
• Describe precautions to prevent and tackle fires and to minimize injury to people.
• Describe the main points of health and safety legislation as it applies to UK flour mills.
• Understand the principles which support a health and safety culture in the workplace.
• Explain how mills can plan and maintain a safe working environment.
• Describe how a suitable and sufficient risk assessment should be conducted.
• Understand the different styles of safety signs and their functions.
• Describe a range of insect and other pests of stored wheat and flour.
• Slate the significance of infestation and the best means of prevention,
• List the most likely sites of infestation in mill premises.
• Describe the principles behind a good system of mill hygiene,

ONE TEAM – ONE VISION Page 2

HYGIENE, HEALTH & SAFETY

CONTENTS

Introduction 3.0 Health and safety Culture

3.1 Organising for health and safety
1.0 Hazards and Precautions 3.1.1 Competence
11 Fire and explosions 3.1.2 Control
1.1.1 Common causes of fire [Link] Target setting
1.1.2 Fire protection and precautions 3.1.3 Co-operation
1.1.3 Tackling fire 3.1.4 Communication
1.1.4 Minimising injury
1.1.5 Preventing dust explosions 4.0 Planning and implementation of safety activities
1.2 Falls from height 4.1 Risk assessment
1.2.1 Safe use of ladders and stepladders 4.1.1 Look for the hazards
1.2.2 The Working at Height Regulations 4.1.2 Decide who might be harmed and how
1.3 Electricity 4.1.3 Evaluate risks and decide if any additional
1.3.1 Controlling the risks controls arc required
1.3.2 The Electricity at Work Regulations 4.1.4 Record the findings
1.4 Workplace transport 4.1.5 Review the assessment
1.4.1 Off-site transport safety 4.2 The hierarchy of risk control
1.4.2 Legislation 4.2.1 Safe systems of work
1.5 Machinery 4.3 Permits to work
1.5.1 Machinery hazard controls 4,4 Personal protective equipment
1.5.2 Safety during maintenance 4.5 Site safety rules
1.5.3 Legislation 4.6 Safety signs
1.6 Lone working 4.7 Accident reporting and accident investigation
1.6.1 Risks for lone workers 4.7.1 Accident reporting
1.6.2 Controlling risks to lone workers 4.7.2 Legal obligation
1.6.3 Legislation 4.7.3 Insurance claim
1.7 Manual handling 4.7.4 In-house accident investigation
1.7.1 Dangers associated with manual handling 4.8 First aid
1.7.2 Controlling the risks
1.7.3 Manual Handling Operations Regulations 5.0 Environmental Impact
1.8 Slips and trips 5.1 Waste
1.8.1 Controlling the risks 5.2 Energy use
1.9 Harmful substances 5.1.1 Processing
1.9.1 Controlling the risks 5.2.2 Distribution
[Link] Risk assessments under COSHH

ONE TEAM – ONE VISION Page 3

HYGIENE, HEALTH & SAFETY

[Link] Workplace exposure limits 6.0 Hygiene and pest prevention

[Link] Dust 6.1 Insect pests
1.10 Noise 6.1.1 Insect life cycles
1.10.1 Controlling the risks 6.1.2 Primary insect pests
1.10.2 Legislation [Link] Mites
1.11 Confined spaces 6.1.3 Secondary insect pests
1.111 Controlling the risks 6.1.4 Insect infestation
1.11.2 Bin entry [Link] Significance of insect infestation
1.12 Striking objects [Link] Potential sites of insect infestation
1.12.1 Controlling the risks 6.2 Rodent pests
1.13 Off-site safety 6.3 Bird pests
1.13.1 Controlling the risks 6.4 The Food Safety Act
1.14 Occupational road safety 6.5 1Hygiene principles
1.14.1 Controlling the risks 6.6 Prevention of infestation
6.7 Hygiene strategies
2.0 Legal Health and Safety Responsibilities
2.1 General duties under the Health and Safety
at Work Act
2.2 Management of Health and Safety at
Work Regulations
2.3 Other legislation
2.4 Enforcement action
2.4.1 Powers of Factory Inspectors

Introduction
It may seem strange that the first module in a series on flour milling should be about “health, safety and hygiene ” and not about
wheat or milling or flour. However, whatever else it does, a flour mill cannot operate efficiently in the long-term unless it pays due
attention to:

i) the safety of its employees and others on site;

ii) the safety of consumers, through ensuring that products are fit for consumption;
iii) the effect the industry has on other people through its impact on the environment.

In any workplace, just as in the home, there are hazards to be faced every day. Good health and safety practice is not about eliminating
all possible hazards; nor is it about ignoring them. It is to recognize the hazards that exist and then to minimize the risks that they
pose. This is not only good practice, it is required by the law.

(Throughout this book there are references to specific UK-based sources and legislation. Although this may not be strictly relevant
globally, all readers should be encouraged to research the relevant bodies and laws associated with the flour milling industry in their
own countries. Furthermore, behind the UK legislation lies the promulgation of good practice, applicable anywhere in the world; it is
on this that the book concentrates.)

As soon as you start work, in any industry and any occupation, the law imposes responsibilities:

i) upon you, to do nothing that might harm yourself or others;

ONE TEAM – ONE VISION Page 4

HYGIENE, HEALTH & SAFETY

ii) upon your employer, to ensure that you are trained to be aware of hazards and how to control them.
This applies as much to a mill as to a building site, farm or nuclear power station and as much to an accountant as to a miller,
electrician or driver. Anyone, through carelessness or ignorance, has the capacity to endanger the well-being of themselves, other
employees or the general public.

In the first four sections of this module, we consider:

• the typical hazards that may be found on a flour mill site and the strategies used for reducing the risks that they pose;
• the legal framework for health and safety, concentrating on the responsibilities of all parties involved;
• how to organize and plan for good health and safety.

Section five considers the environmental impact of flour milling and some basic steps that can be taken to minimize this impact.
Finally, section six looks at the reasons why good hygiene is vital to a flour mill and then at the principles and strategies which help
that need become a reality.
If everyone on site knows, understands and, crucially, acts on the contents of this module in its entirety, then the mill will be a safe,
clean and healthy place to work - and more efficient too
1.0 Hazards and precautions
1.1. Fire and Explosions
Every year, heavy losses are caused by fires throughout industry at large - loss of life, loss of equipment, lost production. Jobs are
lost too, since even if insurance meets the cost of the damage, rebuilding takes time, skilled staff may move elsewhere and
customers may find other suppliers. Over a third of factories which suffer a major fire close down.
1.1.1 Common causes of fires
Three things need to be present for a fire to start. These are:
1. Oxygen present in the atmosphere
2. fuel can be anything combustible
3. Ignition any source that will raise the temperature above ignition point
Oxygen is freely available in the atmosphere and therefore is always present. However, fires may be prevented by minimising fuel
and ignition sources present in the workplace.

Here are a few examples:

Causes of fires Precautions

Poor housekeeping
leading to a build-up of Regular cleaning with rubbish disposed of in suitable containers
flammable material

Electrical faults Do not overload circuits; ensure correct fuses are fitted; provide adequate cooling
airflow; ensure appliances are not left on inadvertently

Hot bearings/motors Keep clean and well maintained

ONE TEAM – ONE VISION Page 5

HYGIENE, HEALTH & SAFETY

Heating pipes Ensure all combustible materials are stored well clear of pipes

Welding and gas cutting Remove combustible materials from area; have suitable extinguishers positioned
nearby; ensure good control of contractors by permit to work

Smoking Prohibit or limit smoking to designated areas

Oils and Solvents Store outside, use only enough for day or shift; use non-spill containers for
handling;

Oily rags Dispose of in non-flammable (metallic) bins

1.1.2 Fire protection and precautions

The principles of fire prevention and control are identified in the Regulatory Reform (Fire Safety) Order. This is the current UK
legislation on fire safety, but the principles it follows can be applied in any country.

Under this piece of legislation the employers are required to:

• Carry out a fire risk assessment identifying the risk and hazards.
• Consider who may especially be at risk. e.g. lone workers or people with mobility problems.
• Eliminate or reduce the risk of a fire starting and provide general lire precautions to protect people if a fire Should start.
• Take additional measures to ensure fire safety where flammable or explosive materials are used or stored, e.g. oil, diesel, etc.
• Create a documented plan to deal with any emergency.
• The main objective of fire precautions is to prevent a fire starting in the first place but. in case a fire does occur, the next priority
is to ensure the layout of the building is such that it will stop it spreading and hence keep the damage and disruption to a
minimum.
Fire can spread easily on a milling site:
• Across open plan layouts;
• Through gaps or holes in fire-break barriers;
• Across the surface of ducts in roof spaces;
• Carried through ventilation and exhaust ducting;
• Along corridors;
• In lift shafts and stair wells.
If a fire does start, the main objective is to save lives. This is done by introducing other general fire precautions such as:
1) Means of detecting and giving warning in case of fire;
2) Escape routes;
3) Fire-fighting equipment;
4) Training staff in fire safety.
1.1.3 Tackling fire
Fires should only ever be tackled by people who are trained to do so and in situations which will not put that person at risk.

Although traditional firefighting equipment such as fire buckets, fire blankets and hose reels may be present, these days the most

ONE TEAM – ONE VISION Page 6

HYGIENE, HEALTH & SAFETY

common form of firefighting equipment is the fire extinguisher. These can be filled with liquid, gas or powder. Always check before
use what the contents are, since some are unsuitable for particular types of fire. In the UK all newly certified fire extinguishers are
coloured red with a coloured panel of not less than 5% indicating its content
The following are the main types of extinguisher and the types of fire they can tackle (see also fig. 1):

Fig.1 Fire Extinguisher signs

Type and
Identifying Suitable for Method
Colour

Water
Wood, textiles and paper Water- used to cool fires. Never to be used on electrical fires
Red

Foam smothers fires with a blanket of foam. Harder to use than most
Flammable liquids, can
other types of extinguisher, the foam must be aimed at the base of the
be used on most fires
Foam Cream fire and allowed to spread gradually over the burning material. The
where water would
whole fire must be smothered or it will take hold again. Like water
work.
they can conduct electricity and must not be used on electrical fires.

Smothers flames with a fine dense cloud of dry powder. They work in
two ways - gas is given off which prevents air reaching the fire and the
Dry Powder
Suitable for all types of residue acts as an inert blanket. They are a very good general purpose
Blue fires
extinguisher, but can leave deep seated fires to smoulder only to re-
ignite later. It can also prove to be a health hazard for those with chest
problems.
Carbon Dioxide Electrical or liquid fires
(C02) Black Used to smother flames by shooting out a cloud of cold C02 gas. Must
be used carefully as the gas is very cold; the operator must not hold
the horn during discharge, as this could cause frostbite. Where dust is

ONE TEAM – ONE VISION Page 7

HYGIENE, HEALTH & SAFETY

present, care must be taken to avoid the C02 creating a dust cloud.
Large amounts of C02 in a confined space can cause suffocation.

Fire extinguishers must be serviced regularly. The types of firefighting equipment and where they are placed depends on the site and
hazards. Make sure you know where equipment is located in your workplace, how each type works and its specific application.
Where few people are on duty, a fire could take hold without being noticed. In such cases, or where a fire could grow quickly, a
sprinkler system is useful. They are usually designed to operate if a particular temperature is reached, though some are smoke-
operated.
Many mills use sprinklers, though sprinkler protection of silos is rare, since water could cause grain to swell and burst the silo.
Warehouses also rarely have sprinklers but, if they do, it is important that stored goods do not obstruct the sprinkler heads. A free
space of about half a metre beneath the sprinkler head is usually needed for effective operation.
Heat or smoke detectors can be installed to raise the alarm if a fire breaks out. Modern detectors raise the alarm at an early stage in
the fire, allowing it to be tackled before it becomes serious. Heat detectors can also be fitted to some equipment (e.g. to a roller mill
to stop it in the event of fire).

Flour mills are normally divided by fire doors between each section (e.g. screenroom, mill, packing etc). These prevent or slow the
spread of fire and are an important line of defence. They should never be wedged open.

Fire-fighting equipment should be:

• Mounted on red-painted or plastic fire points
• Well identified
• Located adjacent to fire exit
• Include an alarm point
Training is also a defense against fire. Training should be provided to:
• all staff in fire drill
- what to do when alarm sounds
- assembly points
- roll call
- role of fire marshals
• supervisors and selected staff
- use of extinguishers
1.1.4 Minimising injury
All mills should have an audible fire alarm system which can be activated at several points on the site. This should be tested
regularly to ensure that it works and is heard and understood. Everyone should recognise the signal as a warning to evacuate the
building. Delay can kill.
Mill management should ensure that should a fire break out:
a) Someone is responsible for alerting all in the building and for calling the fire brigade (unless this is automatic), and that someone
is on hand to guide the brigade on arrival (for example to tell them where water sources are, and answer queries on layout and
where persons may be trapped):

ONE TEAM – ONE VISION Page 8

HYGIENE, HEALTH & SAFETY

b) Everyone knows where escape routes are (this is a legal responsibility of management) and where to assemble after escape:
c) After evacuation a 'roll-call' is taken to check no-one is still in the building. Time-cards can be useful here, but remember also to
check the visitors book.

Everyone should be familiar with evacuation procedures, including how to shut down the plant. Regular fire drills are valuable - twice
a year is a recommended minimum. Fire drills not only ensure people know what to do, they can also reveal problems (e.g. disabled
staff who may have problems getting out or hearing the alarm, emergency exits which are blocked). Management may consider
inviting fire brigades to participate in drills, to check procedures more fully - for example that access to all buildings is possible. An
example of instructions on what to do in the event of a fire is at Fig. 2.
EXAMPLE OF FIRE INSTRUCTIONS
TO ALL EMPLOYEES, CONTRACTORS AND VISITORS

1. ANY PERSON DISCOVERING A FIRE

1.1. Sound the alarm at nearest "Break Glass' point.
1.2. If in the Mill, operate the plant emergency stop if safe to do so.
1.3. Call Fire Brigade (9) 999 (or ensure that this has been done). Ask
for the Fire Sen/ice and state the Mill address.
Telephones with outside lines are available in the Laboratory, Main Office, Weighbridge Office, Mill Control
Room and Packing Floor.

1.4. Attack the fire if of a minor nature using the appliances provided.

DO NOT TAKE RISKS

2. ON HEARING THE FIRE ALARM

2.1. The Fire Alarm is a continuous high frequency warble.
2.2. All personnel and any Visitors they may have accompanying them should leave the building by the nearest
available route.
2.3. Press Emergency stop buttons on exit.

REPORT TO THE FIRE MARSHALLING POINT OUTSIDE THE MILL GATES

2.4 Duty Miller/Security Guard to check location of fire on panel.
2.5. Outside office hours the Fire Brigade will be met by the Security Guard or miller, who will give them as much
information as possible 2 6 The Senior member of the Staff present will assume control of the evacuation and roll
call. (Including Visitors Book check).
2.7 USE THE NEAREST AVAILABLE EXIT
DO NOT STOP TO COLLECT PERSONAL BELONGINGS DO NOT RE-ENTER THE BUILDING

3. FIRE ALARMS AND EXITS

[Link] fire alarms will be tested every Friday morning at 10.00am. Alarm should only sound for a maximum of
20 seconds. If this is exceeded, carry out the above procedure.
3.2 It is the responsibility of all staff, contractors and visitors to make themselves familiar with the location of fire
exits and break glass points.

Fig2. Model Fire instructions

If you discover a fire, raise the alarm then decide quickly whether to tackle the fire. Small fires may be easily tackled, for example
with an extinguisher. But if you are in personal danger or the fire is beyond your capacity the priority is to raise the alarm, then get
yourself to safety. Try to contain the fire until the fire brigade arrives, for example by closing doors or using extinguishers from a

ONE TEAM – ONE VISION Page 9

HYGIENE, HEALTH & SAFETY

position of safety.
1.1.5 Preventing dust explosions
The Dangerous Substances and Explosive Atmosphere Regulations (DSEAR) now apply to all UK flour mills; other European Union
countries have similar legislation introduced in the last few years under the ATEX Directive.

DSEAR is a set of regulations concerned with protection against risks of fire, explosion and similar events from dangerous substances,
used or present in the workplace. Dangerous substances include dusts such as flour which when mixed with air could cause an
explosive atmosphere. An explosive atmosphere, in the context of milling, is an accumulation of dust, mixed with air, which has the
potential to catch fire or explode. An explosive atmosphere does not always result in an explosion, but if it caught fire the flames
would travel through it quickly and if this happened in a confined space (e.g. in plant or equipment) the rapid spread of the flames or
rise in pressure could also cause an explosion.

Where the risk of a dust explosion cannot be entirely eliminated employers should apply control and mitigation measures to reduce
risk as follows:
Control measures: in the following order of priority
• reduce the quantity of dust
• avoid or minimise releases at source
• prevent the formulation of an explosion atmosphere
• collect, contain and remove any releases to a safe place (e.g. by ventilation)
• avoid ignition sources
All methods of dust explosion prevention are based on tackling one or more of
the three factors in the dust explosion triangle shown in Fig.3.

Fig3. Dust explosion triangle

To consider each in turn:

1) A flammable dust
Both grain and flour dusts are flammable and obviously cannot be removed from the milling process. The main precaution is to limit
the amount of dust in the atmosphere (by effective exhaust systems and good seals on machinery) and to prevent it accumulating on
beams, machinery and ledges. If dust built up there it could be dislodged and form a dangerous cloud. It is generally accepted that a
cloud of at least 50 grams per cubic metre is necessary for an explosion to occur; however, some would argue that this figure (the
„lower explosive limit‟) should be closer to 500 grams per cubic metre. Either way, such a cloud would resemble a dense fog.

When a lump of material burns, only a small part of it is exposed to the air. As the surface burns, it exposes the material underneath
which then burns. Heat is given off gradually.

If, however, the burning material is in small pieces, the surface area is increased dramatically and, if mixed with air and ignited, it will
burn very rapidly. The energy from the burning is released suddenly, mainly as heat. If the dust cloud is contained, this rapid release
of heat (and gaseous products) causes the pressure to rise to levels most milling plant cannot withstand.

2) Oxygen/air around the particles of dust

ONE TEAM – ONE VISION Page 10

HYGIENE, HEALTH & SAFETY

Fire needs oxygen, otherwise it will not burn. If there is a very large concentration of dust, there will be insufficient oxygen around the
flour particles to cause an explosion. This „higher explosive limit‟ has never been well defined; figures up to 3kg of flour per cubic
metre have been suggested. Flour which has settled does not explode because the amount of oxygen around the particles is too low.
(However, there is the risk that an initial explosion elsewhere will shake the dust into a cloud within the explosive limits.)

Because oxygen is present in air, it can rarely be excluded from the milling process. However, the ignition of oxygen can be
chemically inhibited. This method of explosion prevention is called suppression; it is sometimes used to safeguard bins and dust
collectors. Equipment is installed which, at the first sign of a rise in pressure, shoots a suppressing agent into the bin. This agent
inhibits combustion and thus prevents an explosion.

3) A source of ignition
Although mixtures of dust and air of certain concentrations are capable of explosion, they will not explode of their own accord. Some
part of the dust cloud must be heated to the minimum temperature necessary to ignite the cloud. However, once ignition has started it
will spread throughout the cloud as a chain reaction.
This ignition temperature varies with the material involved but most grain and flour dust can be ignited by hot surfaces. There is no
measurable absolute minimum ignition temperature for any dust cloud as the temperature required will depend on the volume of the
cloud that is heated as well as parameters such as dust concentrations, etc. It is true that most grain and flour dusts can be ignited by
surfaces 400°C-500°C under standard test conditions but lower temperatures could be effective if larger volumes were used. Even at
temperatures around 200°C there is a danger of shouldering should thick layers of dust be allowed to accumulate. Whilst presenting a
relatively low risk, shouldering dust can lead to flame and an outbreak of tire or, if it is dispersed in air, can cause an explosion
Precautions to exclude sources of ignition include forbidding naked flames and smoking within the mill. It is also necessary to ensure
that metal containers and equipment are properly earthed, since static electricity could cause a spark and thus ignition. Static
electricity does not present a high risk in flour mills but can be a problem in three areas:

a) Where two pulleys are joined by an insulated belt. if one pulley is not earthed a static charge can build up. In many cases the
pulleys are connected by the same steel support frame, but this should not be taken for granted;

b) When stocks are flowing mechanically, pneumatically or by gravity. All metal parts of the system must be continuously earth
bonded. Particular attention should be given to sight glasses, rubber connectors on trunking and flanged joints where breaks in
connection could occur. Earthling of bulk tankers during loading and unloading together with use of hoses loading back to the
tanker is also absolutely necessary;

c) Where stock is fed into a container. Flour at normal moisture is not a good insulator and rapidly loses its charge if the container is
earthed. However, if the container is not earthed it can retain charge for a considerable time. Any insulated part inside bins etc could
gain a charge from the flour, so it is essential that these are bonded to the main body.

It is also usual to fit lightning conductors to high buildings and all these systems need to be checked regularly to ensure the continuous
discharge to a good earth.

Particular care must be taken during cutting or welding operations, if these are allowed at all. Some mills forbid cutting and welding
on site; if they are allowed it is essential that all dust is removed from the area to be tackled, that the machinery is isolated and that

ONE TEAM – ONE VISION Page 11

HYGIENE, HEALTH & SAFETY

trained people with the appropriate fire extinguishers and hose reels are on hand during the operation.
Afterwards there should be regular inspections for signs of burning. If a permit to work system is used, a permit will be needed before
any welding or cutting begins. Certainly no cutting or welding should take place on site without specific management approval.

Explosions have occurred in silos and bins due to portable inspection lamps being lowered into them. Putting lamps in bins is
extremely dangerous and should be forbidden. Faulty connections could cause a short circuit, the bulb could be broken, and the heat
of the bulb may ignite the dust. Power lights should be fixed outside the bin: if a light is needed inside the bin, the hand lamp used
should be of a type approved by the Health and Safety Executive (with an Index of Protection (IP.) rating of 5x or 6x). It must be
secured so that it cannot be dropped into the bin.

Although dust clouds at the lower explosive limit should not be found in the mill atmosphere, they will certainly be found in some of
the machines and equipment. Maintenance is especially important on machines where friction can occur. Overheated rolls and
bearings, and elevator band slip have caused serious fires. Stray metal can cause sparks (and serious damage). It is therefore
important that magnets are fitted and cleaned regularly. Look at what you clean off too, as it may show problems earlier in the
process; all metal came from somewhere.

With pneumatic conveying there is a danger of a fire in one part of the mill being carried to another part. It is therefore sensible to
assume that an explosion could occur and take steps to limit its effects. In an explosion there is a rapid rise in pressure. Unless the plant
or building can withstand the very high pressure it will burst, catapulting hot gases and burning material into the surrounding area. This
can set off secondary explosions, usually more violent, as further clouds of dust form and are ignited by the debris. It is rarely possible
to design plant which can withstand the maximum pressures involved (though where this can be done it gives good protection). Steps
can, however, be taken to prevent the spread of the explosion and to relieve the pressure in a safe direction.

A device widely used to prevent an explosion spreading is the power- driven rotary seal or wheel valve, see Fig.4. This does not allow
a blast wave to pass through it. Burning particles may pass through, but this can be prevented by arranging for the power to be cut
from the motor. Another form of choke uses the dust as a plug - if one flight of an inclined screw conveyor is omitted, it will never
empty itself below the level of that flight, see Fig.5a. Horizontal screw conveyors can be treated similarly but the upper half of the
casing has to be closed with a baffle plate, see Fig.5b.

ONE TEAM – ONE VISION Page 12

HYGIENE, HEALTH & SAFETY

Remember that explosion relief systems do not prevent explosions; they only channel the pressure in a safe direction. They have to be
capable of operating almost instantaneously as the pressure rise is rapid, and the area of the system must be large enough to relieve the
pressure quickly. Reliefs usually take the form of bursting panels or explosion doors. These will relieve the pressure and eject a
fireball of hot gases and burning dust. They should be vented to the outside by short, straight ducts of sufficient strength to withstand
the likely pressure. If it is not possible to vent to the outside, care must be taken to ensure that the vent is not into a room or area
regularly occupied. This can sometimes be achieved by use of a blast deflector plate.

Bursting panels are made of many materials, and need to be carefully designed and installed by competent engineers. The pressure
at which they will burst will depend on the material, its thickness and the vent area, amongst other things. To avoid damage to the
panel during normal operation, the thin diaphragm may need to be supported. A wide gauge wire mesh may be used, provided it is
securely fixed on the inside of the vent. It should never be placed on the outside.

ONE TEAM – ONE VISION Page 13

HYGIENE, HEALTH & SAFETY

Bursting panels give good dust-tight seals, but may allow burning dust to leave after an explosion, or allow air into plant causing
further problems. Explosion doors are harder to make dust tight, but can often be made to open at lower pressures and are usually
more reliable. However, if the doors are self-closing, damage can occur after an explosion when the interior of the plant cools down
and the pressure drops. Explosion doors should be securely fixed to the plant or they may become projectiles in an explosion.

Explosion relief should be fitted on all large cyclones, filters, silos, bins and other vessels, placed close to any points where ignition
may take place or where an explosion wave might enter a vessel. On cyclones the reliefs should be on the flat top of the cyclone
body but, if the flat top of the cyclone vortex finder is used, the vortex finder within the cyclone must be cross-braced to prevent it
collapsing during an explosion. Reliefs can be fitted with switches to slop plant when the relief opens this stops burning material
being carried to other parts of the system.

nabim has produced a booklet called ‘The Prevention of Fire and Dust Explosions in Flour Mills and Bulk Flour Containers'. This
booklet gives guidance on avoiding dust explosions and detailed precautions for particular items of plant. It also gives criteria for
deciding where vents are needed and how large they should be. The booklet forms a code of practice for the flour milling industry,
but is also of wider use as a source of information. Students do not need to refer to the booklet for examination purposes, but it is
strongly recommended to anyone who wishes to have detailed information on prevention of dust explosions. The book is available
from nabim. 21 Arlington Street, London SWIA IRN (price on application).

1.2 Falls from heights

Falls from heights are the biggest cause of fatalities and major injuries in UK industry. Surprisingly 2 out of 3 major injuries are
caused by “low falls”, i.e, falls from below two metres. A third of all reported fall- from-height incidents involve ladders and step
ladders.
There are many circumstances in flour mills where people are working substantially above ground or floor level: they may also work
near the edge of an opening where they may be at risk of falling.
Such risks arise where access to roofs for cleaning and bird proofing is required, access to high level spouts and pipe work for
cleaning and unblocking chokes.

A number of precautions must be taken to prevent falls, for example:

1) Do not make mobile scaffold too high, use stabilizing outriggers or make sure they are secured.
2) Forklift trucks must not be used as make-shift platforms.
3) Many are killed or injured by falls through fragile roofs or skylights. A safe system of work, together with a suitable
working platform and safety harnesses, should be used.

1.2.1 Safe use of ladders and step ladders

Falls from ladders or step ladders are especially serious, since they often cause broken bones. Due to the nature of much of the
work in milling, many tasks have to be undertaken that involve working at height, and in particular from ladders and stepladders.

The golden rules when using ladders and stepladders:

1 Check the Condition:

ONE TEAM – ONE VISION Page 14

HYGIENE, HEALTH & SAFETY

a) make sure the ladder is sound with no visible defects they should have a pre-use check each working day. Ladders should
be not painted, since this can hide defects;
b) ladder feet are essential to prevent the base of the ladder slipping missing stepladder feet cause it to wobble;
c) the feet should be clean, and in good repair (not loose, missing, splitting, excessively worn).

2. Use Them Safely

a) never stand on the top three rungs of a ladder;
b) do not use the top two steps of a stepladder unless a suitable handrail is available;
c) avoid holding items when climbing ladder/stepladders (for example by using tool belts);
d) do not overload them - the person and anything they are taking up should not exceed the highest load stated on the ladder;
e) do not overreach keep the body inside the ladder confines;
f)always maintain three points of contact (hands and feet) at the working position (i.e. two hands and one foot or one hand and
two feet);
g) if appropriate, tie the ladder to a suitable point, making sure both stiles are tied; where this is not practical use a safe unsecured
ladder or a ladder supplemented with an effective ladder stability device; if this is not possible, footing a ladder is the last
resort and should be avoided where possible.
3. You should only use ladders or stepladders:
a) where they will not be struck by vehicles, by protecting them with suitable barriers or cones;

b) where they will not be pushed over by other hazards such as opening doors;
c) where pedestrians are prevented from walking under them or near them;
d) where ladders can be put at the correct angle of 75% (angle of 1 unit out for every 4 units up);
e) where the restraint device on stepladders can be fully opened;
f) only use ladders/stepladder for short duration work.

1.2.2 The Working at Height Regulations

Under these regulations some common flour milling tasks considered to be working at height include:
i. Work on the back of a lorry;
ii. Working on a scaffold or tower scaffold;
iii. Working on a mobile elevated platform (such as a cherry picker);
iv. Climbing permanent structures such as gantries.

The Working at Height Regulations require that:

a) all work at height is properly planned and organised;
b) all work at height takes account of weather conditions that could endanger health and safety;
c) those involved in the work are trained and competent;
d) the place where work at height is done is safe;
e) equipment for work at height is appropriately inspected and controlled;
f) the risks from fragile surfaces are properly controlled; and
g) the risks from falling objects are properly controlled.

ONE TEAM – ONE VISION Page 15

HYGIENE, HEALTH & SAFETY

1.3Electricity
Electricity is the most convenient and flexible source of power and is commonly used in flour mills, to drive mill machinery and in
the office to power computer systems.
Electricity is probably one of the most dangerous hazards used at work because:
You cannot sec it;
You cannot smell it;
If you feel it, it may be too late.

Electrical faults are also a common cause of fires, which in a milling environment could result in serious damage or even a dust
explosion.
Effect of electricity on human body
Electricity can cause death or serious injury by:-
Shock: electricity causes muscular spasm; it can interfere with the regular action of the heart; and it can cause respiratory
failure.
Burns: electricity can cause both surface burns and deep tissue burns

Other dangers from electricity

Fire: from electrical faults; overloading of conductors; or discharge of static electricity.
Explosion: electricity can provide a source of ignition, one of the elements necessary for a dust explosion to occur.

1.3.1 Electricity - Controlling the risks

Fuses
- essential for safety but primarily for the protection of the cable; will cut off supply if the current becomes too high because the
circuit is being overloaded or in the event of a short circuit.

RCDs- Residual Current Devices

- an RCD is a type of circuit breaker that continuously compares the current in the phase and neutral conductors of the circuit.
The currents in a healthy circuit will be equal but, in a circuit that develops a fault, some current will flow to earth and the
phase and neutral currents will no longer balance. The RCD detects the imbalance and disconnects the circuit.
Isolating Switches
- every piece of equipment using electrical power should have its own isolating switch which should have means for locking
them in the OFF position.
Earthing
- prevents conducting parts of equipment (i.e. metal frames or lids) which do not normally conduct electricity from becoming
live during faults.

Portable Electrical Equipment

This is electrical equipment that can be carried about during its normal use and which uses a mains power supply. Typically
equipment includes hand-held power tools, hand lamps etc.

ONE TEAM – ONE VISION Page 16

HYGIENE, HEALTH & SAFETY

The appliance should be:

a) in good condition and repair
b) properly wired
e) suitable for the supply voltage
d) properly earthed unless double insulated
e) regularly inspected by a competent person (plug, cable and appliance) and have suitable dated tag attached.

Users of portable equipment should visually check for signs of damage to the appliance before use, particularly the plug and lead.
These precautions are simple and easy to implement and they provide a high level of protection in the use of portable
equipment

1.3.2 The Electricity at Work Regulations 1989

These UK Regulations emphasise the duty of the employer to assess the risk to health and safety of all areas of work where
electricity is used. It is the employer’s responsibility to consider not only the possibility of electric shock, but also aspects of design,
construction and installation of electrical systems, and any damaging effects on the environment or in other ways.

Only qualified persons should work on electrical equipment and wherever possible such work should be carried out when plant and
equipment has been turned off and the supply isolated. A Safe System of Work must be adhered to by a competent person where
live or potentially live circuits are involved.

Any faults identified or suspected in electrical equipment should be reported immediately to a competent electrician.

1.4 Workplace transport

The term “workplace transport” is used to refer to any vehicle or piece of mobile equipment from mobile cranes to fork lift trucks in
warehouses which you might find in use in the workplace.

On virtually every flour mill site, there are movements of grain delivery trucks, bulk flour tankers, and forklift trucks. These
vehicles pose a variety of risks to the health and safety of people at work, and are a significant cause of fatalities and serious
accidents.

The most common type of workplace transport accidents are:-

Being struck by a maneuvering vehicle, particularly when reversing

Operators falling from vehicles

Vehicles overturning - particularly fork lift trucks as a result of operating on uneven ground

Vehicles striking buildings or obstructions

Manufacturers' instructions for the safe operation of vehicles being disregarded; and

Unsafe loading and transportation of materials

ONE TEAM – ONE VISION Page 17

HYGIENE, HEALTH & SAFETY

In addition, some transport accidents occur because vehicles have not been properly maintained or are being used for purposes for
which they are not suitable. Drivers who adopt unsafe working practices - for example, by driving too fast or failing to follow
established site traffic routes - can also pose a risk to the health and safety of themselves and others.

Although everyone has a part to play in preventing workplace transport injuries and fatalities from designers of workplaces and
vehicles to operators and drivers employers ultimately take responsibility for providing and maintaining safe systems of work and
for taking all reasonable precautions to ensure that transport risk are properly controlled and managed.

All mill sites are different in their layout and the level of transport activity. At some older sites, lack of operating space leads
to specific problems such as:
• Congestion
• Vehicles having to man oeuvre and reverse in difficult circumstances
• Lack of space means no opportunity to provide segregated, pedestrian routes
• However, there are certain precautions that are applicable to all sites:-
• Only competent and authorized persons may operate a works vehicle
• Ensure all vehicles are thoroughly maintained by suitably qualified people
• Use seat belts, or lap belts, to prevent fork lilt operators front being crushed between the machine and the ground in the
event of a roll-over, due to uneven or wet conditions.
• Implement, wherever possible, segregated traffic and pedestrian routes with adequate signage and instructions - to ensure
drivers and visitors, can easily follow them.
• Provide safe pedestrian routes from parking areas to offices, welfare facilities and workplaces
• Implement mandatory wearing of high visibility clothing when not using designated pedestrian walkways
• Minimize vehicle reversing if at all possible:
-implement one way systems round sites and loading/ unloading areas
-provide designated turning areas for vehicles
-reduce the number of vehicle movements as far as possible
-consider fitting closed-circuit television, convex mirrors to overcome restrictions to drivers' visibility
-ensure all vehicles on site are fitted with appropriate warning devices
-consider fitting reversing cameras ensure safe systems of work

In addition, drivers should be instructed to avoid reversing operations unless they are absolutely necessary.
Other operations associated with workplace transport which pose particular risks and must have a planned safe system of work. These
are:-

a) Loading and unloading

b) Tipping
c) Opening and closing curtain-sided vehicles
d) Sampling of loads
1.4.1 Off-site transport safety
All precautions mentioned above also apply to delivery vehicles. Specific concerns are safety at customers' delivery points, and
sampling from bulk tanker tops. Both these areas should be subject to risk assessment and reference should be made to the nabim
leaflet “The Safe Delivery, Handling and Storage of Flour" and Section 13 on Off Site Safety'.

ONE TEAM – ONE VISION Page 18

HYGIENE, HEALTH & SAFETY

1.4.2 Legislation
b) The Provision and Use of Work Equipment Regulations
These are the main set of regulations covering transport safety at work. They require employers to select workplace vehicles
that are suitable for the work for which they are intended. Essentially, this means that employers must ensure that all
vehicles are operated according to the manufacturers‟ instructions and specifications. In addition there are a number of other
UK regulations that cover transport safety at work. These include:-
c) The Workplace (Health. Safety and Welfare) Regulations These require employers to ensure that pedestrians and vehicles can
circulate in a safe way. for example, by establishing pedestrian only areas from which vehicles are completely excluded. It
also requires employers to establish safe vehicle routes round the workplace;
d) The Lifting Operations and Lifting Equipment Regulations (LOLER)
These require employers to carry out risk assessment of lifting operations, including the selection and use of such equipment
as lift trucks, and training the staff who operate them.

Just its road signs play a vital role in creating a safe road network, so too is it important to display appropriate safety signs to
alert people to the transport hazards that exist in the workplace. Signs can be used to warn drivers of potential hazards including
sharp bends, pedestrian crossings and steep gradients - and to give instructions on safe working practices, such as speed
restrictions. Safety signs and road markings should be clear and comply with the design prescribed by the Traffic Signs
Regulations and General Direction

1.5 Machinery
The numbers of injuries associated with machinery in the flour milling industry is relatively low. However, the risk of serious and
sometime fatal injuries as a result of coming into contact with moving parts of machinery is still high. The injuries caused by
machinery can be classified into four main hazard categories:-

Hazard Injury Machinery

Friction burns or Roller Mills

Contact abrasions Grinding Wheels
Amputations Circular saws

Clothes, long loose hair, can become entangled in

Entanglement Shearing or crushing unguarded shafts, pulleys or belts, conveyors,
hydraulic scissor tables

Rotary Air Locks

Trapping Crushing
Roller Mill Nips
Clamps on packing equipment
Physical wounds - bruises, Palletiser
grazes,
Pallet Inverters
Impact lacerations
(coming into contact with fast
moving machinery during the

ONE TEAM – ONE VISION Page 19

HYGIENE, HEALTH & SAFETY

cycle)

1.5.1 Machinery Hazard Control

Where any of these hazards are identified, action should be taken to eliminate or reduce to a minimum the risk faced by
employees. If the hazard cannot be eliminated a risk assessment should be made to deter what safety control measures
should be taken. These measures include

Control Measures:
Physical Guards - to prevent operators reaching a dangerous part
- Fixed Guards requiring a tool or key to release it
(prevents physical
- Adjustable Guards with parts that can be adjusted to follow the profile of the work being
access to hazard) carried out
- Interlocked Guards can be electrical, mechanical, pneumatic or hydraulic
- Fencing - a barrier all around a machine
- Trips - devices which when actuated trip the machine and cause it to stop or revert to a safe
Procedural (make condition.
Planned preventative maintenance and regular inspection of machines and
work tasks safer) safeguards/safety devices Safe Systems of Work

- usually as back-up to guarding systems

- should be in writing to prevent ambiguity
- E.g. electrical isolation and lock out tag out (LOTO)
- for high-risk work a permit-to-work system should be used.
Behavioural (develop
safer people)
Providing employees with suitable and sufficient information, instruction, training and
supervision on the risks they face in their work
- precautions and preventative measures in place to protect them
- emergency procedures
- employer should take account of the employees abilities both mental and physical,
to do the work required of them.

1.5.2 Safety during maintenance

Maintenance is one of the more hazardous types of work and particular attention needs to be given to assessing the risks and
preparing for the safe implementation of the work. The main maintenance areas where high risks arise in milling are:

work on buildings and roofs at high levels;

power driven machinery;
in confined spaces such as bins, silos and underground pits.
Common precautions that should be taken whenever maintenance work is being organised include:
a) planning what work is to be done:
b) assess potential risk:

ONE TEAM – ONE VISION Page 20

HYGIENE, HEALTH & SAFETY

e) prepare work method statement;

d) develop safe system of work where necessary including permit- to- work;
e) check the equipment and area to ensure it is safe to start work;
I) instruct operatives and provide training where required:
g) provide suitable work and safety equipment;
h) prepare for unforeseen circumstances make emergency plans;
i)monitor that the agreed work methods are being followed.

1.5.3 Legislation:
Provision and Use of Work Equipment Regulations 1998 - PUWER 98 These regulations, which apply to employers, are aimed
specifically at protecting the health and safety of workers. They detail the "management duties" covering selection of suitable
equipment, maintenance, inspection, specific risks, information, instruction and training. In addition, they have requirements for
guarding of dangerous parts of work equipment, and the provision of appropriate stop and emergency controls, stability, lighting and
suitable warning or devices. They apply to all work equipment, including machinery, tools or mobile plant used at work. These
regulations cover anything provided for use at work, from a stapler to a sifter, a cup to a conveyor.

1.6 Lone working

Flour milling is a continuous process, operating on a 24 hour basis, and mills are often partially or fully automated, with often only
one or two operators monitoring the plant at any one time. Therefore, it is possible for someone to be alone on the premises (for
example night-time security), or in part of the mill or warehouse.
1.6.1 Risks for lone workers
In some situations lone workers may be at risk because they are not physically capable of carrying out certain activities safely on
their own. These may relate to:-

Manual Handling Activities

- where team handling is identified as being necessary.
 Use of Certain Types of Equipment
- particularly heavy and bulky equipment, or where another person needs to be available to carry out adjustments.
Operation of Controls etc.
- controls may be physically separate from each other requiring
- second person to activate them.
Achieving Safe Access
- a second person may be necessary to ensure safe use of access equipment

In addition some work activities may involve such a high degree of risk that another person needs to be present to take appropriate
emergency actions such as:-
Isolating electrical supplies particularly where live work is being carried out.
Rescuing a worker from inside a confined space use of a rescue line or wearing respiratory PPE.
Giving immediate first aid attention important for electrical accidents.
Safely recovering a worker who has fallen whilst wearing a safety harness.

ONE TEAM – ONE VISION Page 21

HYGIENE, HEALTH & SAFETY

1.6.2 Controlling risks to lone workers

Lone workers must be made aware of the types of risk that they may encounter and the precautions which must be taken to control
those risks - this will require information, instruction and training supported by effective on going supervision.
Some types of lone working may justify formal written procedures or
rules, but following risk assessment some activities may be identified as being ones which lone workers must never carry out alone:

a) Work in confined spaces

b) With live electricity
c) Working at height

Good communication is essential to ensure the safety of lone workers. This is likely to involve provision of mobile phones, radios,
man down emergency alarms etc.
Emergency arrangements response to alarms must be planned and documented, covering such specific details as who is to
respond to emergency alarms and what actions they should take. In addition, employers should ensure the provision of basic
first aid equipment.
Those responsible for managing and supervising lone workers must ensure that their activities are monitored effectively. It is also
vital to check the effectiveness of communications equipment and alarms and the awareness of staff on how they should react to
emergency situations.

1.6.3 Legislation
There are no general legal restrictions or regulations on working alone- however, the activities of lone workers must be subject to the
same sort of risk assessment process as any other type of work.

1.7 Manual handling

In the UK over one third of all reported lost-time absences are attributed to injuries caused by manual handling. Manual handling can
be defined as “any transporting or supporting of a load by hand or bodily force whether lifting, putting down, pulling, pushing,
carrying or moving.”

1.7.1 Dangers associated with manual handling

It is sometimes assumed that most manual handling accidents in flour mills will involve lifting bags and occur in the warehouse
packing areas however, this is not the only cause and unusual operations are often associated with accidents. Many occur through
lifting, carrying and handling equipment, the majority result in back injuries and other sprains.

Typical causes of manual handling accidents include:

a) Faulty handling techniques.
b) Loss of control of the load during handling.
c) Miscalculation of the weight of the load being handled particularly in the case of machinery and equipment.
d) The failure to allocate a sufficient number of workers to the operation.
e) Lack of awareness of the potential hazards of manual handling and related injury' for example when employees continue to work
despite back pain arising from manual handling or attempting to recover falling sacks etc.

Common Injuries
 Strains- injury done to a limb or part of the body through being forcibly stretched beyond its proper length.

ONE TEAM – ONE VISION Page 22

HYGIENE, HEALTH & SAFETY

 Sprains - severe wrench or twist of a ligament or muscle of a joint causing pain and swelling of the part, resulting in pain and
difficulty in moving.

 Wounds - handling sharp or rough surfaces without the correct personal protective equipment (e.g. gloves) could leave
employees with cuts and bruises on their arms and hands.

 Fractures a slip, trip or fall or dropping a heavy load could mean broken bones.

 Hernias - the strain of lifting, when it's not done correctly, can cause ruptures in the abdominal wall; and hernias can be very-'
painful and debilitating.

 Spine and Nerve Injuries - these are sadly very common and the most difficult to treat. In some cases when the injury occurs,
there is a possibility of long term or permanent damage. One of the common spinal injuries is the slipped or prolapsed disc.

Muscular-skeletal injuries
Wear and tear on muscles and joints may occur after many years of lifting or handling heavy objects - this is more likely if the loads
are handled incorrectly. Cumulative injury - is when you damage your back over a period of time by poor manual handling, and at
that point in time the damage becomes a painful injury. Any of these injuries could occur at any time, it just depends on the
circumstances. You could be simply lifting a rubbish bin incorrectly into a skip and suffer serious damage to your back.

You might spend a number of months or even years lifting heavy or awkward loads and suddenly you get out of your car or bend
down to tie your shoelace, and you suffer severe pain and seemingly sudden injury to your back. Some tasks undertaken in the
milling industry can be frequent and repetitive, from word processing to bag packing; these hazards need to be considered in the risk
assessment and the risk minimised by such precautions as job rotation.

1.7.2 Controlling the risks:

Employers should avoid manual handling operations that could put employees at risk of injury (use mechanical handling
wherever possible).

Employers should consider a range of control measures in order of priority:

Where manual handling is unavoidable, employers should carry out a risk assessment of the handling operations. A detailed
assessment of every manual handling operation is not necessary; for example, the occasional lifting of a small lightweight object,
will involve negligible handling risk. To help identify situations where a more detailed risk assessment is necessary the USE has
developed a filter to screen out straightforward cases.

Using the MAC (Manual Assessment Chart) will help with the initial screening of possible high risk manual handling activities.
However, the MAC is not appropriate for all manual handling operations and does not comprise a full risk assessment. To be
“suitable and sufficient” a risk assessment should cover:

 the task what has to be done - over what distance

 the individual physical capability, previous injury etc.
 the load the weight, size and shape etc.
 the environment weather, workplace temperature, lighting, steps, uneven floors

ONE TEAM – ONE VISION Page 23

HYGIENE, HEALTH & SAFETY

Safe Techniques of Manual Handling

Specific information and training on manual handling injury risk and prevention is essential, but it should be remembered that
training alone will not prevent injury. Where possible manual handling operations should be designed to suit individuals, not the
other way round.
However, as a complement to a safe system of work, rather than a substitute for it, effective training has an important part to
play in reducing the risk of manual handling injury.

Any training programmed for safe manual handling should give a clear understanding of the following:
1) how potentially hazardous handling operations may be recognized:
2) how to deal with unfamiliar handling operations:
3) the proper use of handling aids;
4) the proper use of personal protective equipment;
5) features of the working environment that contribute to safety:
6) the importance of good housekeeping;
7) factors affecting individual capability;
8) good handling techniques (see below )

A number of practical techniques have been developed to facilitate the manual handling of loads and therefore reduce injure.

a) PLAN stop and think, where is the load going to be placed? Use appropriate handling aids if possible. Do you need help with the
load? Remove obstructions from the planned route. For a long lift such as floor to shoulder height consider resting the load mid-
way on a table or bench in order to change grip.
b) POSITION adopt a good posture: position yourself close to the load, feet apart, to form a stable base, with the leading leg as far
forward as is comfortable. Bend the knees so that, when grasping the load, hands are nearly level with the waist.
c) GRIP Lower yourself onto the load with a straight back (in a natural line). Take a firm and secure grip and make ready for the
lift.
d) LIFT with a straight back, head forward, chin in. eyes forward, lift the load using your upper legs and thighs as the power for
the movement. Always hold the load close to the body. Do not bend or twist your back or neck. Do not jerk.
e) MOVE: now you have picked up the load, move carefully and steadily with the minimum of upper body movement to your
lowering point.
f) LOWER reverse the lift. Straight back, eyes forward and release the load to its resting place. Release the weight and pressure
from your upper body, stand up and check that the load is safe and in the correct place.

Even safer is not to lift at all! Using a mechanical aid, such as a sack barrow or pallet truck is much less effort for heavy loads. Used
correctly, with the proper training, use of mechanical lifting equipment not only helps you to do your job more efficiently, it also helps
you to do it more safely.

1.7.3 Legislation - Manual Handling Operations Regulations The regulations establish a clear hierarchy of measures;

a) Avoid hazardous manual handling operations so far as is reasonably practicable this may be done by redesigning the task to

ONE TEAM – ONE VISION Page 24

HYGIENE, HEALTH & SAFETY

avoid moving the load or by automating or mechanising the process;

b) Make a suitable and sufficient assessment of any hazardous manual handling operations that cannot be avoided:
c) Reduce the risk of injury from those operations so far as is reasonably practicable. Particular consideration should be given to
the provision of mechanical assistance but, where this is not practical, then other improvements to the task, the load and the
working environment should be investigated.

1.8 Slips and trips

Across the whole of industry, accidents involving slips and trips tire the most common and yet they often seem to be those which
could be most easily avoided. Many are caused by obstructions or spillages being left on stairs, gangways and other pedestrian
routes; some occur when people are in a hurry or do not look where they are going or when they are jumping down from a truck or
other height; according to the reports of those involved, others just seem „to happen'!

Many slip and trip accidents result in minor injuries: however, a significant number end up with broken limbs or serious head
injuries. This is particularly so if the slip or trip occurs while working at height or in areas where vehicles are operating.

1.8.1 Controlling the risks

One of the most effective ways of eliminating or reducing slips and trips is to introduce good housekeeping procedures in the
workplace. Keep floors and traffic routes clear of obstructions, store things in their proper place, maintain equipment to prevent
leakages of wheat or flour and clear spillages up immediately.

Floor surfaces should be able to be cleaned easily and should be resistant to damage caused by traffic flow, and any damaged tiles,
paving slabs etc, should be reported and repaired. There should be adequate lighting for safe passage, particularly at places where
there is a change of level, for example staircases or ramps.

Correct footwear should be used where slip resistance is required but. as with all personal protective equipment, it is a last resort to
be used when all the other control measures have been implemented and some residual risk remains.

1.9 Harmful substances

Thankfully, there are fewer harmful substances now on flour mill sites than in the past; for example, chlorine and chlorine dioxide
were in quite common use up until the 1990s. However, there is still a reasonably long list of harmful substances to be found in
mills: insecticides and fumigants; laboratory chemicals; oil etc. Yet potentially the most harmful substances, if not treated with
respect, may be the raw materials, product and additives used in the milling process itself.

It is possible for certain susceptible people to become allergic to dusts arising from grain or flour or to the moulds found on uncleaned
grain. In the UK, both grain dust and flour dust are subject to a Workplace Exposure Limit (WEL) because they can cause
occupational asthma. Asthma is a breathing problem; people suffering from it have recurring attacks of breathlessness, coughing or
wheezing and a feeling of tightness across the chest. It has many causes: indeed, often the cause cannot be identified. Some people
suffer from it from childhood; others can develop it from exposure to a sensitising agent. Dusts, fumes, enzymes and some chemicals
can be sensitising agents; it is not known why some people can become sensitised while others are unaffected. A doctor should
examine anyone who has asthmatic symptoms. If the diagnosis is occupational asthma, the symptoms normally disappear if the

ONE TEAM – ONE VISION Page 25

HYGIENE, HEALTH & SAFETY

sufferer avoids exposure to whatever is causing the allergic reaction.

The flour milling industry considers that some bread improvers may pose a greater hazard than flour itself, because they contain
fungal alpha-amylase. However, if a mill operates safe systems of work and employees are made aware of the hazards then, certainly
under normal operation, the actual risk posed to health by these substances is believed to be very low.

1.9.1 Controlling the risks

In the UK, the Control of Substances Hazardous to Health (COSHH) Regulations provide a step-by-step approach to the control of
hazardous substances encountered at work.

[Link] Risk assessments under COSHH

Employers are required to make an assessment of likely risks to health. These must determine:

i) what hazards exist, and in what form;

ii) who will be affected;
iii) the degree and time of exposure;
iv) the workplace location affected;
v) what control measures will be necessary to maintain accepted exposure limits;
vi) how the control measures will be monitored;
vii) what level of instruction, information and training is required.

These assessments should be carried out for every hazardous substance encountered in the workplace, and any assessment must cover
the entire site (laboratories, offices, etc, as well as the mill areas). Work carried out by the maintenance and engineering departments
will need careful attention. In assessing risks, the supplier’s own safety data sheets will be useful.

[Link] Workplace exposure limits

Expert advice on risk may be needed in some instances, which may also extend to training by outside specialists who will advise as
necessary which substances are subject to Workplace Exposure Limits (WELs). It is an offence to exceed Workplace Exposure
Limits. Efficient exhaust ventilation and the use of breathing protection may be required, although Personal Protective Equipment
(PPF.) and Respiratory Protection Equipment (RPE) are ‘last resort' options.

An effective monitoring system should include maintenance, examination, and testing procedures for all control equipment, including
Local Exhaust Ventilation equipment and records of all examinations and tests held on file.
It is also now considered appropriate for Personal Health Surveillance to be available for those involved in the flour milling industry.

[Link] Dust
a) Wherever possible, take measures to contain dust securely and avoid exposure due to leakage from joints and gaps in machinery
or handling systems.
b) A competent person should assess dust exposure levels in the workplace. Compare the results to current Workplace Exposure
Limits (WELs) - flour and grain dusts are subject to (8-hour time- weighted average) WEL of 10mg/m3 (which would be a
visible mist in which it would be uncomfortable to work). Because these dusts are ‘sensitisers’ and can cause occupational
asthma, exposure must be reduced to as far as is reasonably practicable below this limit.

ONE TEAM – ONE VISION Page 26

HYGIENE, HEALTH & SAFETY

c) Ensure the use of good working practices which reduce the amount of dust generated. For example, the use of vacuum cleaning
equipment rather than a brush can significantly reduce dust exposure.
d) Apply engineering controls wherever possible. The use of local exhaust ventilation, close to the point of dust generation is
particularly effective.

Personal Protective Equipment must be provided and used when exposure cannot be controlled by other means.

1.10 Noise
Continued exposure to noise can cause permanent hearing damage; either loss of hearing or tinnitus (a ringing, whistling, buzzing or
humming in the ears). The damage can be caused immediately by sudden, extremely loud, explosive noises, for example from a
cartridge operated nail gun. But hearing loss is usually gradual due to prolonged exposure to noise; the louder the noise and the
longer the exposure, the greater the risk.

Noise can be a problem in some areas of flour mills. The noisiest areas are probably roller floors and around grinders, blowers and
compressors. Workers are unlikely to spend a lot of time on the roller floor, much of their work being done in control rooms where
noise levels will be much lower, and grinders usually operate with little direct supervision. Grinders are also usually enclosed to
contain noise, and rarely run for more than a few hours a day. However, it is sensible to wear hearing protection if you spend more
than a few minutes in areas where you have to shout to make yourself heard by someone nearby

1.10.1 Controlling the risks

The first consideration in any noise control programme is to eliminate the source of noise and hence protect the whole workforce.
However it is not always possible to eliminate noise emissions completely, so action must be taken to reduce noise emissions as far
as possible. A hierarchy of action to eliminate or control noise is as follows:

1. Specify - low noise machinery at the purchase stage.

2. Engineer out noise - by replacement, redesign or modification of plant; or by altered plant layout to achieve acceptable noise
levels. (Guarding, if poorly designed or lilted, can amplify noise.)
3. Reduce noise at source - by using non-metallic components or fitting exhaust silencers and ensuring planned maintenance is
undertaken.
4. Contain the noise source within an acoustic enclosure, suitably ventilated.
5. Isolate personnel from noise in acoustic cabins or sound havens.
6. Absorb the noise by using noise absorbent materials in linings, panels etc.
7. As a last resort Provide Personal Hearing Protection.

1.10.2 Legislation
The UK's Noise at Work Regulations impose a duty on employers to assess the average daily noise exposure of employees and
take the following actions on the results:

First Action Level - Daily personal noise exposure of 80dB(A). Employees should be informed and personal ear protection
issued on request.
Second Action Level - Daily personal noise exposure of 85dB(A). Ear Protection Zones should be designated and marked with
signs. All employees must wear ear protection in these areas.

ONE TEAM – ONE VISION Page 27

HYGIENE, HEALTH & SAFETY

1.11Confined spaces
Confined spaces include closed and open topped water and fuel tanks, wheat and flour bins, dust collectors and cyclones, flour
tankers, service tunnels and drainage systems. Hazardous conditions may be caused by a build up of carbon dioxide from damp wheat,
by toxic fumes from paint or by high levels of Hour or wheat dust, which may cause breathing problems or become an explosion risk.
There is also the risk posed by the moving parts of machinery such as screw bin dischargers.

Accidents in bins and silos are extremely rare but the results can be very serious, sometimes leading to fatalities. As well as the
hazards mentioned above, wheat bins are particularly dangerous because a person can be sucked down into the wheat and asphyxiated
if the bin is being discharged.

If someone does become incapacitated in a confined space, it can be difficult to evacuate them to a place of safety where suitable
treatment can be administered; this delay may compound the effects of an injury.

1.11.1 Controlling the risks

Before anyone enters a confined space they should be:
Issued with an authorized Permit to Work
Suitably instructed and trained
Well informed of the safe system of work Other precautions that should be followed are:
Make sure the atmosphere is safe and that there is enough fresh air
Make sure that there is no risk from the start-up of any machinery
I have trained help at hand
1.11.2 Bin entry
a) Avoid entry into bins containing wheat or products if at all possible.
b) Work from outside the bin whenever better work planning or a different approach can reduce the need for entry.
c) If entry to the bin is unavoidable, follow a Safe System of Work*.
d) Put in place adequate emergency arrangements before the work starts.
(* nabim Recommended Bin Entry procedure. Appendix 11)

1.12 Striking objects

This category covers the far too frequent occasions when people simply walk into stationary objects. In the flour mills of today, where
many employees are peripatetic (that is, they move from place to place on site), it is perhaps unsurprising that this type of accident
remains relatively common; the same is true with slips and trips. Such incidents are more likely to occur when people are moving
about and when they are less familiar with their surroundings than in the days when someone might stay in the same area for virtually
the entire working day.
However, this is no excuse for not tackling the problem and mills should ensure that employees and others on site are aware
of their surroundings and of health and safety issues; this category is a particular cause of head injuries.

1.12.1 Controlling the risks

Flour mills are full of machines, conveyors, lift pipes etc, often installed into relatively small spaces. As part of their induction
training, all personnel and contractors must be made aware of the hazard this poses and they should be instructed to move carefully

ONE TEAM – ONE VISION Page 28

HYGIENE, HEALTH & SAFETY

about the site.

When a new mill is being planned or changes are being made to a working mill, all efforts should be made to design out any
potential striking hazards, by making sure there is plenty of headroom and pedestrian routes are free from obstructions. This
precaution is especially important when designing emergency escape routes.

In existing mills, areas must be well lit so that people can see obstacles clearly and notices used to give advance warning of low
ceilings etc.
Yellow and black warning paint or tape should be used to alert people to specific objects such as low beams or temporary equipment.

As a last resort, personal protective equipment in the form of plastic bump hats' can be issued to personnel who have to spend
time in particularly hazardous areas.

1.13 Off-site safety

A range of accidents occur each year to people who are working off- site. These accidents can occur to drivers making deliveries or
to sales people or technical staff visiting customers' premises. A whole range of hazards will be encountered by these employees,
including slips and trips, manual handling, exposure to dust or dangerous machinery, etc.

1.13.1 Controlling the risks

The employer must make themselves aware of the risks to which their employees are being exposed. They must then consult with the
controller of the premises (e.g. the customer) to minimize those risks. For instance, they may work together to produce a safe system
of work for delivering flour. This might include the safe movement and parking of the delivery vehicle, the introduction of mechanical
handling equipment to reduce manual handling, etc.

1.14 Occupational road safety

It has been estimated up to a third of all UK traffic accidents involve somebody who is at work at the time for instance, making a
delivery or driving between clients. Health and safety law applies to on-the-road work activities as it does to all work activities, and
risks should be managed effectively.

1.14.1 Controlling the risks

First of all consider the use of air or rail transport as a partial alternative to driving. Ensure that the driver is licensed, experienced and
trained to do the work safely and that they are fit and healthy. Vehicles must be suitable for the task and be maintained in a safe and
fit condition - this will entail regular servicing and daily safety checks by drivers. There must be methods of ensuring vehicles do not
exceed their maximum safe working load and that goods are secured during transit. Finally, drivers must not exceed the driving hours
laid down in legislation and they must take regular rest breaks.

2.0 Legal Health and Safety Responsibilities

Across the world, standards of workplace safety are laid down by law. This section uses the framework in the United Kingdom to
illustrate the general principles adopted by many countries.

In the UK the law is divided into two broad areas: Civil and Criminal.
In Civil Law a person may take action against another individual, or an organization, in order to obtain compensation for an injury or

ONE TEAM – ONE VISION Page 29

HYGIENE, HEALTH & SAFETY

illness caused by the negligence of the accused person or organization. This is the basis for the injury compensation claims made by
employees against their employers. UK law states that all employers must have sufficient insurance to cover any such claims.

Criminal Law is made up of a set of „statutes' (Acts and Regulations), laid down by Parliament, which define the standards that all
parties are expected to achieve. Failure to comply with these statutes could lead to prosecution and punishment by fines or
imprisonment.

The principal piece of health and safety legislation in the UK is the Health and Safety at Work Act 1974 (HSWA). This lays down
general duties to protect all people at work or others who might be affected by work activities. The Act is enforced by the Health and
Safety Executive (HSE), through (in the case of mills) the Factory Inspectorate. Local Authorities enforce the Act in certain types of
premises, e.g. offices and depots.

The Health and Safety at Work Act is backed up by several sets of more specific regulations. These complement, or in some cases
extend, file requirements of the Act. These regulations often come with an Approved Code of Practice ‟ (ACOP) which explains
how, in more practical terms, to comply with the requirements.

The HSE also issues 'Guidance Notes' which indicate good practice but are not legally binding. It is necessary to keep up to date
with new developments in health and safety legislation and how they are likely to affect the flour milling industry, since ignorance is
no defence in law.

2.1 General duties under the Health and Safety at Work Act 1974
The main intention of the Health and Safety at Work Act is to ensure that, so far as is reasonably practicable, people should be
protected against risks arising from work activities. The Act imposes general duties on employers, employees,
manufacturers/suppliers and all persons at work.
Employers have a duty to ensure, so far as reasonably practicable, the health, safety and welfare at work of their employees. This
includes:

a) providing and maintaining safe plant and systems of work;

b) ensuring there are no risks to health from the use, handling, storage and transport of articles and substances;
c) providing adequate information, instruction, training and supervision to ensure the health and safety at work of employees;
d) maintaining the workplace in a safe condition with sale means of access and exit;
e) maintaining a safe working environment with adequate facilities for employees' welfare.

Employers of five or more persons must prepare a written statement of company policy in respect of health and safety, and the
arrangements for carrying it out. This must be revised as necessary and brought to the notice of all employees.

Employers must also ensure, so far as is reasonably practicable, that people not employed by them (e.g. employees of contractors,
visitors, the general public) are not exposed to health and safety risks created by the mill's operations. This also applies to self-
employed people who must take precautions not to harm themselves or anyone else by their activities.

A milling company has a duty to protect its own employees whether they are working on-site or off-site. If those employees are

ONE TEAM – ONE VISION Page 30

HYGIENE, HEALTH & SAFETY

delivering flour to a bakery, both the bakery owner and the milling company have legal duties not to expose them to unacceptable
risks.

Employees have three duties;

a) to take reasonable care for their own health and safety and that of those who might be affected by their acts or omissions;
b) to co-operate with employers and others to enable legal duties to be performed;
c) not to interfere with anything provided in the interests of health and safety at work.

Manufacturers and suppliers have a duty to ensure that any article they make or supply for use at work is safe when used, cleaned and
maintained - again, so far as is reasonably practicable. They must provide adequate information about any conditions which must be
observed in using it. Those who install milling plant must ensure it is safely installed.

2.2 Management of Health and Safety at Work (MHSW) Regulations

These Regulations supplement the Health and Safety at Work Act. One of their key requirements is for employers to undertake a
systematic programmed of risk assessment in order to develop effective preventive and protective measures w here health and safety
are concerned. A suitable and sufficient risk assessment should:
 identify the significant risks arising out of work;
 enable the employer to identify and priorities necessary action;
 be appropriate to the nature of the work and be such that it remains relevant for a reasonable period of time.
The implementation of detailed preventive and protective measures will often depend on other relevant legislation; however, the
MHSW Regulations emphasize that it is best, if possible, to avoid risk altogether.
Where risks are unavoidable they should be combated at source and prevention measures should form part of a coherent policy and
culture throughout an organization. It is also essential that employees are informed of and understand their part in this health and
safety policy and receive the appropriate training.

Other issues dealt with by the Regulations include the appointment of a person known as the 'competent person'. This is a person
who combines a thorough understanding of health and safety together with knowledge and experience of the activities of the
business. The competent person assists the employer in dealing with health and safety requirements within an organization.

2.3 Other legislation

In addition to the health and Safety at Work Act and the Management of Health and Safety Regulations, the UK has a number of
other sets of regulations which cover specific topics. For example:
 The Electricity at Work Regulations
 The Provision and Use Work Equipment Regulations
 The Control of Substances Hazardous to Health Regulations
 The Manual Handling Regulations
 Etc.

all of which have been covered in more detail in Section I.

2.4 Enforcement Action

The Health and Safety at Work Act 1974 defines the general duties for employers, employees etc, and it also details the penalties
which may be imposed if the duties are not carried out. For most offences this is a fine of up to £20.000 but some offences can

ONE TEAM – ONE VISION Page 31

HYGIENE, HEALTH & SAFETY

receive an unlimited fine, or even imprisonment. Employers, employees, manufacturers and suppliers can be prosecuted for breach
of their duties under the Act.

In addition, to enforce the Act and Regulations. Factory Inspectors can issue two types of notice:

a) Improvement notice - this says what legal requirements the inspector thinks are being broken and gives a period for putting
matters right. This notice does not stop any work activity;
b) Prohibition notice - this is used where the inspector thinks work involves a risk of serious personal injury. It prohibits the work
activity which gives rise to the risk until matters have been put right. Prohibition notices can be either immediate, which stop
work at once, or deferred, which do not take effect for sometime. (An inspector might issue a deferred notice if the
consequences of halting the work activity would be severe but the time allowed before the notice takes effect is unlikely to be
more than a few hours.)
If matters are put right the notice ceases to have effect; there is no need to apply for it to be withdrawn.

failure to comply with an improvement notice can result in a fine of up to

£20,000 (or even more in serious eases). Failure to comply with a prohibition notice can lead to a very severe fine and even
imprisonment.

2.4.1 Powers of Factory Inspectors

As previously mentioned the Health and Safety at Work Act is enforced by the Factory Inspectorate, whose inspectors have wide-
ranging powers laid down in the Act, including:

a) At any reasonable time they may enter any premises where they believe an offence under the Act is being committed. (In a
dangerous situation they may enter at any time).

b) They can carry out any examination or investigation which they deem necessary.

c) They may direct that premises, or any part of those premises or anything within, shall be left undisturbed for as long as is
necessary to complete the examination or investigation.

d) They can take measurements, photographs or any other recording deemed necessary.

e) In the case of any article or substance which appears or is likely to cause danger to health and safety, they can cause it to be
dismantled or subjected to any other process or test as they believe necessary'.

f) They can require any person, whom they reasonably believe is able to give any information, to answer all questions that are
relevant and to sign a declaration of the truth of their answers.

g) They may require the production of, inspect, and take copies of:
i) Any books or documents required to be kept either by law or any other book or document which is necessary in the course of
the examination or investigation.
ii) To require any person to provide facilities or assistance, within their control or responsibility, to enable the inspector to carry

ONE TEAM – ONE VISION Page 32

HYGIENE, HEALTH & SAFETY

out their duties.

3.0. Health and safety culture

Any workplace develops its own culture made up of shared attitudes, beliefs and ways of behaving. It is essential that organizations
develop a proactive culture where everyone puts health and safety high on their list of priorities and people are not put at risk for
operational reasons.
There are a number of key actions an employer can take in order to create and maintain a positive health and safety culture:
Inform and consult with the workforce via notice boards, safety meetings, toolbox talks etc.
Recognise the fact that everyone has a role to play, not just managers and supervisors.
The senior managers must be committed and involved - they must set a good example.
Employees must co-operate with each other - for instance by keeping each other informed of any potential safety issues at shift
handover.
Good, open two-way communication at all levels both formal and informal
High quality training, including refresher training where necessary.

3.1 Organizing for health and safety

To make the health and safety policy effective and to ensure that the workplace is safe, the culture development has to be supported
by good and effective organization of people, plant, processes, safety systems etc. One way of doing this is to use the “Four Cs”
model. The four „Cs‟ of good health and safety organization are:
1. Competence: recruitment, training and advisory support.
2. Control: allocating responsibilities, securing commitment.
3. Co-operation: between individuals and groups.
4. Communication: spoken, written and visible.
3.1.1 Competence
There must be suitable procedures in place to ensure all employees recruited or promoted have the necessary physical and mental
abilities to do their jobs or are able to acquire them through training and education.
Training should be organized systematically, that is:

The skills needed to carry out all tasks safely should be assessed. This includes all employees, including managers, supervisors
and temporary staff.
People doing especially dangerous work should be given special attention, e.g. electrical workers, and they should be given
refresher training as and when necessary'.
Young and inexperienced people must be carefully supervised by a competent person until they have the necessary training and
experience.

The site must have competent advice on which it can call for help with safety issues. This can be within the organisation, e.g. the
Health and Safety Manager, or a range of external people who can help with specialist areas, such as dust explosion protection.

3.1.2 Control
Control starts with clear commitment and direction from the top managers of the company, making sure everyone realizes health and

ONE TEAM – ONE VISION Page 33

HYGIENE, HEALTH & SAFETY

safety is an important issue. This commitment, together with the overall health and safety objectives of the company, is usually
described in the 'Health and Safety Policy Statement’, This Statement forms the first part of the company’s ‘Health and Safety Manual'
and must be made available to all employees.

The next step is to ensure that there is an organisational structure in place which is capable of meeting the objectives. Everyone
including directors, managers and supervisors must understand their health and safety responsibilities and be given enough time and
resources to carry them out properly.

All employees should know their personal responsibilities for health and safety and what they have to do to fulfil them. They should
also be informed of the consequences of not taking their responsibilities seriously. Those people responsible for particular health and
safety jobs, for example carrying out risk assessments or workplace inspections, should be identified and everyone made aw are of
their specific roles.
This organisational structure and the key responsibilities form the second part of the Health and Safety Manual.
The third part of the Health and Safety Manual, known in the UK as the 'Arrangements ‟, consists of the detailed plans and procedures
covering all the important issues needed for managing health and safety properly. For instance:

Risk assessment scheduling;

First aid arrangements;
Evacuation procedures and other emergency procedures;
Thorough examination of lifting equipment and pressure systems;
The storage and handling of hazardous substances;
Arrangements for carrying out health surveillance;
The permit to work system;
Manual handling training;
Etc.
[Link] Target setting
Another important aspect of control is setting specific improvement targets or objectives and establishing systems for ensuring the
targets are being met. This can be done using the following model.
PLAN  DO  MONITOR  REVIEW

If we take, as an example, a mill which has set a target to reduce slips, trips and falls by 50% over the next six months

A PLAN will be produced which analyses the causes of slips, trips and falls and lists the actions needed to eliminate or reduce
these causal factors' for instance, replace slippery stairs, tidy up the workshop or introduce an awareness programme for all
employees.

The DO part, often referred to as the implementation phase, is carried out according to the plan.

 MONITORING is another way of saying measuring progress (or lack of it). This can be done by analysing the accident
statistics, inspecting the workplace to see if the necessary improvements have been carried out and examining the training
records.

ONE TEAM – ONE VISION Page 34

HYGIENE, HEALTH & SAFETY

 A REVIEW of the initiative can take place at the monthly safety meetings (it should not wait until the end of the six month
period) and decisions taken on whether progress is good or whether extra resources need to be allocated.

3.1.3 Co-operation
A good place to start is by forming a Health and Safety Committee made up of representatives from all departments and levels in
the organisation. One of the prime tasks of this committee is to ensure all staff are consulted on a regular basis. Consultation is a
two-way process and therefore, whenever possible, the person doing the job should be involved in planning and reviewing
performance, writing procedures and work instructions and solving problems.

Co-ordination and co-operation are particularly important (yet more difficult) when involving contractors who work on the
premises. Ii is very important to manage contractors properly and ensure there is an effective exchange of information between all
parties concerned. Any contractors not willing to co-operate and communicate fully should not be allowed on site.

3.1.4Communication
Sometimes the communication will be a one-way transfer of instructions or information to employees, contractors and other visitors
about hazards, risks and preventive measures. This information can be given verbally in „tool-box‟ talks or contractor induction
briefings, or may be in written form, for instance:

Health and safety policy statement on notice boards:

Organisational structures showing health and safety roles and responsibilities;
Documented rules and performance standards;
Risk assessments and control procedures;
Health and safety notices warning people of potential hazards, escape routes etc.

However, every opportunity should be taken to encourage two-way discussions at management meetings, team briefings etc. Again,
the regular 'tool-box‟ talks by supervisors on specific safety issues are very useful as they give employees opportunities to put
forward their own suggestions for improving safety.

4.0 Planning and implementation of safety activities

4.1 Risk assessment
An assessment of risk is nothing more than a careful examination of what could cause harm to people in the workplace. It establishes
whether enough precautions have been taken to prevent harm or if more are required. The aim is to make sure that no one gets hurt or
becomes ill. Accidents and ill health can ruin lives, and seriously affect a business if output is lost, machinery is damaged, insurance
costs increase, or enforcement action is taken.
Meaning of Hazard and Risk
• A “Hazard‟ is anything that can cause harm (e.g. chemicals, electricity, holes in floors etc);

• A “Risk‟ is the chance, great or small, that someone will be harmed by the hazard combined with the severity of harm
There are five steps involved in completing a risk assessment:
Look for the Hazards:
1. Decide who might be harmed and how

ONE TEAM – ONE VISION Page 35

HYGIENE, HEALTH & SAFETY

2. Evaluate risks and decide if any additional controls are required

3. Record the findings

4. Review the assessment

4.1.1 Look for the hazards

Walk around the workplace and look afresh at what could reasonably be expected to cause harm. Ignore the insignificant and
concentrate on significant hazards which would result in serious harm or affect several people.
Ask your colleagues what they think; they may have noticed things which are not immediately obvious. Manufacturers ‟ instructions or
data sheets and guidance from the health and safety authorities can also help spot hazards and put risks in their true perspective, as can
accident and ill-health records.
4.1.2 Decide who might be harmed and how
Remember to include:
• Young workers, trainees, new and expectant mothers etc who may be at particular risk.
• Cleaners, visitors, contractors, maintenance workers, etc who may not be in the workplace all the time.

• Members of the public or people you share the workplace with - if there is a chance they could be hurt by your activities

4.1.3 Evaluate risks and decide if any additional controls are required

Consider how likely it is that each hazard could cause harm and the likely severity of that harm. Once again, guidance produced by
the HSE and trade associations such as nabim will help you make these judgments. If the level of risk, with the existing controls in
place, is still unreasonably high, additional control measures will have to implemented. Even after all precautions have been taken,
some 'residual' risk usually remains.

If you find that something needs to be done, draw up an “action list” and give priority to any remaining risks which are high and/or
those which could affect most people. In taking action, ask yourself:

a) Can I get rid of the hazard altogether?

b) If not, how can I control the risks so that harm is unlikely?

Only use personal protective equipment when there is nothing else that you can reasonably do.

If the work you do tends to vary a lot or employees move from one site to another, you still have to identify the hazards you can
reasonably expect and assess the risk from them. After that, if you spot any additional hazards when you get to a site, obtain
information from others on site and take what action seems necessary.

Remember that employees are not the only people in the workplace. Tell the other employers (e.g. contractors) and self-employed
people there about any risks your work could cause them, and what precautions you are taking; also, think about the risks to your
own workforce from those who share your workplace. Be aware of any hazards posed by or to local residents.

You do not have to duplicate assessments for risks that have already- been assessed. For example, if you have already assessed the
risks and precautions required for hazardous chemicals that are in use under the Control of Substances Hazardous to Health

ONE TEAM – ONE VISION Page 36

HYGIENE, HEALTH & SAFETY

Regulations (COSHH), you can consider them „checked' and move on.

4.1.4 Record the findings

A record must be kept of the significant findings of the assessment by writing down the significant hazards and conclusions. Examples
might be: 'Electrical installations: insulation and earthing checked and found sound'; or „Fumes front welding: local exhaust
ventilation provided and regularly checked.' Everyone who is affected must be informed about your findings.

Risk assessments must be suitable and sufficient. This means that:

a) A proper check was made.
b) Everyone who might be affected has been consulted.
c) All the obvious significant hazards have been dealt with, taking into account the number of people who could be involved.
d) The precautions arc reasonable and the remaining risk is low.

The written record should be kept for future reference or use; it can help i fan inspector asks what precautions have been taken, or if
any action for civil liability is taken. It can also act as a reminder to keep an eye on particular hazards and precautions.

4.1.5 Review the assessment

Sooner or later new machines, substances and procedures will be introduced which may lead to new hazards. If there is any
significant change, add to or re-do the assessment to take account of the new hazard - but don't amend the assessment for every
trivial change.

If a new job introduces significant new hazards of its own, these should be considered in their own right and steps should be taken
to reduce the risk. It is good practice to review your assessment from time to time to make sure that the precautions are still
working effectively.

4.2 The hierarchy of risk control

When controlling risks, the methods used should be applied using the following order of priority:
a) Try less risky option - e.g. talk to a customer about putting in a bulk silo to eliminate the need to handle lots of bags.
b) Prevent access to the hazard - e.g. by putting fixed guarding on drives.
c) Organise work to reduce exposure to the hazard. This is often referred to as the 'safe system of work' (SSW) and should be put
together after the risk assessment has been carried out. A SSW can be very simple “clear up any oil spills after lubricating all
the conveyor bearings” - or complex, for example when the task involves a number of serious hazards such as those faced
when carrying out maintenance work on a bag palletiser.

d) Provide adequate information, training and supervision

e) Issue personal protective equipment. This should only be done as a „last resort' when all the other control factors have been
applied and there is still some residual risk- e.g. face masks will still be needed when changing filter sleeves, even though the
sleeves have been cleaned as thoroughly as possible using a vacuum cleaner, because there is still a chance of some dust being
in the atmosphere.

f) Provide welfare facilities (e.g. first aid and washing facilities for removal of contamination.)

ONE TEAM – ONE VISION Page 37

HYGIENE, HEALTH & SAFETY

Improving health and safety need not cost a lot. For instance, placing a mirror on a dangerous blind corner to help prevent vehicle
accidents, or putting some non-slip material on slippery steps, are inexpensive precautions which could prevent a serious injury or
even a fatality,

4.2.1 Safe Systems of Work

A Safe System of Work is a considered method of working that takes into account the potential hazards to employees and others
such as contractors and visitors. Safe systems of work provide a formal documented framework to ensure that all steps necessary for
working safely have been considered and implemented.

All systems of work should be safe, but where the potential consequences of harm are high, the system of work should be in writing.

Typical procedure for developing a safe system of work:

1) Identify hazards from:

(a) Stored energy - electricity; compressed air; hydraulic systems; steam or high pressure hot water.
(b) Plant machinery; lifting equipment.
(c) Workplace Transport - large goods vehicles; fork lift trucks; powered pallet trucks.
(d) Dangerous Places - confined spaces; working at height; restricted environments; explosive atmospheres.

(e) Materials - toxic substances; flammables; corrosives; asphyxiate gases.

2) Remove Danger - change or substitute materials.

3) Provide Protection guards; Personal Protective Equipment.
4) Develop a Safe System of Work - in writing; Use Lock Out Tag Out (LOTO); Use Permit To Work.
5) Provide suitable and sufficient training and supervision.
6) Provide special equipment - safety harnesses; respiratory equipment; hearing protection; safe working platforms.
7) Monitor that the system is being followed.

4.3 Permits to work

Certain operations present higher than normal risks and require stricter controls: for example, bin entry, hot work, working at height
etc. To control these high risk activities, many sites use “permit-to- work” systems. These systems require any employee or
contractor intending to work on site to obtain a permit from a senior manager stating what they arc to do and when and how it must
be done.

A permit-to-work is a formal written system of authorization containing certain essential elements:-

1. Description of the work to be undertaken and the safety precautions to be implemented before work can commence.
2. Confirmation that the precautions have been taken and it is safe to commence the work.
3. Statement that the work is complete and it is safe to return the
plant to production.
In carrying out this procedure it is essential that:

ONE TEAM – ONE VISION Page 38

HYGIENE, HEALTH & SAFETY

• There is clear understanding of who may authorise each part and is responsible for specifying the necessary precautions. Proper
training and adequate instructions are provided in: the work to be carried out; and the procedure to be followed in the issue and
use of the permits.
• The work should be monitored to ensure that the laid down procedures and methods are being followed.
Permit systems have six objectives:
a) reduce to a minimum the risk of injury' or ill-health to those carrying out the work;
b) ensure proper authorization or the procedures and work;
c) make clear to those carrying out the designated work:
- the exact identity, nature and extent of the work;
- the hazards faced, the precautions to be taken;
- any limitations on the extent of the work or time allowed;
d) ensure the person in charge of the plant or area is aware of all the work to be carried out;
e) provide a record of the nature of the work, the precautions taken and the people involved;
f) provide a formal hand-back procedure to ensure that the part of the plant affected by the work is in a safe condition to return to
production.

The occasions when permits are required and the content of the site safety rules will depend very much on the particular site and its
problem areas.
A typical permit to work is shown in Appendix 2.

4.4 Personal protective equipment

When purchasing safety equipment in the UK, look for the CE Mark. This shows that the equipment conforms to current European
approved standards. Equipment should always be chosen which meets the hazard identified and is suitable for those using it. It is a
good idea to involve those who will use the equipment when purchasing it - they will then be more likely to wear it. Remember,
however, that safety equipment should be the last line of defence; it is always better lo remove the hazard if this is possible and cost-
effective.
Those who use protective equipment should be told: why it is needed; when to use it: and how. Safety gear should always be worn
when appropriate; it is there to protect the wearer.
Under the Health and Safety at Work Act: “It shall be the duty of every employee while at work to take reasonable care for the
health and safety of himself and of other persons...”

EXAMPLE OF SITE SAFETY RULES

These safely rules are in place so as to protect the health and safely of everybody on site at all times. They apply lo
employees, contractors and visitors. Failure to comply is a disciplinary offence and can lead lo immediate removal from the
site and to summary dismissal.

Conduct - It is prohibited lo do anything which might startle or distract other persons or in any way expose them to danger.
Running is prohibited throughout the site unless (here is an over-riding need to do so).
Alcohol is not to be consumed on the premises at any time.
Dangerous behavior must be reported to your supervisor.

Smoking - Smoking is strictly prohibited in all areas, except the specially designated areas of ……………….and

ONE TEAM – ONE VISION Page 39

HYGIENE, HEALTH & SAFETY

Fire Prevention and Procedures: Never interfere with firefighting equipment

Report any fire hazards to your supervisor.
All people on site should be familiar with evacuation procedures and follow them in the event of a fire alarm sounding Fire
exits must be kept clear at all times.

Clothing - With the exception of wedding rings, all jeweler (including watches) must be removed before entering
production and related areas.
Hats and safety footwear must be worn in all production areas.
Employees and contractors must wear a close-fitting one piece overall, in a good state of repair, in areas with moving
machinery. Visitors will be issued with white food quality coats, which must be worn in all areas except the office.

Accidents - All accidents at work (and near misses) must be reported to your supervisor. These will be entered in the site
'Accident Book'. This is both a legal duly and is important to help the company review its arrangements and protect
everybody's health and safely.

First Aid - In the event of injury, however slight, you may need First Aid treatment. You should be aware of the qualified first
aiders on site and where to find them.

Electrics - Visually check that electrical equipment is in good condition before you use it.
Report any observed faults to your supervisor or the maintenance department and mark out of service' until
repaired.
Place extension leads and cables thoughtfully so that they do not present a hazard to others

Hazardous Substances - Such substances must be kept in clearly marked containers at all times and must not be used without
prior approval by mill management. When using these substances, adequate precautions must be taken as instructed.
Details of permitted use, safety precautions and emergency procedures are contained on the COSHH risk assessment sheets
held in the appropriate department.

Dust - All steps must be taken to reduce dust in the environment, especially when undertaking maintenance or cleaning.
Where this is not possible, particularly when working in enclosed areas, dust masks must be used.

Noise - Much of the mill and screenroom has been designated a noise risk area. Ear defenders will be supplied lo all
entering these areas and must be worn where indicated.

Machinery - Guards must not be removed from machinery without proper authorisation.
All machinery must be isolated and locked-off before cleaning or maintenance commence
At start-up, always ensure that the alarm sounds before machinery starts moving. On hearing the alarm, stand well
clear of all machinery
Never work with belts running towards pulleys. Never put your arm through running belts.
Never climb onto or over machinery.

Chokes - Never put your hands out of your sight

Never put your hands into spouts immediately above or below worm conveyors or rotary seals. Alert clearing a choke,
inspection doors and lids must be replaced
Spouts leading to or from a rotary seal must be secured in such a manner as lo require a special tool to remove the spout.

Confined Spaces - No-one may enter a bin or other confined space (eg a tank) without a properly authorised permit to
work. It you remove a bin lid, It must be replaced before you leave the vicinity of the bin.

ONE TEAM – ONE VISION Page 40

HYGIENE, HEALTH & SAFETY

Compressed Air - Never misuse or abuse compressed air. Serious injury can be caused by directing if into eyes, nose or any cut.

Vehicles - Pedestrians must keep to the indicated pathways and remain alert to vehicle movements.
Only authorised and certificated personnel may use fork lift trucks. Carrying passengers on these trucks is strictly forbidden
All vehicles must keep within site speed limits at all times.

Hygiene - All personnel should keep their work areas clean and tidy at all times
Any substances spilled on floors should be cleared up immediately.
Pest control monitors are situated throughout the site. Any sightings of pest activity must be reported immediately.
All personnel must maintain a good standard of personal hygiene.

General - Ladders must be used as appropriate and securely mounted

Gangways must be kept clear at all times.
Excessive loads should not be carried by hand.
Correct lifting methods should be employed to avoid back and other strains.

Fig.6 Model site safety rules

4.5Site safety rules
Your firm will almost certainly also have site safety rules (see Fig.6 for an example), setting out the need to work safely and
describing how this should be done. If you do not know the safety rules for your site then you should ask your manager for a copy.

New employees should receive a copy of these rules, as should any contractors who conic to work on the site. It is sensible, once
contractors have read the rules, to get them to sign a statement that they have seen, and will work to, the rules.

The occupier has the primary responsibility for contractors on the site. The occupier can discharge this by taking all practicable
precautions to engage only safe and competent contractors and to monitor their working in respect of the health and safety risks to
their employees.

Before any contracting firm is permitted to carry out work on the premises, the contractor or sub-contractor must understand their
duties under the statutory-' regulations applicable to the work that they will be carrying out. It is a contractor’s responsibility to
draw the attention of any sub-contractors for whom they are responsible to the relevant parts of the “Safety Rules for Contractors”
as well as the general duties of safety provision and supervision.

It is of great importance that the safety rules in force for a mill’s own employees are equally known, understood and practised by a
contractor’s employees. Contractors should be required to acknowledge formally their understanding of these requirements.

4.6 Safety signs

Each safety sign is there to tell you something. It does this in two ways - by the design, and by the colour and shape. Many designs
are used, and it would be impossible to list them all. It should be clear what a design means. If you don’t understand a sign, ask.
There are four basic styles of signs:
i) Red Prohibiting, round shaped with a diagonal bar across. These mean 'do not, forbidden‟. (Red is also used for firefighting
signs. These are rectangular);
ii) Yellow - Hazard, triangular shaped with a black edge. These mean „beware‟ and warn of danger;

ONE TEAM – ONE VISION Page 41

HYGIENE, HEALTH & SAFETY

iii) Blue Mandatory, round shaped. These mean „must do‟;

iv) Green Safe Condition, rectangular shaped. These give emergency information, such as escape routes and where first aid is
available.
Fig.7 gives some examples of safety signs of each of these types.
Safety signs should always be obeyed; they are put up for everyone’s protection

4.7 Accident reporting and accident investigation

4.7.1 Accident reporting
Mills should keep a record of all accidents, even if minor, in the site accident book.
There are three main reasons for reporting accidents.
a) Statutory Obligation
b) Insurance Claim
c) In-house accident reporting

4.7.2 Statutory obligation

Some accidents must be reported to the Health and Safety Executive (HSE) under the Reporting of Injuries, Diseases and Dangerous
Occurrence Regulations (RIDDOR). The categories and duties for the reporting of accidents under RIDDOR arc as follows.
Death or Major Injury
When an employee, contractor or visitor working on site is killed or suffers major injury, milling management must notify the HSE
by the quickest possible means and follow with a written report (F2508) within ten days.

ONE TEAM – ONE VISION Page 42

HYGIENE, HEALTH & SAFETY

Examples of major injuries include:

- any fracture other than to fingers, thumb or toes;
- any amputation;
- electrical injuries such as burns;
- shock and loss of consciousness;
Injuries requiring admission to hospital for over 24 hours
Statutory records and accident reports must be retained for a period of at least three years.

Under social security legislation, the employer is required to have and keep a copy of form BI 510, the "accident book" for accidents
to be recorded in.
Certain diseases such as occupational asthma or legionnaires disease.
Over-three day injury
When any one on site suffers an accident which renders them unable to do their normal work for more than three consecutive days,
excluding the day of injury, employers must send a completed accident report form (F2508) to the HSE within ten days.

4.7.3 Insurance claim

In eases following an injury it is possible that the injured person will bring a claim for personal damage against the employer, who
would normally pass this onto the insurance company. Insurers will w ant details of the accident and will often send their own agent
to investigate the incident.

From this investigation the insurers will assess the likely damages and make suitable financial provisions and also use the information
to decide whether to negotiate a settlement or to challenge the claim if it is made.
4.7.4 In-house accident investigation

This has three functions:

i) It lets senior managers know an accident has occurred and the facts of its circumstances;
ii) It may highlight any shortfall in organisational safety arrangements and enable these to be corrected:
iii) It provides the basic data which companies can use to analyses and utilize to prevent reoccurrence.

All accidents should be investigated; this includes near misses, which should not be ignored - it may have only been good luck no-one
was hurt.

4.8 First aid the facilities First aid is defined as:

• Emergency treatment until the arrival of medical practitioner or nurse.
• Treatment of minor injuries that do not warrant medical attention or would otherwise receive no treatment.

Each company should assess the risks associated with the workplace and determine an appropriate number of First Aiders: as a guide,
one per fifty employees for low-risk work, with the number of employees per suitable person reducing as the risks increase.

To become a qualified First Aider at work, the person must complete a course and pass an examination to a syllabus approved by the
health and Safety Executive.

ONE TEAM – ONE VISION Page 43

HYGIENE, HEALTH & SAFETY

A Qualified First Aider will have been trained and have knowledge of:
• Resuscitation:
• Treatment and control of bleeding;
• Treatment of shock;
• Care of unconscious casualties:
• Contents of First Aid boxes:
• Purchase of first aid supplies:
• Transport of casualties;
• Recognition of illness;
• Treatment of bone, muscle and joint injuries:
• Treatment of burns and scalds;
• Eye irritation;
• Poisons;
• Keeping of records;
• Personal hygiene in treating wounds:
• Methods of communication and delegation in an emergency.

Where there are low risks and very few employees or where there are exceptional and temporary absences of qualified first
"appointed person", deputies can be named - these do not need to be fully qualified but should have had basic training in the
principles of first aid.

First Aid Boxes should contain:

• a guidance card;
• individually wrapped sterile adhesive dressings:
• sterile eye pads with retaining attachments:
• individually wrapped triangular bandages;
• safety pins;
• individually wrapped sterile un-medicated wound dressings;
• disposable gloves:
• a supply of tap or sterile bottled water for irrigating eyes.
Additional items can be provided as follows:
• a stretcher;
• pair of blunt nosed stainless steel scissors:
• blankets;
• a suitable bin for disposal of used swabs and dressings.

Employers are given a certain amount of discretion in they provide.

5.0 Environmental Impact
Protecting the environment is important to everyone; issues such as the efficient use of energy and the minimising of waste have
critical social and business implications. The milling industry interacts with the environment in a number of ways:

ONE TEAM – ONE VISION Page 44

HYGIENE, HEALTH & SAFETY

• the use of raw materials - principally wheat;

• the use of different forms of energy;
• the location of the mills and their effects on neighbours;
• the nature of the activities manufacturing, storage and distribution;
• the production of waste - e.g. dust and packaging;
• the emission of noise.

This section takes a brief look at the three principle environmental impacts waste production, energy use and distribution. Other
considerations, such as environmental management systems, are covered in Module 7, “Flour Milling Management”.

5.1 Waste
Flour milling is a dry- process and produces negligible waste. Millers have traditionally been very' effective in converting almost
100% of the wheat bought into flour and co-products, c.g wheatfeed.

The milling process inevitably produces dust and it is vital that so called fugitive emissions' of dust are not allowed to escape into the
atmosphere. This is done by keeping all stages of the milling process from handling of raw materials through to the packaging of
finished products enclosed. Key stages of milling and product transfer, where dust could be emitted, are put under ‘negative pressure',
with the dust captured in filters and fed back into the system,

A number of precautions need to be taken to ensure the dust capture and collection systems work effectively. For instance:

• all employees should be instructed to report any dust leaks from machinery, spouting, bins etc.
• filters and dust collectors should be monitored to ensure the correct levels of negative pressure are being maintained
• filter sleeves should be cleaned or replaced at regular intervals
• filter outlets should be formally monitored to ensure they are not allowing any dust to escape
5.2 Energy Use

5.2.1 Processing
The greatest environmental impact of flour milling results from energy usage. Most of this is in the form of electricity, but limited use
is also made of gas in certain speciality manufacturing processes. Millers have always been keen to improve energy efficiency, not
least to reduce their own costs. Although nearly half of the total energy is used in the milling and grinding process, the pneumatic
systems used for conveying in modern mills use over 30% of total energy consumed.

For many years, millers and milling engineers have worked together to improve the energy efficiency of the overall milling plant
and individual machines. For instance, the use of high efficiency motors, coupled with control systems that automatically turn off
motors that are not being used, have led to significant reduction in energy use.

These 'design' features must be backed up by good maintenance of equipment and the efficient operation of the plant in order to
minimise the transfer of materials and to gain the maximum efficiency from the milling process. All employees can contribute to the
reduction in energy use by switching off lights, heaters, etc. when they are not needed.

ONE TEAM – ONE VISION Page 45

HYGIENE, HEALTH & SAFETY

5.2.2 Distribution
The sourcing of raw materials and the distribution of finished products must be carefully planned so that the distance travelled, and
therefore the fuel used, by vehicles is minimised. Increased efficiencies have been achieved by the use of large bulk vehicles for both
wheat deliveries and product distribution and these can be further improved by good driving technique.

6.0 Hygiene and pest prevention

This section sets out the basic requirements for mill hygiene and provides an introduction to pests and the prevention of infestation.
Further information on specific pests of stored wheat and flour can be found in Appendix 3 whilst the control of infestation is
covered in the Module 4 textbook. 'Materials Handling, Storage and Distribution'.

Stored wheat and wheat products are attacked by insects, mites, birds and rodents Millers must prevent and control infestation for
several reasons:
a) Flour is food. Consumers expect it to be produced, distributed and sold under clean conditions. Poor hygiene standards may result
in bad publicity and could damage trading viability. Retailing and manufacturing companies require high standards of hygiene
from their suppliers and mills are regularly inspected by customers' specialists.
b) High mill hygiene standards are necessary to fulfil the miller's legal requirements under the:
Health and Safety at Work Act (1974) Food Safety Acts (1990 and 1994)
Food Safety (General Food Hygiene) Regulations (1995)
Mills are subject to inspection, not only by HSE Inspectors but also by Environmental Health Officers, responsible to local
government Departments of Environmental Health, to ensure that these requirements are met.
c) To maintain the high standards and morale of employees.
d) To minimise the bacteria count of the final product.

6.1 Insect pests

Beetles (e.g. weevils, which always have a head extended to form a snout) and moths (e.g. mill moths) are the main insect pests of
stored wheat and flour.

6.1.1 Insect life cycles

Insect species are 'cold-blooded', hence their development is dependent upon environmental temperatures. Higher temperatures up to
about 38°C cause increased activity and speedier development.
Most insects, including all primary grain insect pests (see 6.1.2 below), have a life cycle characterised by a 'complete' metamorphosis.
This includes four distinct stages:

1. Adult (Imago in moths)

This displays typical insect features three pairs of legs, two pairs of wings (these are sometimes fused together and non-functional in
some beetles), one pair of compound eyes, one pair of antennae, three body regions, an exoskeleton etc. Males and females mate to
produce large numbers of eggs.

2- Egg
This stage is always small, whitish and inconspicuous, laid by the female either near to or upon a food source.

ONE TEAM – ONE VISION Page 46

HYGIENE, HEALTH & SAFETY

3. Larva ('caterpillar’ in moths, 'grub' in beetles)

This is very small when first emerging from the egg, but it feeds voraciously and grows rapidly. Typical insect features are less
evident - the larva is sexually immature and lacks wings and compound eyes.
Larval and adult forms are, therefore, very different. The larval 'shell' (the exoskeleton) is soft, allowing significant expansion during
growth. Periodic moulting allows the larva to increase in site. A series of moults usually between 4 and 6 terminates with pupation.

4. Pupa
Sometimes referred to as the chrysalis, this is a 'non-feeding' and hence non-damaging' stage. Although the pupa appears to be
inactive, this is the metamorphosis in the life cycle. As in the egg stage, the pupa is usually inconspicuous and resistant to adverse
conditions. It is sometimes helped in this by being contained in a silken cocoon, particularly in most moth species.

6.1.2 Primary insect pests

Insect pests of wheat and wheat products can be divided into primary and secondary insects. This is a practical division, enabling a
better understanding of why pests are there and how to prevent or control them.
Primary insect pests are true storage pests, attacking cereal grains and other stored foods, feeding and breeding in the foods and in
which all life stages will be found. Primary insect pests include:
Saw-toothed / Grain Beetle (see Fig.8); Grain Weevil;
Rust-red Grain Beetle: Lesser Grain Borer; Confused Flour Beetle; Broad-horned Flour Beetle; Indian Meal Moth;
Mediterranean Flour Moth (also known as Mill Moth). (NB: The two flour beetles are sometimes classified as 'secondary'.)

Fig8. Adult Saw-toothed Grain beetle Fig9. Adult Australian Spider Beetle

[Link] Mites
Several species of mites are also primary pests. Mites are arachnids, not insects, having eight legs (like spiders) rather than six. They
eat the germ and sometimes the endosperm. Most serious to the miller is the flour mite. Mites are usually detected only when
infestation is severe, when they appear as a moving layer of dust. However, their presence in flour can sometimes be detected by
gently pinching a flour sample into a small peak. If mites are present the peak will flatten out within a short period of time. Using a
simple hand lens on the sample is a better way of confirming the presence of mites. Infestation only occurs under damp conditions
(mites cannot prevent the loss of body water through evaporation, and will die of desiccation if subjected to a humidity lower than
55%).

ONE TEAM – ONE VISION Page 47

HYGIENE, HEALTH & SAFETY

6.1.3 Secondary insect pests

These beetles, psocids and moths live on debris of older spillages of broken grains or on Hour and other wheat products and on other
dead insects and mites; sometimes found in bird nests. A few live on other insects and mites as predators; others need a supply of
fungal growth in their diet. When damage is evident, it may be caused by larvae and adults of beetles or the larvae of moths. The main
secondary insect pests are:

Foreign Grain Beetle; Cadelle Beetle: Australian Spider Beetle (see Fig.9); Confused Flour Beetle; Broad-horned Flour Beetle;
Yellow Mealworm-Beetle; Brown House Moth; White-shouldered House Moth; Psocids (Booklice). (NB: The two flour beetles are
sometimes classified as •primary'.)

6.1.4Insect infestation
The nature of flour and wheatfeed and the suitability of mill conditions for insect development makes infestation possible
throughout the milling process. This is always a potential problem for millers and most mills are susceptible to infestation.

Although there are many insect pests of grain and flour, only a few species occur in sufficient numbers in the United Kingdom
to cause serious problems. Few can overwinter outside and most only attack warm grain. Mites can attack cool grain (down to
5°C') though they need a raised moisture content to survive and breed (>14.5% moisture in cereal grains) and weevils breed in
grain above 14°C.

Silos and flour mills provide insect and mite pests with ideal living conditions:

a) Food and humidity

b) Harbourage
Any cracks, crevices and dead spaces which are inaccessible to normal cleaning provide ideal sites for infestation.
c) Warmth
This is especially important to those species of tropical origin, though increased temperatures encourage all species. Mills are
frequently warmer than outside temperatures.
Insects and mites can enter the mill in many ways. They may:

i) already be established in buildings and machinery before a consignment of grain arrives;

ii) arrive in lorries carrying incoming loads of grain or wheat products (germ, gluten, bought-in or returned flour);
iii) be present in old food residues in freight containers;
iv) be carried into the mill from infested wood or plastic pallets;
v) be transported in the holds of grain-carrying ships and barges;
vi) be transferred from a neighbouring infested site.

[Link] Significance of insect infestation

1. The deterioration of wheat
a) Grain Weight loss
Insects eat grain. However, serious losses in grain weight occur only- after prolonged storage under suitably warm
conditions. This rarely occurs in the UK and, long before this, the level of contamination would be enough to cause rejection

ONE TEAM – ONE VISION Page 48

HYGIENE, HEALTH & SAFETY

at the intake laboratory.

b) Hot Spots
Infestation can develop rapidly from a small number of insects if storage conditions are sufficiently warm. Grain has low
thermal conductivity. This means that temperatures of the grain in regions near to insect populations rise due to the
accumulation of their metabolic heat. These are called hot spots', which encourage even faster breeding and development
and can occur in grains dried down to normal moisture contents of 14%.

As the localised temperature rises above 30°C, insects move outwards from the hot spot and may appear on the surface.
Moisture moves outwards and upwards through convection into cooler grain and condenses. This may result in the grain
caking and sprouting, especially if bulked round a pillar or against a wall, and particularly on the surface of the bulk above the
hot spot. This damp layer or region can additionally become heavily infested by mites and fungus beetles. Hot spots frequently
form beneath overhead conveyor filling spouts, where a larger proportion of dust hinders aeration.

Caked grain in silos hinders wheat supply to the mill. It frequently harbours insect and mite infestation, and will contain
fungal toxins (mycotoxins) produced during the moulding phase of the developing hot-spot.

2. The contamination of flour

Insect fragments, their excreta, and mites contaminate flour. Even low levels of infestation cause significant contamination.
Flour infested by beetles can smell sour and its baking qualities are reduced. However, heavy infestations are rare. Flour
beetles are intermediate hosts of parasitic worms between rodents and man. Some insect species transmit intestinal diseases
caused by bacteria and protozoa.

Mite body fluids taint flour and baked products with a sour minty smell. It is also becoming better recognised that most
storage mite species can be powerful allergens, affecting human and animal health.

3. Interference with the mill process

Webbing produced by mill moth larvae can block spouts and machinery and can seriously disrupt milling. Annual fumigation
helps to prevent such stoppages but regular cleaning of spouts, conveyors and discharge worms is essential to give continuous
good running conditions. In the UK, disruption caused by webbing is largely a thing of the past.

Mill beetles bore into woodwork, making harbourages for themselves and other pests. Heavily infested wood may need replacing.
Beetles can bite holes in the silk covers of dressing machines. Of course, in the UK, there are now few wooden structures and silk
covers and so this is again a problem more of the past than the present.

[Link] Potential sites of insect infestation

1. Grain silo and screen section
Insects able to breed and overwinter in farm grain stores may be found on wheat arriving at flour mills. Potential problem areas are:
a) Dead spaces between bins and outer walls, below bins in conveyor and elevator pits, and between joints of conditioning bins, can
support insect infestation.
b) Damp wheat residues inside conveyors and elevators are often infested with small black flies and mites.

ONE TEAM – ONE VISION Page 49

HYGIENE, HEALTH & SAFETY

c) Areas of high humidity arc ideal for white-shouldered house moth larvae, mites and psocids.
d) Any dark, inaccessible areas where spillage is left unattended.

2. Lowest level
Infestation levels in the basement or other lowest level reflect housekeeping standards throughout the mill. Elevator pits, beneath silos
or mills, can become infested by beetles. Moths and beetles can also be found in elevator boots. Mealworms and moths are common
basement pests.

3. Mill area
Heat generated by mill machinery makes mills suitable for infestation by tropical insect pests. Mills can be up to 10°C warmer than
the outside air. For example, the spread of the Mediterranean flour moth was due largely to the introduction of roller mills, which kept
mill premises warmer than previously. Potential problem areas are:

a) Dead spaces
Flour beetles infest dead spaces in machinery, spouts and conveyors particularly on the break and wheat feed sides of the mill which
provide the B-group vitamins they need. Similarly, wholemeal is more susceptible to attack than white flour. Infestation may continue
after flour has left the mill if storage conditions are sufficiently warm.
Conveyors etc with dead spaces, where moist flour may cling and become mouldy, provide a breeding site for fruit flies, fungus
beetles, psocids and mites. These may occur in the warmer parts of the production area.
b) Floor and wall surfaces
i) Smooth terrazzo floors are better than concrete screed, which becomes pitted and is more difficult to clean.
ii) Concrete polished or painted with heavy duty gloss is easier to clean than plain concrete or linoleum floor tiles.
iii) Linoleum tiles tend to lift, particularly around machine footings. This is a likely site for beetle infestation.

iv) Black plastic wall/floor junction strips often ease away as flour gets between the adhesive/wall interface. This can become
infested with beetles. Horizontal ledges and surfaces which hold flour deposits can support insect infestation; 90 degree angles
between floor and wall can be a particular problem for cleaning. Many floors in flour mills are of a double skin wooden
construction and insect infestation problems have been found between the two skins. Many mills now have floors cut away
front the walls to avoid the wall/floor junction problem.
c) Machinery
i) Break and reduction rolls may be infested by mill moth, grain and flour beetles. Infestation may be found deep inside
machinery, eg behind roll cheeks.
ii) Some machines have dead spaces into which infested stock gradually finds its way, allowing intermittent re infestation of the
more exposed parts of the machine (e.g. feedgates).
iii) The pneumatic system can carry insects up to the seals floor. The main areas for infestation are:
• Spouting directly below the pockets of the rotating seal may support flat grain beetles, confused flour beetles and broad
horned flour beetles.
• Dust extraction units and exhaust trunking may harbour mill moths and flour beetles.
MS Pneumatic systems produce far fewer chokes and spillages. Any that do occur can and should be removed fairly quickly.
iv) Modern purifiers are made of metal and polycarbonate. They are less likely to become infested than their wooden

ONE TEAM – ONE VISION Page 50

HYGIENE, HEALTH & SAFETY

predecessors. However, flour beetles can get under the elasticated ends of connecting sleeves, as well as become established
in any stock residue allowed to build up in the aspiration channels.
v) Plan-sifters
• Flour beetles can infest the circular metal spouting leading to and from the plan-sifter. They also get under the elasticated
ends of the connecting sleeves and in residues of stock present in the joints.
• Some sieves are fine enough to allow adult beetles, larvae and even eggs to be over-tailed. Coarser mesh allows eggs to pass
through and be directed into different machines. When the sieves are not being agitated, larvae can pass through quite fine
sieves and then be redirected to various parts of the mill when milling begins again.
vi) The spouts floor
• Insects escape from circular inspection covers on the spouting and land on flour-collecting worms, which they enter via
inspection panels.
• Disused lengths of spouting should be removed as soon as possible - residual stock can support infestation which might
spread to adjacent systems. Unused machines pose a similar problem.
• The main worm conveyors have some slower moving stock below the worm blades and in the dead-end section at the end of
the worm, beyond the down spout.

4. Flour silos, hanging areas and warehouses

Production bin tops should be kept clean as moths and beetles may breed in spillages and enter bins via lids and dust extraction units.
The horizontal drag conveyors that move production flour to the holding/outloading bins can become infested.

a) Silo
Silos can be difficult to keep clean. The design should provide full access to every level: if it does not, some horizontal girders, pipes,
light fitments and external silo-wall flanges are virtually inaccessible.

Insects can infest silo bin interiors, especially above the normal maximum level where there is no scouring action of descending
flour. The discharger mechanisms in the silo bases and interiors of horizontal conveyors are also susceptible to infestation.

Insects and mites can live in the cracks of perished insulating foam found in outer silo walls. Dust control equipment is also
susceptible to infestation, especially by flour beetles and moths.

b) Bagging section and warehouse

i) Insects pass through weigher mechanisms and enter feed chutes of either individual bagging machines or multiple feed 'carousel'
units. Flour spilt onto the internal ledges of belt conveyors and self- stacking/pallet loading machines may become infested.
ii) Sparrows can introduce several species of beetles (eg spider beetles) and mites to bagged flour awaiting dispatch. These pests
breed in bird nests and are carried in their plumage. The birds themselves pose a serious contamination risk to finished bagged
flour. Such contaminated loads will be rejected by customers and may generate the (unwanted) interest of the Environmental
Health Departments of Local Authorities.
iii) The bulk wheat feed collection system or pellet making plant may also become infested. Moths and beetles can be found in wheat
feed worms, holding bins, the dust collection system and in the discharge mechanism on bulk out-loading bays. Insects breed
very rapidly in wheat feed because of its comparatively high protein content. This can contaminate adjacent milling areas. Germ

ONE TEAM – ONE VISION Page 51

HYGIENE, HEALTH & SAFETY

is particularly susceptible to infestation by moths and beetles.

iv) Some warehouse areas are separated from milling sections by wooden partitions. Gaps around the panels can be difficult to
clean, thus encouraging infestation.
v) Pallets should be thoroughly cleaned before being used in the bagging section. It may be advisable to treat them occasionally with
an insecticide spray. Ensure that any treated pallets are fully dry before the next load is placed on the sprayed surfaces. A layer
of soft cardboard can be used to isolate the treated wood of the pallet from the flour bags, thus avoiding any risk of cross
contamination from pesticide residues.
6.2 Rodent pests
Rats and mice are until pests. They enter buildings via damaged walls, gantries, pipe runs and badly-fitting doors. Once inside, they
enter roof voids, hollow floors, wall cavities and cupboard bases. Mice may also be brought in with incoming grain and imported
returned products eg germ, gluten, returned flour, particularly on palletised loads.

All rodents gnaw materials habitually to limit the length of their continually-growing incisor teeth, which can cause considerable
damage to doors, windows, wiring and computer systems. Thus, rodents are known to have caused significant fires in stores, mills
and other buildings.

Potential damage
i) Rodents spread diseases such as salmonellosis, murine typhus and rat bite fever. Some, like Weil’s disease, can be fatal to man.
ii) Rodents cat grain and flour and contaminate much more with their urine, droppings and body hairs.
iii) Rodents damage the structure of buildings, water pipes and electric cables.

The two main rodent pests in flour mills are:

a) The Brown Rat
Also known as the Norway. Common or Sewer rat. it is the most widespread species of rat likely to invade mills and lives
anywhere offering food and shelter. Each rat produces about 40 droppings per day. (The Black Rat also known as the ship or roof
[Link] an infrequently-encountered species, living only indoors in Britain and known to occur in only two port areas.)

b) The House Mouse

This species, characterised by its large hairless ears, longish tail and grey-brown fur, is now regarded as the most common rodent
pest in UK mills. It is territorial and marks its boundaries with urine. Each mouse produces about 80 droppings per day.

6.3 Bird pests

Bird pests eat grain. They also contaminate it with droppings, feathers and nesting material. (However, bird control methods are
tightly controlled in the UK by the Wildlife and Countryside Act.)

Potential damage
a) External
i) Fouling and defacing buildings.
ii) Threats to human health and food hygiene. Bird nests harbour a variety of insects and mites, most of which are pests of stored
products.
iii) Secondary damage to property. Nests and droppings block gutters and spouts. The resulting water overflow leads to timber

ONE TEAM – ONE VISION Page 52

HYGIENE, HEALTH & SAFETY

decay, broken rendering and structural damage.

Hazards to workforce and equipment. For example, workers could slip on droppings on external metal stairways, and nests above
doorways have resulted in personnel breaking limbs by slipping on wet droppings.

b) Internal
i) Birds spread diseases such as salmonellosis to man.
ii) Birds contaminate products through nesting materials, droppings and feathers.

6.4 The Food Safely Act

The Food Safety Acts 1990 and 1994 strengthen the law on food safety and consumer protection in the food sector, throughout Great
Britain. It is important to consider this in the context of health and safety at work, as many of the working practices which are
required for product hygiene are inextricably linked with personal hygiene, health and safety. The food safety requirements are that
food, not only for retail sale but throughout the food chain, must not:
i) have been rendered injurious to health (e.g. if glass were found in the flour);
ii) be unfit (e.g. if the flour was mouldy);
iii) be so contaminated, whether by extraneous matter or otherwise, that it would be unreasonable to expect it to be eaten
(e.g. if the flour contained insect fragments).
Flour is a food product and therefore the milling industry must ensure that its production is carried out under such conditions that
contamination does not occur. These Acts are enabling Acts and therefore it is likely that further regulations will be introduced in
the future.

Customers may also impose hygiene requirements. Many large customers have their own hygiene inspectors who will examine
mills before orders are placed. Ultimately the pressure comes from consumers, who expect a pure product and rightly complain if
they find any contamination. Good hygiene makes business sense. It also contributes to a good working environment for
employees.

6.5 Hygiene principles

The milling industry has always attached great importance to hygiene the preparation of an uncontaminated product in clean
working conditions. There are, of course, legal requirements requiring people who handle food to keep themselves and their
working clothes clean. They must also tell their employer if they suffer from any infection which could cause food poisoning (e.g.
typhoid, dysentery, diarrhoea, septic cuts or nose and throat infections). The regulations forbid the use of unsanitary premises -
every room used for food must be kept clean and free from infestation.
There are three basic principles behind a good system of hygiene:
a) Clean premises and equipment;
b) high personal standards;
c) Control of infestation.

These are dealt with below; all three are essential to a well-run flour mill

a) Clean premises and equipment

All areas where dust gathers should be cleaned regularly. Cleaning schedules should exist which state the frequency of cleaning -

ONE TEAM – ONE VISION Page 53

HYGIENE, HEALTH & SAFETY

some areas will need more frequent cleaning than others. Schedules should also say who is responsible and how the cleaning is to be
done, including any safety precautions which are needed (eg plant isolation, use of a safety harness). Cleaning should include
machines, beams and ledges - dust can build up on these and form a fire risk. (A Yorkshire textile factory was wrecked in 1986
because dust had been allowed to build up on beams. A compressor failed, blowing part of it through the roof. This dislodged the
dust, which ignited causing serious injury and damage.)

Flour and grain dust can explode in the right conditions (see section 1.1.5); indeed several fatal grain dust explosions have occurred
in North America and France in recent years. It is therefore doubly important to ensure that dust is minimised and cleared up
regularly.

Chokes and spillages should be removed promptly, as should any refuse from maintenance work. Cleaning up is part of the job.
Most spillages are due to improperly fastened, worn or damaged equipment. Any problems should be reported and remedied quickly.
Textile sleeves, as used with plan-sifters, frequently cause spillages when they become worn or damaged. They should be repaired or
replaced when necessary.

Buildings should be maintained in good condition and structural damage and broken windows repaired promptly. This keeps the
working environment sound, and reduces the risk of infestation.

b)High personal standards

Personal hygiene isn't just about washing hands before meals and after using the toilet; it covers all aspects of keeping yourself clean,
neat and tidy. It is important because anyone handling, or in close contact with, food is a potential source of many harmful bacteria.
An acceptable daily personal hygiene routine includes washing your body daily, regular hand washing, changing the clothes next to
your body daily, cleaning teeth, washing your hair regularly and keeping your hair and nails neat and tidy. There are also unpleasant
personal habits to be avoided; for example, coughing without covering your mouth, picking your nose, and spitting. Any cuts or
grazes should be covered by bandages or plasters, and these should be changed if they are becoming dirty. (Special detectable plasters
must be available. These are brightly coloured to be readily spotted if they accidentally get into stock. They should all be metal-
detectable).

Maintaining high personal standards, however, covers more than this. It involves keeping the workplace clean, and not leaving
equipment, cables etc where people can trip over or bump into them. Glass bottles or utensils should not be used anywhere where
there is a risk of them getting into stock. Overalls and other protective clothing should be kept clean and repaired as necessary. Take
pride in your work and your appearance; people notice and it impresses visiting customers.
Protective clothing, including hats, must be worn in production areas.
High personal standards protect the person from the product and the product from the person; they are also an important part of the
self- development process that is of great advantage to both the company and the individual.

c) Control of infestation
Cleanliness is important, since it removes items which will feed and harbour insects and rodents. Any evidence of rodents or their
droppings should be reported at once. Insect bait traps and pheromone traps should be checked to a schedule and the findings
recorded. In warehouses, pallets should be stacked away front walls, to allow the whole stack to be inspected. Stock rotation also
reduces the risk.

ONE TEAM – ONE VISION Page 54

HYGIENE, HEALTH & SAFETY

Unnecessary and disused equipment should be removed from production and storage areas, since it may provide a home for pests; it
should be thoroughly cleaned before being put into engineering stores.

The problem of infestation is never completely solved. The best defence is regular cleaning and constant vigilance. Cleaning staff
should be trained in cleaning methods and also on how to recognise signs of infestation (for example, the meandering trails left in
flour residue by the confused flour beetle). They should also be encouraged to realise that their contribution is of great importance to
the well-being of the business.

6.6 Prevention of infestation

Good housekeeping is essential:
Insects
1. A site cleaning schedule should detail areas and machinery to be cleaned, the methods and frequency of cleaning and should
also indicate responsibility to see that this work is carried out, see Fig. 10.
2. Food spillages should be removed frequently.
3. Spare or disused equipment should be cleaned and removed from production and storage areas - this reduces potential
harbourages for insects and rodents.
4. False ceilings and hollow partitions allow infestations to build up unseen. They should be avoided where possible - if not, easy
access should be provided for scheduled inspection/treatment.
5. Access for pests can be inhibited by proofing doors, windows, air vents, holes in the brickwork, etc.
6. Structural damage should be repaired, and cracked or broken windows replaced.
7. Premises should be thoroughly cleaned after maintenance work. Vacuum cleaners are more efficient than brooms for removing
dust and dirt but must be emptied regularly.
8. Ledges allow dust to accumulate and should be avoided where possible. If not, they should be included in cleaning schedules.
9. Proper warehousing techniques, such as stock rotation, should be adopted. Stacking pallets away from walls enables the whole
stack to be inspected for infestation.

Rodents
1. Edible spillages should be removed and access to water supplies prevented. (Rats require a source of water. Mice generally
obtain sufficient water from the products they are eating, including flour.)

Cover (i.e. shelter or harbourage) should be minimised around premises - debris or disused machinery left close to buildings
encourage nesting.
2. Vegetation adjacent to buildings should be cut back, giving about 3 metres clearance.
3. Stock rotation discourages nesting.
4. A 50cm gap should be left between stacks and walls to allow for inspection and bait setting.
5. Where possible, buildings should be proofed against rodent entry'. All structural defects should be sealed, including gaps around
badly-fitting doors and any holes in the building which allow nesting and access to adjoining sections. It is generally possible to
proof against rat entry but mice can squeeze through a gap of as little as 7mm.

Birds

ONE TEAM – ONE VISION Page 55

HYGIENE, HEALTH & SAFETY

1. Food availability should be restricted by eliminating spillages and carrying out effective cleaning.
2. Nesting should be prevented.
3. Premises should be proofed to prevent birds entering or resting. (Professional advice should be sought as necessary'.)
4. Where access cannot easily be prevented, such as to bulk flour loading bays, loading spouts should be fitted with a cover kept
in place when not in use.

6.7 Hygiene strategies

In a well-run mill hygiene is planned. Hygiene should have been taken into account in building the mill. Machinery will be located so
that cleaning is easy and appropriate materials will have been used in construction: this is the ideal. Older mills will need to plan their
hygiene management within the constraints of their equipment and premises. All mills should have a system for reporting infestation
and hygiene problems, and also structural defects (eg broken windows), so that these can be remedied promptly. If you spot a defect
or indication of infestation, report it.

The most important thing, however, is a cleaning schedule. Unless cleaning is planned, parts will get missed and infestation may
take hold. A schedule should cover the entire mill, not just production areas, and should ensure all parts will receive regular
attention. In deciding how long the timescale should be, mills need to take into account the age, design and layout of the mill, and
the materials used. Some equipment may only need one cleaning in the period of the schedule, other equipment may need to be
cleaned much more frequently.
When drawing up a cleaning schedule, mill management needs to decide:
a) What needs cleaning
To avoid confusion, it may be useful to number machines. The schedule should include delivery vehicles-these can pick up infestation
at other places and it is essential that material which could contaminate the product is not conveyed in or on vehicles. Remember also
to clean the cleaning equipment. Vacuum cleaners and brushes should be treated (by those permitted and trained to do so) with
pesticide and cleaned regularly, otherwise they may spread problems.

b) What standard of cleaning is needed

Obviously, standards will be high throughout but known problem areas may need more thorough attention. Any machinery following
infestation destroyers may also need higher standards.

c) When the work is to be done

In deciding this the important factors are risk of infestation, the life cycle of possible pests (since they can’t be allowed to multiply),
the life of any insecticide applied, and the manageable workload. A schedule which cannot be met is useless the work will be left
undone, standards compromised and it will fall into disuse. It is most cost- effective to spread the workload evenly throughout the
period of the schedule, and

this helps make cleaning a habit. It may be possible to clean some equipment when routine maintenance work is done. This saves
time and often allows better cleaning, especially where machinery must be stopped for internal cleaning.

d) What equipment will be used

The equipment must be suitable and available and, ideally, returned to a suitable storage point when work is completed. Vacuum
cleaners should be spark-free and earthed and need to be serviced regularly, with cleaning contents disposed of carefully. Brushes

ONE TEAM – ONE VISION Page 56

HYGIENE, HEALTH & SAFETY

should be of the type with coloured nylon bonded bristles and it is common practice for a colour code system to be used, where red
brushes are used for 'high- risk' machinery interiors, to identify the source of any brush hair contamination of the flour. If machines
have to be stripped or chemicals used, the need to work safely, with approved 'food safe‟ products, must also be observed. All
engineering components should be removed immediately after completion. Compressed air is not suitable for cleaning task. Not only
can it be dangerous, it just spreads the problem to areas which may be less accessible.

e) Who will do the cleaning

Larger mills may well employ full-time cleaning staff; this is the traditional ideal, where responsibilities are clearly designated.
However, modern premises and work methods allow greater scope for mill staff to carry out necessary cleaning schedules. Periodic in-
depth cleaning or major workloads, such as during and after new projects, may require the temporary assistance of a contract cleaning
company.

If the mill works on a shift system, areas for cleaning might be divided between shifts. Management will also need to decide who is
the manager responsible both for cleaning and for reviewing the schedule’s effectiveness. This manager (or a nominated hygiene
officer) will need to monitor standards and investigate any reports of infestation found during cleaning. Fig. 10 shows a simple
cleaning schedule for the roller mill floor.

In practice the cleaning plan will be more complicated. However, the same principles apply. A good idea is to write the cleaning plan
on a large sheet of paper (or on a board) and put it up on a wall. This shows clearly what is to be done, and when. Each item can be
marked off when the job is completed. Certainly some form of record must be kept of which areas have been cleaned

A SIMPLE CLEANING SCHEDULE

ITEM FREQUENCY RESPONSIBILITY METHOD NOTES

Rollermills:
External Daily Cleaner Vacuum/Wipe With mill maintenance
Internal Weekly Miller Vacuum

Spouting:
External Daily Vacuum/Wipe
Cleaner Contract Report leaks to engineer
Internal Monthly Mechanical
Co. Cleaner Liaise with Miller
Daily Vacuum/Wipe
Lift pipes

Floor Daily Cleaner Vacuum -

Walls Weekly Cleaner Wipe -

Windows:
External Monthly Contract Co, Wash Wash Liaise with engineer Liaise
Internal Monthly Daily Contract Co.
Vacuum/Wipe Remove &

ONE TEAM – ONE VISION Page 57

HYGIENE, HEALTH & SAFETY

Ledges with engineer

Weekly Cleaner Cleaner Vacuum
Fly Screens
Report defects

Control room Daily Miller Vacuum -

Fig10. Model cleaning plan for roller floor

ONE TEAM – ONE VISION Page 58

HYGIENE, HEALTH & SAFETY

BIBLIOGRAPHY GLOSSARY
Dead Space
The Prevention of Fire and Dust Explosions in Flour Mills and An area in a mill or mill machine which is inaccessible to cleaning
Bulk Flour Containers and
Published by nabim, London (1992).
Storage Mites, a resume of their biology, importance and
Pest Control in the Flour Milling Industry control

by G.C. Crowe (1985). Published by Rentokil, West Sussex. by M.P. Kelly (The Acheta Partnership, Maidenhead, Berks).

Pest Birds - A Major Threat to Health, Property and Profit Grain Storage to avoid Infestation
by M.P. Kelly (The Acheta Partnership - published by the Home-
Published by Rentokil, West Sussex.
Grown Cereals Authority, London)
GLOSSARY Dead Space
Pest Control in Buildings
An area in a mill or mill machine which is inaccessible to cleaning
Published by Rentokil, West Sussex.
and is thus likely to harbour undetected infestation.

Identification Cards 130-143. Insects in Stored Grain

Frass
Published by Central Science Laboratory, York.
Faecal pellets including particles of foodstuff produced by insects.

Identification Cards 270-289 Insects in Food Stores

Musculo-skeletal
Published by Central Science Laboratory, York.
To do with muscles and bones.

Moths of Stored Products

Mycotoxins
by P.D. Cox and C.H. Bell (Second Edition 1985). Published by
ADAS, HMSO. Fungal contaminants sometimes found in stored cereal products.

‘So Far as Reasonably Practicable’

Controlling insect Pests in Flour Mills
Whether an action is ‘Reasonably Practicable’ will depend on the
Published by ADAS, HMSO.
individual circumstances of the issue concerned. It is essentially a
matter of balancing the degree of risk against the time, trouble,
Pests of Stored and Manufactured Foods
cost and physical difficulty of the measures necessary to avoid
Published by Central Science Laboratory, York. that risk. Clearly, the greater the risk the more reasonable it is to
do something about it; and vice versa. It is important to remember
The Invertebrate Pests of Stored Grain that the judgement is driven by the RISK and NOT the size or
by M.P. Kelly (The Acheta Partnership, Maidenhead, Berks). financial position of the company or employer concerned.

Storage Mites, a resume of their biology, importance and

control

ONE TEAM – ONE VISION Page 59

HYGIENE, HEALTH & SAFETY

by M.P. Kelly (The Acheta Partnership, Maidenhead, Berks).

Grain Storage to avoid Infestation

by M.P. Kelly (The Acheta Partnership - published by the Home-
Grown Cereals Authority, London)
Websites:Health and Safety Executive: [Link]. nabim: [Link]
Self-assessment questions 7. If you discover a fire your first priority is to
(a) Raise the alarm
In each case select the correct answer. (b) Contain the fire

(c) Find out how it started

1. Which of the following is expressly forbidden by the Health
(d) Run
and Safety at Work etc Act 1974?
(e) Find a fire extinguisher
(a) Misusing anything provided in the interests of

health and safety at work 8. Which of the following is not one of the four C’s of good
(b) Working on unfenced machinery health and safety organisation?
(c) Using passenger lifts which have not been (a) Communication

examined by a competent person (b) Competence

(d) Removing asbestos without a licence (c) Confidence

(e) Smoking in flour mills. (c) Control

(d) Co-operation

[Link] picking up an object from the ground, what should you

9. The maximum exposure limit for flour dust over an 8-hour
do?
work period is:
(a) Bend your back
(a) 0.1 mg/m3
(b) Keep your back straight
(b) 1 mg/m3
(c) Keep your legs straight
(c) 10 mg/m3
(d) Keep your legs together
(d) 100 mg/m3
(e) Keep your arms straight.
(e) 1000mg/m3.

3. When putting a 2 metre ladder against a wall, how far out from
10. Which is first in the hierarchy of risk control?
the wall should you place the bottom of the ladder?
(a) try less risky option
(a) 10 centimetres
(b) prevent access to hazard
(b) 25 centimetres
(c) provide adequate information and training
(c) 50 centimetres
(d) issue personal protective equipment
(d) 1 metre
(e) provide welfare facilities.
(e) 2 metres

4. A round blue safety sign indicates 11. Infestation by which pest can sometimes be detected by a sour

(a) Something is forbidden minty smell?

(b) Where fire-fighting equipment is located (a) Beetles

ONE TEAM – ONE VISION Page 60

HYGIENE, HEALTH & SAFETY

(c) A danger is present (b) Mice

(d) Something must be done (c) Mites

(e) Where first aid equipment is located. (d) Moths

(e) Rats
5. Which of the following will not help to prevent a dust
12. The minimum gap size through which an adult house
explosion?
mouse can gain access to the mill
(a) A lightning conductor on a high building
(a) 1 cm
(b) A ban on smoking in the mill
(b) 77 mm
(c) Regular cleaning of mill premises
(c) 44 mm
(d) Earthing vehicles during loading and unloading
(d) 22mm
(e) Fitting venting to bins and silos.
(e) 7 mm

6 . Afire extinguisher coloured black (or red with a black panel)

contains
(a) Water
(b) Carbon dioxide
(c) Foam
(d) Dry Powder
(e) Halon

nabim Flour Milling Examinations

The test specification for the nabim examination on this module is sent to all correspondence course students with their lessons. It is
subject to change but, at the time of publication, it requires a 2 hour paper of 8 questions covering all aspects of the module. The test
specification further indicates the number of questions to be set on each section.

12 marks may be awarded for each question, usually distributed between two or more parts of the question (although a question may be
in just one part). Below are examples of questions taken from past examinations.

1. Under the Health and Safety at Work Act 1974, state

a) FOUR duties of employers
b) TWO duties of employees
c) SIX powers of enforcement available to Factory Inspectors.

2. a) State the THREE factors necessary for a dust explosion to occur.

b) State FIVE precautions necessary if cutting or welding must be done in a mill.
c) i) Excluding Halon, state THREE types of portable fire extinguisher.
ii) For EACH extinguisher you have listed, identify the most suitable type of fire it will tackle and any precautions that should

ONE TEAM – ONE VISION Page 61

HYGIENE, HEALTH & SAFETY

be taken in its use.

3. List and briefly describe TWELVE items for inclusion in site safety rules.

4. a) Describe the FOUR basic styles of safety sign and briefly state what EACH means.
b) Give FOUR rules for the safe use of ladders.
c) State what is meant by the term ‘occupational asthma’.

5. a) List the FIVE steps involved in completing a risk assessment.

b) State THREE types of MAJOR INJURY which must be reportedto the Health and Safety Executive (HSE)
c) State FOUR items recommended for inclusion in a First Aid Box.

6. Describe SIX steps that an employer must undertake to prevent damage to employees’ hearing, under the Noise at Work
Regulations.

7. a) Give THREE reasons why millers must prevent and control pest infestation in stored wheat
and flour products
b) State FOUR ways that insect and mite pests can enter a mill.
c) Define the term ‘hot spot’ in the context of wheat deterioration.

8. a) State the THREE main requirements of the Food Safety Act.

b) List THREE basic principles of a good hygiene system.
c) Explain in detail one of the above principles.

9. a) Explain briefly FOUR common causes of Manual Handling accidents in the flour milling industry,
b) List FOUR operations associated with workplace transport, which pose particular risks and must have a planned safe system of
work.

Appendix 1. Nabim recommendations on safety bin entry procedure

INTRODUCTION
Entry into bins containing wheat or product is to be avoided and must only be with the specific authorization of the site. If it is
possible to carry out the necessary work from outside the bin, entry should be prohibited. If entry is to be made the
precautions outlined below must be taken.
(i) Safe bin by employees or contractor personnel must be achieved by adherence to a written procedure which utilizes a “Permit
to work”, which must be under the direct supervision of a responsible person nominated by the senior site manager. All
contracts must specify use of this procedure. Where such entry is necessary it is preferable to use a contractor, particularly
one who has access to equipment to clean the bridging from outside the bin.

ONE TEAM – ONE VISION Page 62

HYGIENE, HEALTH & SAFETY

(ii) The total task involves the following three stages:

PREPARATION AND MAKING SAFE

ENTRY AND CARRYING OUT OF WORK

RETURN OF PLANT TO SERVICE.

(iii) Prior to the introduction of the above bin entry procedure it is essential to:
a) Clearly define individual responsibilities.
b) Carry out training in all aspects of the total task, including first aid and resuscitation techniques.
c) Establish emergency procedure

STAGE 1 – PREPARATION AND MAKING SAFE

This stage requires the identification and elimination of hazards prior to entry
(i) Use of Bin

This bin should be withdrawn from use and all relevant personnel notified in writing
(ii) Isolation

Plant feeding to and from the bin must be switched off. Such plant must be isolated and locked in that position to the
satisfaction of the operative entering the bin
(iii) Notices

Notices starting the work is taking place inside bins and prohibiting unauthorized entry should be exhibited at both top and
bottom of the bin
(iv) Ventilation
a) Wheat and Wheatfeed bins. The atmosphere must be tested for:
- Oxygen depletion (minimum level 19%)
- The presence of carbon dioxide (must not exceed 5000 PPM – 0.5%)

These measurement must be made before entry and the result, if indicating safe levels, recorded on the permit to work.
Entry must not be permitted until safe measurement are recorded. (see current edition HSE EH40). Whilst the bin
is occupied the levels of oxygen and carbon dioxide must be monitored until the job is completed and the bin
vacated, either by:
- Measuring the levels every 30 minutes and recording the results, or
- By the person in the bin wearing a monitoring device which gives a constant readout of the two levels and
incorporates an alarm system.
b) Flour Bin

Bin which can be opened at the top and bottom

Flour bin which can be ventilated for one hour prior entry and throughout the occupancy do not require measurements to
be taken of the atmosphere. Ventilation should be achieved by opening the top bin and either removing a hatch cover
at the bottom or dropping the cone/rotary seal. (Where a hatch is opened at the bottom this should be sufficient in

ONE TEAM – ONE VISION Page 63

HYGIENE, HEALTH & SAFETY

size to allow human entry).

Bin which can only opened at the top.

Follow the procedure for wheat bin (see iv a) above)

(v) Equipment and clothing

The items listed below must be available and have a current test certificate where legally required. A visual examination must
also be carried out by the responsible person prior to use. Such equipment must be properly stored at and used only for
authorized purpose.

G General Pe Personal
a) Winch a) Safety helmet
b) Bosun’s chair or safety cage b) Anti-static overall
c) Safety harness and rope c) Appropriate respiratory protective equipment (RPP)
d) Oxygen/carbon dioxide measuring equipment d) Anti-static safety footwear (this must not create
e) Lamp (s) sparks impact with metal or concrete surface)

(vi) Permit to work

This must be completed, sign and issued by the Responsible Person when he is satisfied that the above condition have been
implement. The permit to work is then handed to the person in charge of the operation as an authorization for the work to start.

STAGE 2 – ENTRY AND CARRY OUT OF WORK

(i) Top entry must be by use of a bosun’s chair or safety cage and not by use of a ladder
(ii) A safety harness must be worn by the person(s) entering the bin and attached to a separate rope
(iii) Where an electrical winch is used in conjunction with a fixed safety rope and sliding fall arrester a manual winch
must also be available in case of failure of the electrical winch.

Two men must be positioned at the top of the bin. in either case there must be an effective means of
communication, detailed in writing, between the men at the top of the bin with:
a) The person inside
b) A responsible person on site to act in the ‘event of an emergency’.
(iv) Explosions have also occurred in silo due to portable lamps being lowered into them. power light should be fixed
outside the bin or in a large frame such that they cannot be lowered into the bin. If a light is need in the bin it
should be a non-glass, battery – operated, self-contained type, certified for flameproof use. It must be secured so
that it cannot be dropped into the bin and must never be allowed to remain contact with a mass of product.
(v) Any person entering the bin must wear:
a) A safety helmet
b) Anti -static overall
c) Appropriate Respiratory Protective Equipment (RPE)
d) Anti-static safety footwear.

ONE TEAM – ONE VISION Page 64

HYGIENE, HEALTH & SAFETY

(vi) No items of equipment or material, other than those identified on the permit to work, must be taken into a bin
(vii) Personal effects must not be taken into the bin

STAGE 3 – RETURN OF PLANT TO SERVICE

(i) On completion of the task all men and equipment must be removed from inside the bin
(ii) The person in charge of the operation shall inform the responsible that the job is completed
(iii) All access openings or hatches must be replaced and the bin and associated plant prepared for operation.
(iv) The permit to work is then cancelled by the responsible person

SILO ENTRY – INSTRUCTION TO CONTRACTORS

(i) It remains the responsibility of mill management to ensure that the bin is safety to enter
(ii) All action detailed under Stage 1 must be carried out before a permit to work is completed and issued to the
contractor.
(iii) The contractor must comply with the instruction listed under:
a) ‘stage 2 – Entry and carrying Out of Work’
b) Silo entry – instruction to Contractors

The following must also be observed:

(i) All equipment and protective clothing must be supplied by the contractor
(ii) A current test certificate for lifting tackle and ropes to be used shall be available for inspection by the Site Engineer.
(iii) Any electrically powered equipment must be earthed and should conform to BS 5490 or BS 6467 part 1
(iv) All tools and clothing must be incapable of producing sparks either by discharging static electricity or as a result of
impact.
(v) No light must be taken into the silo without permission of the site engineer.
(vi) Smoking is not permitted in any part of the silo structure or housing
(vii) At least two men must remain outside the silo but in visual contact with the man inside throughout the operation.
(viii) All employees must be competent and have been trained in the procedures for entering and working in silos as
defined in the bin entry procedure.

EQUIPMENT FOR ENTERING BINS

(i) Ropes and lifting tackle - factories Act 1961 s 26: Chain, rope and lifting tackle (register) order 1938
(ii) Chair/cradle - BS 2930: 1973
(iii) Ropes/cables - BS 3367:1980
(iv) Harness - BS 1397: 1979
(v) Safety helmet - BS 5240:1987
(vi) Respiratory protect equipment (RPE) – Appropriate for the conditions

ADDITIONAL NOTES
(I) Monthly examination and recording of all mechanical equipment including ropes etc. by a competent person.

ONE TEAM – ONE VISION Page 65

HYGIENE, HEALTH & SAFETY

(II) Certificate of guarantee for minimum breaking strength to be obtained from maker or supplier of the rescue line.
(III) Design of the chair/cage to be such as to prevent injury of the occupant in the event of failure of the winch/cable.

Appendix 2
PERMIT TO WORK
To be completed by Employee/Contractor before work commences

I. This is to certify I have instructed relevant personnel in the precautions required, will inspect the work as necessary and that it is
safe to proceed. (Health and Safety Requirements and Fire Drill issued where applicable).

Signed on behalf of ABC MILLS LIMITED POSITION

2. Description of Work:

3. This is to certify that I have read and understood the documentation issued and will carry out the work in accordance with them.

Permit Holders Name and Signature............................................................................................................................................

Signed on behalf of:.....................................................................................................(Company name where applicable)

4. This is to certify that the job is finished and that the site and all the equipment has been left safe and clean as found.
Permit Holders Name and Signature............................................................................................................................................
Signed on behalf of ABC MILLS LIMITED...............................................................................................................................

ONE TEAM – ONE VISION Page 66

HYGIENE, HEALTH & SAFETY

Appendix 3 - Pests of Stored Wheat and Flour

Primary Insect Pest

Saw-toothed Grain Beetle

Appearance:- A red-brown or black-brown elongate beetle, approximately 2-3mm long, 0.75mm wide.
Distribution:- World-wide. It is the most important pest of home-grown grain in the UK. Adults can
overwinter in cracks in unheated buildings and infest new stocks of grain the following year. They may
wander considerable distances from the grain store.
Damage:- Attacks whole, broken and damaged grain, but develops most successfully on damaged
kernels

Grain Weevil
Appearance:- A red-brown or dark brown, slightly shiny beetle with an obvious snout. It is incapable of
flight.
Distribution:- World wide, but mainly in temperate zones.
Damage:- Larvae and adults feed on wheat and adults sometimes feed on flour. The adult chews through
the grain and the larvae feed internally; the latter therefore being a ‘hidden infestation' and producing
hollow grains.

ONE TEAM – ONE VISION Page 67

HYGIENE, HEALTH & SAFETY

Rust-red Grain Beetle

Appearance:- A red-brown, flat and shiny beetle with long unclubbed antennae. Active and capable of
flight at temperatures above 25°C. Breeds above 20°C.
Distribution:- Well established in the UK, where it is able to overwinter in unheated premises.
Damage:- Larvae eat germ

Lesser Grain Borer

Appearance:- A dark red-brown, slightly shiny, cylindrical beetle. The head is tucked under the thorax
and is not visible from above.
Damage:- The adults chew into the seed coat and the larva is an internal feeder (hidden infestation),
again resulting in hollowed-out grains.

Confused Flour Beetle

Appearance:- A slim red-brown beetle. The antennae gradually broaden near the tip. The mobile
yellow-brown larvae reach up to 6mm long.
Distribution:- World-wide; in cooler climates these beetles survive only in heated premises.
Damage:- Frequent mill pests. Badly infested flour has a distinctive odour, turns brown and is unfit for
baking or other use.

Broad-horned Flour Beetle

Appearance:-Similar to the confused flour beetle but with a much wider thorax. The male beetles have
large mandibles, curving outwards in front of the head. The female’s mandibles are much smaller.
Distribution:- World-wide but is not cold-hardy. It cannot survive even mild winters in the UK in
unprotected conditions. However, the inside of a flour mill is always at a high enough temperature for
this species to survive and breed.

Damage:- Larvae attack grain and grain products.

ONE TEAM – ONE VISION Page 68

HYGIENE, HEALTH & SAFETY

Indian Meal Moth

Appearance:- Adults are not always seen and the main problem is larval contamination. The larvae are
yellow-white, without the black speckles common in other species.
Distribution:- Very common Source: Detia Degesch GmbH in Europe and sub-tropics, now
spreading to the UK although still uncommon in flour mills.

Damage: Larvae can chew through most packaging and produce silk which webs food particles
together. Tell-tale signs are their small white droppings (trass) and webbing

Mediterranean Flour Moth (or Mill Moth)

Appearance:- The blue-grey forewings are marked with dark, wavy bars and a row of dark spots on the
tip. Larvae are white, with a pink or green tinge and blackish speckles.
Distribution:- Most temperate countries.
Damage:- Larvae feed on flour and bran. They are serious potential pests in mills, where their webbing
can clog machinery. The webbing is natural silk which traps their faecal pellets together with particles of
foodstuffs.

Mites
Several species of mites are also primary pest. Mites are arachnids, not insects, having eight legs (like spiders) than six. They eat the
germ and sometimes the endospom. Most serious to the miller is the flour mite. Mites are usualy detected only when infestation is
severe when they appear as a moving layer of dust. However, their presence in flour can sometimes be delected by gently pinching a
flour sample into a small peak

If mites are present the peak will flatten out within a short period of time. Using a simple hand lens on the sample is a better way of
confirming the presence of mites. Infestation only occurs under damp conditions (mites cannot prevent the loss of body water through
evaporation, and will die of desiccation if subjected to a humidity lower than 55%).

Flour Mite
Appearaace The female is 0.5mm and the male 0.4mm long. Adults are transparent/white: the eight legs
are pale violet.
Dirtribatma:- World-wide.
Damage:- Infestation produces a sour minty smell and rapid deterioration of foodstuffs. The taint in
wheat and flour is permanent. Seeds (including malting barley) can be seriously affected by mite damage
to the germ

ONE TEAM – ONE VISION Page 69

HYGIENE, HEALTH & SAFETY

Secondary insect pests

These beetles, psocids and moths live on debris of older spillages of broken grains or on flour and other wheat products and on other
dead insects and mites; sometimes found in birds’ nests. A few live on other insects and mites as predators: while others need a supply
of fungal growth in their diet: When damage is evident, it may be caused by larvae and adults of beetles or the larvae of moths. The
main secondary insect pests are: Foreign Grain Beetle: Cadelle Beetle: Australian Spider Beetle; Yellow Mealworm Beetle;
Brown House Moth; White-shouldered House Moth; Psocids (Booklice).
These are described be
Foreign Grain Beetle
Appearance:- A light red-brown beetle which has clubbed antennae and is covered in
short, fine hairs.
Distribution:- Commonly found in UK grain. It feeds partially on moulds and is more likely to be
present in grain which has a moisture content of more than 15%
Damage:- Damage to the grain occurs only when conditions are suitable for large populations to
develop. At this stage, the grain is usually damaged by dampness and moulding

Cadelle Beetle
Appearance:- A flat brown-black beetle with well developed mandibles. Antennae and legs on the
ventral side of the body are red-brown. Whitish larva is up to 18mm long, with black head, two black
hooks at the posterior end and long body hairs.
Distribution - World-wide, though now rarely found in the UK.
Damage:- Cadelle beetles can live in mills, silos and warehouses. A serious pest in the tropics, they eat
grain and cereal products. They are also predaceous on other insects. Adults gnaw through silk bolting
cloths (now rarely used) and their tunnelling may weaken timber sections in mill equipment and storage
bins.

Australian Spider Beetle

Appearance:- A dark-brown beetle covered with yellow-brown hairs. The yellow-white larvae have
brown heads, grow to 7mm long and are curved (or C-shaped). The adults are nocturnal, making it
difficult to find them in daytime inspections. They form spherical cocoons amongst the food.
Distribution - Originally from Australia and Tasmania, they are now world-wide.
Damage - Adults and larvae attack grain and grain products.

ONE TEAM – ONE VISION Page 70

HYGIENE, HEALTH & SAFETY

Yellow Mealworm Beetle

Appearance: - A brown-black beetle. Larvae, known as mealworm, are yellow-brown and grow up to
28mm in length.
Distribution:- Typically found in temperate regions of the world; unable to breed in the tropics. Very
resistant to cold. It is a common inhabitant of birds’ nests. The adult beetles fly and are attracted to light
at night.
Damage: - A minor grain pest which rarely causes serious damage unless present in grain and wheat
products which have been stored for long periods. It thrives in contaminated residues and feeds on dead
insects as well as wheat and wheat products. Most commonly found in basements and lagged storage
areas.

Brown House Moth

Appearance:- The upper side of the forewings are bronze-browm with dark flecks or spots.
Distribution:- Widespread in temperate zones: unable to breed in the tropics. A common dry-nest
inhabitant.
Damage:- Larvae attack wheat and wheat products and all food residues. Damaged grains are more
likely to be attacked.

White-shouldered House Moth

Appearance:- Similar to brown house moth in size but has white scales on head and thorax or ‘white
shoulders’.
Distribution/Damage:- Similar to, and often found in conjunction with, the brown house moth. Not
uncommon in grain stores.

Psocids
Soft-bodied winged or wingless primitive insects which feed partly on mould and develop well in conditions of high humidity. Psocids
attack the packaging of finished products and inhabit wooden pallets, particularly if damp or stored outside, then brought into the mill.
Rodents pest

ONE TEAM – ONE VISION Page 71

HYGIENE, HEALTH & SAFETY

Rodents foul food materials and severely damage packaging and pallets. Two kinds of rodent pests may be found in UK mills:

The Brown Rat

Also known as the Norway, Common or Sewer rat, it is the most widespread species of rat
likely to invade mills and lives, anywhere offering food and shelter. Each rat produces about 40
droppings per day.

The House Mouse

This species, characterized by its
large hairless ears, longish tail and
grey-brown fur, is now regarded as
the most common rodent pest in UK
mills. It is territorial and marks its
boundaries with urine. Each mouse
produces about 80 droppings per day.

Bird pests: The main bird pests of UK flour mills are feral pigeons, house sparrows and collared doves
FeralPigeon House Sparrow

ONE TEAM – ONE VISION Page 72

HYGIENE, HEALTH & SAFETY

ONE TEAM – ONE VISION Page 73