Commercial Bakery Safety Manual

What Should a Commercial Bakery Safety Manual Include?

The contents of a Commercial Bakery Safety Manual should reflect the bakery’s actual operations.

A small wholesale bakery may require a different combination of programs than a large automated facility containing bulk flour systems, silos, industrial mixers, dough-processing lines, tunnel ovens, conveyors, packaging machinery, forklifts, loading docks, and dedicated sanitation or maintenance departments.

Depending on operations, the manual may address:

• Bakery machinery.
• Machine guarding.
• Lockout/Tagout.
• Flour handling and flour dust.
• Combustible dust.
• Commercial ovens.
• Burn prevention.
• Heat stress.
• Sanitation.
• Chemical safety.
• Conveyors.
• Ergonomics.
• Material handling.
• Forklifts.
• Electrical safety.
• PPE.
• Emergency procedures.

Programs should be selected according to the work actually performed, the hazards present, and applicable requirements.

Commercial Bakery Safety Program

An effective Commercial Bakery Safety Program establishes responsibilities and procedures for identifying hazards, safeguarding machinery, controlling hazardous energy, protecting employees from flour dust and chemicals, preventing burns and other injuries, maintaining equipment, and correcting unsafe conditions.

Management should provide the training, equipment, safeguards, PPE, and resources necessary for employees to perform bakery operations safely.

Managers and supervisors should:

• Identify workplace and process hazards.
• Ensure bakery machinery is appropriately guarded.
• Establish hazardous-energy-control procedures where required.
• Maintain flour-handling and dust-control systems.
• Evaluate employee exposure to airborne flour and other ingredients.
• Maintain ovens and heat-producing equipment safely.
• Coordinate production, sanitation, and maintenance activities.
• Evaluate chemical hazards.
• Provide appropriate PPE.
• Train employees before assigning hazardous work.
• Correct unsafe conditions.
• Investigate incidents and near misses.
• Follow up on corrective actions.

Employees should follow established procedures, use required safeguards and PPE, report unsafe conditions, and operate only machinery for which they have received appropriate instruction and authorization.

Bakery Hazard Assessments

Bakery operations should be evaluated to identify hazards associated with machinery, flour and ingredient handling, baking processes, sanitation, chemicals, material handling, and other employee exposures.

Hazard assessments may consider:

• Points of operation.
• Ingoing nip points.
• Rotating machinery.
• Conveyors.
• Hazardous energy.
• Flour dust.
• Combustible dust.
• Hot surfaces.
• Steam.
• Heat exposure.
• Sanitation chemicals.
• Electrical equipment.
• Repetitive production work.
• Heavy lifting.
• Noise.
• Forklift traffic.
• Slippery floors.

Assessments should be reviewed when machinery, processes, ingredients, chemicals, or production methods change significantly.

Bakery Safety Inspections

Commercial bakeries should be periodically inspected to identify unsafe conditions and verify that established procedures are being followed.

Inspection topics may include:

• Machine guards.
• Interlocks.
• Emergency stops.
• Mixers.
• Dough-processing equipment.
• Conveyors.
• Ovens.
• Flour-handling systems.
• Dust-control systems.
• Electrical equipment.
• Chemical storage.
• Floors and stairs.
• Forklifts.
• PPE.
• Emergency equipment.
• Fire-protection equipment.
• Exit routes.

Deficiencies should be documented and corrected in a timely manner.

Job Safety Analysis (JSA/JHA)

A Job Safety Analysis or Job Hazard Analysis can be used to evaluate higher-hazard bakery operations.

JSAs/JHAs may be appropriate for:

• Commercial mixer operation.
• Dough-divider operation.
• Dough-moulder operation.
• Dough-sheeter operation.
• Conveyor operation.
• Slicer operation.
• Oven operation.
• Flour handling.
• Ingredient dumping.
• Equipment cleaning.
• Jam clearing.
• Maintenance.
• Forklift operation.
• Loading and unloading.

The JSA/JHA should identify task steps, hazards, and controls necessary to perform the work safely.

Bakery Machinery Safety

Commercial bakery machinery can create caught-in, caught-between, crushing, cutting, shearing, and amputation hazards.

Employees should understand:

• Machine controls.
• Operating procedures.
• Guards.
• Interlocks.
• Emergency stops.
• Feed systems.
• Safe operating positions.
• Jam-clearing procedures.
• Cleaning procedures.
• Shutdown requirements.

Employees should keep hands, clothing, tools, and other body parts away from moving-machine danger zones.

Machine Guarding

Required machine guards and safeguards should remain in place and functional.

Potential machine hazards include:

• Points of operation.
• Ingoing nip points.
• Rotating components.
• Gears.
• Chains and sprockets.
• Belts and pulleys.
• Rollers.
• Cutting blades.
• Reciprocating components.
• Conveyors.

Employees should not remove, defeat, bypass, or intentionally interfere with required guards or protective devices.

Machinery with missing or defective safeguards should be removed from service when necessary until appropriate protection is restored.

Commercial Mixers

Commercial mixers can expose employees to rotating agitators, paddles, shafts, belts, gears, and other moving components.

Employees should:

• Keep guards and bowl enclosures in place.
• Keep hands and tools away from moving agitators.
• Follow established ingredient-loading procedures.
• Use controls only from the intended operating position.
• Stop equipment before performing work that cannot be safely completed during operation.
• Follow appropriate shutdown procedures before cleaning or servicing.

OSHA’s bakery standard contains specific requirements for bakery mixers, including guarding of moving power-transmission components and safeguards for mixer bowls and controls.

Horizontal Dough Mixers

Horizontal dough mixers should be operated according to applicable equipment safeguards and manufacturer instructions.

Employees should not reach into mixer bowls while agitators are moving.

Covers, enclosures, interlocks, and other safeguards should remain functional.

Cleaning and servicing should be performed using appropriate shutdown and hazardous-energy procedures.

Vertical Mixers

Vertical mixers should be maintained and operated so employees are protected from rotating mixing components and moving bowls.

Bowl-locking mechanisms should be used as intended.

Mechanical assistance should be provided where necessary for handling heavy bowls or other components.

Mixer Bowls

Mixer bowls can create ergonomic and crushing hazards because of their weight and size.

Employees should use appropriate equipment for moving heavy bowls.

Employees should keep hands and feet clear when positioning bowls.

Wheels, handles, locking devices, and moving mechanisms should be maintained in safe condition.

Ingredient Addition

Ingredients should be added using procedures that minimize employee exposure to moving equipment and airborne dust.

Employees should not place hands or tools into moving mixer components.

Where flour or powdered ingredients are manually added, work practices should minimize unnecessary dust generation.

Dough Dividers

Dough dividers contain moving and reciprocating components that can expose employees to crushing and caught-in hazards.

Guards and covers should remain in place.

Employees should not reach through or around machine guards while the divider is operating.

Interlocked covers should not be bypassed.

Dough Rounders

Dough rounders should be operated only with required guards in place.

Employees should keep hands, clothing, and tools away from moving rollers, belts, and other components.

Jams should be cleared using established procedures.

Dough Moulders

Dough moulders can expose employees to rollers, belts, gears, and nip points.

Stopping devices should remain accessible.

Employees should keep hands away from feed and discharge hazards.

Employees should not reach into moving moulders to reposition dough.

Dough Sheeters and Rollers

Dough sheeters and rolling equipment can create severe ingoing nip-point hazards.

Required barriers, stop bars, trip devices, or other safeguards should remain operational.

Employees should not reach between moving rolls.

OSHA’s bakery standard includes specific protective provisions for manually fed dough brakes, reversible dough brakes, and box- and roll-type dough sheeters.

Dough Depositors

Dough and batter depositors should be appropriately guarded against moving-machine hazards.

Employees should follow established procedures for filling, adjusting, clearing, and cleaning equipment.

Employees should not reach beneath or into energized equipment to remove product or correct a problem.

Slicers and Cutting Equipment

Bread slicers and other powered cutting equipment should be appropriately guarded.

Employees should keep hands away from cutting blades.

Push devices or other tools should be used when provided.

Cleaning, blade changes, and servicing should be performed according to established shutdown and hazardous-energy-control procedures.

Conveyors

Conveyors may expose employees to:

• Nip points.
• Rollers.
• Belts.
• Chains.
• Sprockets.
• Transfer points.
• Automatic movement.
• Unexpected startup.

Employees should keep hands and clothing away from moving conveyor components.

Required guards should remain in place.

Conveyor Emergency Stops

Emergency-stop devices should be accessible and maintained in working condition.

Employees should understand their location and use.

Emergency stops should not be blocked by racks, ingredients, finished products, packaging, or other materials.

Conveyor Crossovers

Employees should use designated crossovers or walkways where provided.

Employees should not climb over or crawl under operating conveyors unless the system is specifically designed to permit such access.

Packaging Machinery

Packaging operations may include wrappers, slicers, baggers, sealers, labelers, case packers, palletizers, and other automated equipment.

Potential hazards include:

• Nip points.
• Cutting components.
• Heated sealing surfaces.
• Crushing hazards.
• Automatic movement.
• Unexpected startup.

Guards and interlocks should remain operational.

Guards and Interlocks

Interlocked guards, doors, and covers should function as designed.

Employees should not bypass interlocks to increase production, simplify cleaning, observe equipment, or gain access to moving components.

Defective safeguards should be reported immediately.

Emergency Stop Devices

Emergency stops should be maintained and periodically inspected as appropriate.

Employees should understand their purpose and location.

Emergency stops should not be used as substitutes for required hazardous-energy isolation during covered servicing or maintenance.

Jam Clearing

Employees should not reach into moving machinery to clear dough, product, packaging, or other jams.

The equipment should be stopped using established procedures.

Where jam clearing exposes employees to unexpected startup, machine movement, or release of hazardous energy, applicable Lockout/Tagout procedures should be followed.

Lockout/Tagout

Commercial bakery machinery can contain electrical, mechanical, hydraulic, pneumatic, thermal, gravitational, and other hazardous energy.

Where servicing or maintenance exposes employees to unexpected energization, startup, or release of hazardous energy, applicable energy-control procedures should be followed.

The Lockout/Tagout Program should address:

• Energy-control procedures.
• Authorized employees.
• Affected employees.
• Energy-isolating devices.
• Lockout and tagout devices.
• Stored energy.
• Verification.
• Periodic inspections.
• Training.

OSHA has specifically clarified that its bakery-equipment standard and general Lockout/Tagout requirements can both apply: machine guarding governs normal production hazards, while covered servicing and maintenance may require hazardous-energy control under 29 CFR 1910.147.

Machine-Specific Energy Control Procedures

Where required, energy-control procedures should identify the energy sources associated with each machine and the methods necessary to isolate them.

Energy sources may include:

• Electrical energy.
• Pneumatic pressure.
• Hydraulic pressure.
• Gravity.
• Mechanical energy.
• Thermal energy.
• Steam or pressure.

Employees should verify isolation before beginning covered servicing or maintenance.

Cleaning and Lockout/Tagout

Cleaning bakery machinery can expose employees to moving components, blades, rollers, gears, conveyors, and other hazardous energy.

The company should evaluate cleaning procedures to determine when Lockout/Tagout is required.

Employees should not assume that pressing a stop button or selecting an “off” control makes machinery safe for servicing.

A 2026 OSHA bakery inspection specifically cited hazardous-energy-control deficiencies associated with dough clearing, reinforcing the importance of distinguishing normal operating controls from energy isolation.

Clearing Dough from Machinery

Employees should use established methods for removing accumulated or jammed dough.

Where possible, employees should use tools or methods that keep hands outside machine danger zones.

If the task exposes employees to hazardous movement or unexpected startup, applicable energy-control procedures should be followed.

Machine Adjustments

Routine adjustments should be performed only when they can be completed safely using the equipment’s intended operating safeguards.

If an adjustment requires employees to bypass guards, enter danger zones, or become exposed to unexpected energization or hazardous energy, appropriate energy-control procedures should be followed.

Blade Changes

Blades should be changed only by appropriately trained and authorized employees.

Employees should:

• Shut down equipment.
• Control hazardous energy where required.
• Use appropriate cut-resistant protection.
• Use proper tools.
• Store removed blades safely.

Maintenance and Repair

Bakery equipment should be maintained according to manufacturer recommendations and company procedures.

Maintenance work should address:

• Hazardous energy.
• Guards.
• Stored energy.
• Hot surfaces.
• Electrical hazards.
• Heavy components.
• Elevated work.
• Contractor coordination.

Only appropriately qualified employees should perform specialized maintenance.

Flour Handling

Commercial bakeries may receive flour in bags, totes, bins, or bulk pneumatic systems.

Flour-handling operations should be designed and performed to minimize employee exposure to moving equipment, manual-handling hazards, airborne dust, and combustible-dust hazards.

OSHA 1910.263 contains bakery-specific provisions for flour-handling equipment, including flour systems, bag handling, conveyors, sifters, dump bins, and dust containment.

Flour Dust

Airborne flour dust can present occupational-health and housekeeping concerns.

Employees may be exposed when:

• Opening flour bags.
• Dumping ingredients.
• Mixing.
• Filling hoppers.
• Cleaning.
• Transferring powdered ingredients.
• Handling flour-contaminated materials.

The company should evaluate operations that generate substantial airborne dust.

NIOSH has documented respiratory symptoms and sensitization among commercial bakery workers with flour exposure, and CDC identifies flour and grain dust among recognized workplace asthma triggers.

Flour Dust Exposure Controls

Potential controls may include:

• Enclosed transfer systems.
• Local exhaust ventilation.
• Dust-capturing hoods.
• Controlled ingredient addition.
• Reduced drop heights.
• Appropriate housekeeping.
• Vacuum cleaning.
• Process changes.

Controls should be selected according to the actual process and exposure.

Adding Flour to Mixers

Employees should avoid unnecessary dumping or throwing of flour that causes large dust clouds.

Where practical, bags should be opened and emptied using methods that reduce airborne dust.

Dust-control equipment should be used where provided.

Bulk Flour Systems

Bulk flour systems may include:

• Silos.
• Pneumatic transfer systems.
• Screw conveyors.
• Sifters.
• Dust collectors.
• Hoppers.
• Weighing systems.

Employees should understand the hazards associated with the equipment they operate.

Moving components should remain guarded.

Flour Bags

Employees handling flour bags should evaluate load weight, grip, travel distance, and lifting frequency.

Mechanical assistance should be used where practical.

Storage should be arranged to minimize unnecessary overhead or floor-level lifting.

Occupational Asthma and Sensitization

Repeated exposure to flour and certain bakery ingredients may contribute to work-related respiratory symptoms and sensitization in some employees.

Employees should be encouraged to report recurring:

• Coughing.
• Wheezing.
• Chest tightness.
• Shortness of breath.
• Nasal irritation.
• Work-related respiratory symptoms.

Potential exposures and controls should be evaluated when symptoms appear to be associated with work.

Skin Exposure

Flour, dough, enzymes, cleaning chemicals, and other bakery substances may contribute to skin irritation or sensitization in some employees.

Employees should use appropriate hygiene practices and task-specific gloves where needed.

Persistent skin symptoms should be reported.

Combustible Dust — When Applicable

Flour, sugar, starch, powdered milk, cocoa, and other finely divided food ingredients can present combustible-dust hazards under certain conditions.

The company should evaluate whether its materials and processes can produce hazardous combustible-dust concentrations or accumulations.

OSHA’s combustible-dust guidance specifically lists flour, starch, sugar, powdered milk, cocoa, cereal, spices, gluten, and similar food products as examples of materials capable of presenting combustible-dust hazards.

Dust Accumulation

Dust should not be allowed to accumulate to hazardous levels on:

• Floors.
• Equipment.
• Beams.
• Ledges.
• Ducts.
• Light fixtures.
• Elevated surfaces.
• Other horizontal surfaces.

Housekeeping procedures should avoid unnecessarily dispersing accumulated combustible dust.

Dust Collection

Dust-collection systems should be appropriate for the materials and processes served.

Systems should be inspected and maintained.

Employees should not disable dust collectors, exhaust systems, or related safeguards without authorization.

Ignition Sources

Where combustible-dust hazards are present, ignition sources should be controlled.

Potential sources may include:

• Hot work.
• Electrical equipment.
• Static electricity.
• Sparks.
• Hot surfaces.
• Mechanical friction.

Compressed-Air Cleaning

Compressed air should not be used in a manner that creates unnecessary airborne dust or introduces a combustible-dust hazard.

Where compressed air is used for cleaning, applicable pressure, guarding, and PPE requirements should also be followed.

Vacuuming or other methods may be preferable for some applications.

Commercial Oven Safety

Commercial ovens present heat, fire, fuel, mechanical, electrical, and possible explosion hazards.

Employees should understand operating procedures and emergency shutdown methods.

Mechanical oven components should be appropriately safeguarded.

OSHA’s bakery standard contains detailed provisions for oven placement, emergency stops, gas piping, ignition safeguards, fuel shutoff, explosion protection, and periodic safety-device inspection.

Rack Ovens

Employees loading and unloading rack ovens should use caution around:

• Hot doors.
• Hot racks.
• Steam.
• Hot pans.
• Moving racks.
• Uneven floors.

Racks should be stable and in usable condition.

Employees should avoid placing hands or body parts where they could be caught between racks and oven components.

Tunnel and Conveyor Ovens

Employees should remain clear of moving oven conveyors and transfer points.

Emergency stops should remain accessible.

Employees should not reach into operating tunnel or conveyor ovens to reposition product.

Maintenance should follow appropriate shutdown and energy-control procedures.

Oven Loading and Unloading

Employees should maintain a clear travel path when moving pans, trays, carts, or racks.

Loads should not obstruct visibility.

Appropriate hand and arm protection should be used where employees may contact hot surfaces.

Burn Prevention

Potential burn sources include:

• Ovens.
• Hot pans.
• Baking trays.
• Steam.
• Hot water.
• Heated piping.
• Hot fillings.
• Heated oils.
• Cooking equipment.

Employees should use appropriate mitts, gloves, tools, and work practices.

Hot Surfaces

Hot equipment should be identified and guarded or insulated where appropriate.

Employees should not place combustible materials against hot surfaces.

Damaged insulation should be reported.

Hot Water and Steam

Employees should use caution around hot-water and steam systems.

Leaks should be reported.

Employees should not open pressurized systems or remove covers until pressure and temperature have been safely controlled.

Heat-Resistant PPE

Heat-resistant gloves, mitts, sleeves, aprons, or other protection should be provided where necessary.

PPE should be selected for the temperatures and tasks involved.

Damaged thermal PPE should be replaced.

Gas-Fired Equipment — When Applicable

Gas-fired ovens and related systems should be maintained according to applicable requirements and manufacturer instructions.

Employees should report:

• Gas odors.
• Ignition problems.
• Flame failures.
• Damaged piping.
• Abnormal burner operation.

Only appropriately qualified persons should perform repairs or adjustments to fuel-gas systems.

Heat Stress

Employees working near ovens, proofers, steam systems, and other heat-producing equipment may experience significant heat exposure.

Where heat stress may be significant, controls may include:

• Ventilation.
• Hydration.
• Work-rest practices.
• Acclimatization.
• Employee rotation where appropriate.
• Cooling areas.

Employees should understand signs and symptoms of heat-related illness.

Sanitation Worker Safety

Sanitation employees may encounter machinery, hazardous energy, chemicals, wet floors, electrical equipment, hot equipment, ladders, hoses, and other hazards.

Sanitation procedures should coordinate:

• Equipment shutdown.
• Lockout/Tagout.
• Chemical use.
• PPE.
• Machine disassembly.
• Electrical precautions.
• Floor cleaning.
• Dust-control methods.

Cleaning Bakery Machinery

Employees should follow equipment-specific cleaning procedures.

Depending on the equipment, cleaning may require:

• Shutdown.
• Energy isolation.
• Lockout/Tagout.
• Cooling.
• Disassembly.
• Blade removal.
• Mechanical blocking.

Employees should not reach into hazardous machine areas unless appropriate safeguards or energy controls are in place.

Dry Cleaning Methods

Some bakery areas may use dry cleaning methods to avoid introducing moisture or spreading flour and powdered ingredients.

Methods should minimize dust dispersal.

Employees should use equipment appropriate for the combustible-dust and respiratory hazards present.

Washdown — When Applicable

Where water is used for sanitation, employees should consider electrical equipment, slippery floors, chemical exposure, drainage, and machine hazards.

Electrical equipment should not be washed down unless it is suitable for the environment and cleaning method.

Sanitation Chemicals

Bakery sanitation may involve cleaners, sanitizers, degreasers, caustics, acids, and other hazardous chemicals.

Employees should follow:

• Product labels.
• Safety Data Sheets.
• Manufacturer instructions.
• Company procedures.

Appropriate PPE, ventilation, dispensing systems, and emergency equipment should be provided.

Chemical Dilution and Dispensing

Concentrated chemicals should be diluted and dispensed according to manufacturer instructions.

Employees should use designated dispensing systems where provided.

Secondary containers should remain appropriately labeled.

Chemical Mixing

Employees should not mix chemicals unless the manufacturer specifically permits the combination and established procedures have been provided.

Incompatible chemicals can generate hazardous gases, heat, pressure, or other dangerous reactions.

Emergency Eyewash and Shower Equipment

Where employees may be exposed to injurious corrosive materials, suitable emergency flushing facilities should be provided as required.

Access should remain unobstructed.

Employees should know the location and use of emergency equipment.

Slips, Trips and Falls

Bakery floors can become slippery or obstructed by:

• Flour.
• Dough.
• Batter.
• Water.
• Oil.
• Grease.
• Packaging.
• Ingredients.
• Hoses.

Spills and accumulations should be corrected promptly.

Flour, Dough and Batter on Floors

Flour can reduce floor traction, while wet dough and batter can create particularly slippery surfaces.

Employees should clean spills promptly using methods appropriate for the material.

Cleaning should not create unnecessary airborne dust.

Oil and Grease

Oil and grease should be controlled at ovens, fryers, production equipment, maintenance areas, and other locations where they may accumulate.

Leaks should be repaired.

Stairs and Elevated Walkways

Stairs should remain clear and in good condition.

Employees should use handrails.

Employees should not carry loads that prevent safe use of stairs or obstruct their view.

Slip-Resistant Footwear

Footwear requirements should consider floor conditions, oils, water, flour, temperature, and other hazards.

Slip resistance may be particularly important in bakery production and sanitation areas.

Walking-Working Surfaces

Floors, platforms, stairs, mezzanines, and other walking-working surfaces should be maintained in safe condition.

Employees should report:

• Damaged flooring.
• Loose mats.
• Missing covers.
• Uneven surfaces.
• Slippery conditions.
• Damaged stairs.
• Unprotected openings.

Electrical Safety

Commercial bakeries contain electrical equipment in production, sanitation, warehouse, refrigeration, and maintenance areas.

Employees should:

• Report damaged cords and plugs.
• Avoid makeshift repairs.
• Keep unsuitable connections away from water.
• Maintain enclosures and covers.
• Follow equipment cleaning restrictions.

Electrical repairs should be performed only by appropriately qualified persons.

Electrical Equipment During Cleaning

Employees should not spray or wash electrical equipment unless it is designed for those conditions.

Damaged electrical enclosures, seals, cords, or fittings should be reported.

Appropriate shutdown procedures should be followed before cleaning electrical equipment.

Hazard Communication

Commercial bakeries using hazardous chemicals should maintain an applicable Hazard Communication Program.

Potential workplace chemicals may include:

• Sanitation products.
• Cleaning chemicals.
• Lubricants.
• Maintenance chemicals.
• Refrigerants.
• Pest-control products.

Employees should have access to labels and Safety Data Sheets and receive applicable information and training.

Personal Protective Equipment

PPE should be selected according to the hazards associated with each task.

Depending on operations, PPE may include:

• Safety glasses.
• Goggles.
• Face shields.
• Chemical-resistant gloves.
• Cut-resistant gloves.
• Heat-resistant gloves.
• Protective aprons.
• Safety footwear.
• Hearing protection.
• Respiratory protection.

PPE should not substitute for required machine guarding or other feasible hazard controls.

Eye and Face Protection

Eye and face protection may be necessary during:

• Chemical handling.
• Sanitation.
• Maintenance.
• Dust-producing work.
• Pressurized cleaning.
• Grinding or repair work.

Face shields should supplement primary eye protection where both are necessary.

Hand Protection

Different bakery tasks may require different types of gloves.

Examples include:

• Heat-resistant gloves for hot pans and racks.
• Chemical-resistant gloves for sanitation.
• Cut-resistant protection for blade handling.
• General work gloves for appropriate material-handling tasks.

Gloves should not be worn where they create an entanglement hazard around exposed moving machinery.

Respiratory Protection — When Applicable

Respiratory hazards may arise from flour dust, powdered ingredients, cleaning chemicals, maintenance activities, or other processes.

Engineering and other feasible controls should be used where appropriate.

Where respirators are required, the company should maintain an applicable Respiratory Protection Program.

Ergonomics

Commercial bakery work can involve repetitive movement, lifting, pushing, pulling, prolonged standing, awkward posture, and forceful exertion.

Potential ergonomic concerns include:

• Ingredient handling.
• Dough handling.
• Mixer-bowl movement.
• Tray loading.
• Rack movement.
• Packaging.
• Palletizing.
• Repetitive production work.

Workstations, tools, and material-handling methods should be evaluated where significant ergonomic hazards exist.

Ingredient Bag Handling

Flour, sugar, and other ingredients may be supplied in heavy bags.

Potential controls include:

• Mechanical assistance.
• Smaller containers.
• Improved storage height.
• Team lifting.
• Appropriate lifting techniques.
• Reduced carrying distance.

Employees should evaluate loads before lifting.

Bakery Racks and Carts

Racks and carts should be maintained in usable condition.

Employees should inspect wheels and handles.

Loads should be stable.

Employees should push rather than pull heavy carts where practical and maintain adequate visibility.

Tray and Pan Handling

Repeated handling of trays and pans may contribute to upper-extremity and back strain.

Employees should avoid excessive load sizes.

Work heights and storage locations should minimize unnecessary bending and reaching.

Repetitive Production Work

Packaging, decorating, sorting, portioning, loading, and other repetitive bakery tasks should be evaluated for excessive repetition, force, and awkward posture.

Potential controls may include workstation adjustment, task variation, mechanical assistance, and improved equipment positioning.

Prolonged Standing

Employees who stand for extended periods should have workstations arranged to reduce unnecessary reaching and awkward posture.

Appropriate footwear and anti-fatigue measures may be considered where suitable.

Manual Lifting

Employees should evaluate the size, weight, and shape of a load before lifting.

Mechanical assistance or team lifting should be used when appropriate.

Repeated lifting tasks should be evaluated for potential improvements.

Material Handling

Bakery employees may handle:

• Ingredient bags.
• Boxes.
• Drums.
• Totes.
• Pallets.
• Packaging materials.
• Finished products.
• Bakery racks.

Materials should be transported and stored securely.

Forklift/PIT Safety — When Applicable

Commercial bakeries may use powered industrial trucks for receiving ingredients, moving materials, warehouse operations, and shipping.

Operators should be trained and evaluated as required.

Procedures should address:

• Pre-use inspections.
• Pedestrians.
• Intersections.
• Racking.
• Loading docks.
• Trailers.
• Battery charging or fueling.

Pallet Jacks

Employees using pallet jacks should inspect the equipment and control loads carefully.

Feet and hands should remain clear of wheels, pallets, and pinch points.

Loads should not exceed equipment capacity.

Racking and Storage

Storage racks should be appropriate for the loads placed on them.

Damaged racking should be reported.

Materials should be stored securely.

Aisles, exits, electrical panels, fire equipment, and emergency equipment should remain accessible.

Loading Docks

Loading docks may expose employees to:

• Dock edges.
• Trucks.
• Trailers.
• Forklifts.
• Dock plates.
• Moving materials.

Applicable procedures should address trailer movement, pedestrian traffic, dock equipment, and material handling.

Receiving and Shipping

Receiving and shipping operations should be organized to separate or otherwise control vehicle, forklift, and pedestrian hazards.

Employees should maintain communication during loading and unloading activities.

Confined Spaces — When Applicable

Commercial bakeries may contain spaces such as:

• Flour silos.
• Ingredient bins.
• Hoppers.
• Tanks.
• Vessels.
• Pits.

The company should evaluate each space to determine whether applicable confined-space requirements apply.

Flour Silos and Ingredient Bins

Employees should not enter flour silos, bins, or similar spaces unless hazards have been evaluated and applicable entry procedures established.

Potential hazards may include:

• Engulfment.
• Dust.
• Hazardous atmospheres.
• Moving machinery.
• Restricted entry and exit.
• Hazardous energy.

Hoppers and Vessels

Employees should not enter hoppers, tanks, mixers, or vessels without evaluating applicable confined-space and hazardous-energy hazards.

Equipment should be isolated as required before entry.

Noise Exposure

Mixers, conveyors, packaging machinery, compressors, blowers, and other equipment may produce significant noise.

Employee exposure should be evaluated where warranted.

Hearing Conservation — When Applicable

Where occupational noise exposure meets applicable criteria, the company should implement a Hearing Conservation Program addressing:

• Exposure monitoring.
• Audiometric testing.
• Hearing protection.
• Employee training.
• Recordkeeping.

Compressed Air

Compressed air should be used only for appropriate purposes.

Employees should not direct compressed air toward themselves or other employees.

When compressed air is used for cleaning, applicable pressure, guarding, and PPE requirements should be followed.

Compressed-air cleaning should also be evaluated for its potential to disperse flour or combustible dust.

Compressed Gas Cylinders — When Applicable

Compressed gas cylinders should be secured, protected from damage, and stored according to the hazards of the gas.

Appropriate regulators and fittings should be used.

Employees should receive instruction before handling compressed gases.

Welding, Cutting and Hot Work — When Applicable

Maintenance and fabrication activities may involve welding, cutting, brazing, or grinding.

Procedures should address:

• Fire hazards.
• Combustible dust.
• Combustible materials.
• Hot-work authorization.
• Ventilation.
• PPE.
• Compressed gases.
• Fire protection.

Particular care should be taken before performing hot work in areas where combustible flour or ingredient dust may be present.

Fire Prevention

Commercial bakeries should identify and control foreseeable fire hazards associated with:

• Ovens.
• Fuel-gas systems.
• Electrical equipment.
• Combustible dust.
• Hot work.
• Oils and grease.
• Packaging materials.
• Maintenance activities.

Employees should maintain access to fire extinguishers and exit routes.

Oven Fire and Explosion Prevention

Oven fuel and combustion systems should be maintained according to applicable requirements.

Safety devices should remain functional.

Employees should not bypass flame safeguards, fuel shutoffs, ventilation sequences, or other protective systems.

Abnormal ignition, fuel, or burner conditions should be reported immediately.

Emergency Action Plan

Commercial bakeries should establish procedures for foreseeable emergencies, including:

• Fire.
• Explosion.
• Chemical release.
• Serious injury.
• Gas leak.
• Power failure.
• Severe weather.
• Other facility emergencies.

Employees should understand alarm systems, evacuation procedures, emergency contacts, and assembly locations.

Emergency Egress

Exit routes should remain clear and accessible.

Materials, carts, racks, pallets, ingredients, packaging, and equipment should not obstruct exits.

Employees should understand primary and alternate evacuation routes.

First Aid

First-aid supplies should be readily available according to workplace hazards and applicable requirements.

Employees should know how to obtain emergency medical assistance.

Serious burns, amputations, crushing injuries, chemical exposures, electrical injuries, and other significant injuries require prompt medical attention.

Spill Prevention and Response

Procedures should address foreseeable spills involving:

• Cleaning chemicals.
• Oils.
• Ingredients.
• Batter.
• Dough.
• Maintenance fluids.
• Other workplace materials.

Employees should understand reporting, containment, PPE, cleanup, and emergency-response limitations.

Hazardous Waste Management — When Applicable

Facilities generating hazardous waste should establish appropriate procedures for identification, accumulation, labeling, storage, handling, and disposal.

Ordinary bakery waste should not automatically be considered hazardous waste.

Applicability should be based on the actual waste generated.

Contractor Safety

Commercial bakeries may use contractors for:

• Equipment maintenance.
• Electrical work.
• Oven servicing.
• Refrigeration.
• Sanitation.
• Construction.
• Pest control.
• Specialized cleaning.

The bakery and contractor should coordinate hazards and procedures that could affect the contractor’s work.

Applicable information may include:

• Lockout/Tagout.
• Machinery hazards.
• Combustible dust.
• Chemicals.
• Hot work.
• Emergency procedures.

Working Alone — When Applicable

Maintenance, sanitation, security, delivery, or other employees may occasionally work alone.

The company should evaluate the hazards of the assignment and provide appropriate communication and emergency procedures.

Tasks requiring immediate assistance or rescue capability should not be treated as routine lone work when doing so would create an unacceptable hazard.

Commercial Bakery Safety Training

Employees should receive training appropriate to their assigned duties and exposures.

Training may include:

• Bakery machinery.
• Machine guarding.
• Lockout/Tagout.
• Mixer safety.
• Conveyor safety.
• Oven safety.
• Flour dust.
• Combustible dust awareness.
• Chemical safety.
• PPE.
• Ergonomics.
• Slips and falls.
• Forklift safety.
• Emergency procedures.

Training should occur before employees independently perform work requiring specialized knowledge, qualification, or authorization.

New and Short-Service Employees

New and inexperienced employees may be unfamiliar with bakery machinery, production pace, flour-handling systems, hot equipment, sanitation procedures, and chemical hazards.

Orientation should address applicable hazards before employees begin independent work.

New employees should not operate specialized machinery, perform Lockout/Tagout, operate forklifts, enter confined spaces, or perform other higher-hazard work until required instruction, qualification, or authorization has been completed.

Supervision should reflect the employee’s experience and familiarity with the work.

Young Workers — When Applicable

Commercial bakeries employing workers under 18 should evaluate applicable federal and state youth-employment restrictions before assigning work.

Certain power-driven bakery machines and other hazardous equipment may be prohibited for minors.

Young employees should not be assigned prohibited operation, setup, adjustment, cleaning, oiling, or repair tasks.

OSHA’s restaurant safety guidance specifically notes that federal child-labor laws prohibit workers under 18 from operating or performing certain servicing activities on power-driven equipment such as bakery mixers.

Commercial Bakery JSA/JHA

JSAs/JHAs can be developed for recurring or higher-hazard bakery operations.

Useful topics may include:

• Commercial mixer operation.
• Dough-divider operation.
• Dough-sheeter operation.
• Conveyor operation.
• Oven loading and unloading.
• Flour handling.
• Ingredient dumping.
• Machine cleaning.
• Jam clearing.
• Blade changes.
• Forklift operation.
• Loading and unloading.
• Hot work.
• Confined-space entry.

The JSA/JHA should reflect the actual equipment, ingredients, chemicals, and workplace conditions.

Bakery Toolbox Talks

Short safety meetings can reinforce hazards associated with current operations.

Useful topics may include:

• Machine guarding.
• Lockout/Tagout.
• Mixer safety.
• Flour dust.
• Combustible dust.
• Oven burns.
• Heat stress.
• Sanitation chemicals.
• Slips and falls.
• Safe lifting.
• Forklift awareness.
• Emergency procedures.

Toolbox talks supplement formal training but should not replace required regulatory or task-specific training.

Additional Commercial Bakery Safety Programs

Depending on the machinery, processes, ingredients, equipment, and employee exposures involved, additional programs may include:

• Combustible Dust.
• Compressed Air Safety.
• Compressed Gas Cylinders.
• Confined Space.
• Conveyor Safety.
• Electrical Safety.
• Emergency Action Plan.
• Ergonomics.
• Fire Prevention.
• First Aid.
• Forklift/PIT Safety.
• Hazard Communication.
• Hazardous Waste Management.
• Hearing Conservation.
• Heat Stress Prevention.
• Housekeeping.
• Lockout/Tagout.
• Machine Guarding.
• Manual Lifting and Material Handling.
• Personal Protective Equipment.
• Respiratory Protection.
• Slips, Trips and Falls.
• Spill Prevention and Response.
• Walking-Working Surfaces.
• Welding, Cutting and Hot Work.
• Working Alone.

Programs should be selected according to actual bakery operations rather than automatically included simply because a company manufactures baked products.

Building a Commercial Bakery Safety Manual

The most useful Commercial Bakery Safety Manual is based on the facility’s actual machinery, ingredients, processes, and employee exposures.

Consider whether employees:

• Operate industrial mixers.
• Operate dough dividers, moulders, sheeters, or depositors.
• Work around conveyors.
• Operate slicers or cutting equipment.
• Use commercial ovens.
• Handle flour and powdered ingredients.
• Work around flour silos or bulk ingredient systems.
• Generate significant airborne flour dust.
• Have potential combustible-dust hazards.
• Perform machine cleaning and sanitation.
• Clear machinery jams.
• Perform maintenance or blade changes.
• Handle concentrated chemicals.
• Work in hot production areas.
• Operate forklifts.
• Perform repetitive or heavy material-handling work.
• Work in high-noise areas.
• Enter silos, hoppers, tanks, or other confined spaces.

These activities help determine which individual safety programs should be included.

A smaller wholesale bakery should not receive a manual filled with programs for bulk flour silos, forklifts, combustible-dust systems, confined spaces, or automated production machinery it does not have. Likewise, a large industrial bakery may require extensive programs addressing machine guarding, LOTO, flour dust, combustible dust, ovens, conveyors, heat stress, ergonomics, industrial trucks, chemicals, noise, and other specialized hazards.

Customized Commercial Bakery Safety Manuals

Companies can request a customized Commercial Bakery Safety Manual containing programs selected according to the bakery’s machinery, production processes, ingredients, sanitation procedures, chemicals, material-handling equipment, and employee exposures.

Manuals can be developed for commercial bakeries, wholesale bakeries, bread and roll manufacturers, industrial baking facilities, tortilla and flatbread manufacturers, pastry and dessert manufacturers, cookie and cracker operations, and other commercial baking businesses.

Applicable programs can be selected for machine guarding, Lockout/Tagout, bakery equipment, flour dust, combustible dust, conveyors, oven safety, chemical safety, heat stress, PPE, ergonomics, forklifts, confined spaces, emergency procedures, and other bakery hazards.

Individual safety programs can also be selected when a company needs to add or update a particular program within an existing safety manual.