Poultry Processing Safety Manual

What Should a Poultry Processing Safety Manual Include?

The contents of a Poultry Processing Safety Manual should reflect the facility’s actual operations.

A poultry slaughtering and processing facility may require a different combination of programs than a further-processing, deboning, packaging, freezing, or distribution operation.

Depending on operations, the manual may address:

• Poultry processing safety responsibilities.
• Hazard assessments.
• Safety inspections.
• Ergonomics.
• Repetitive-motion hazards.
• Knife and scissor safety.
• Machine guarding.
• Lockout/Tagout.
• Conveyors.
• Sanitation worker safety.
• Chemical safety.
• Ammonia refrigeration.
• Process Safety Management.
• Carbon dioxide.
• Liquid nitrogen.
• Biological hazards.
• Live bird handling.
• Personal Protective Equipment.
• Slips, trips and falls.
• Noise and Hearing Conservation.
• Cold work environments.
• Forklifts and material handling.
• Emergency procedures.

Programs should be selected according to the processes, equipment, chemicals, refrigeration systems, and workplace hazards actually present.

Poultry Processing Safety Program

An effective Poultry Processing Safety Program establishes responsibilities and procedures for identifying workplace hazards, protecting employees from machinery and hazardous energy, reducing ergonomic exposures, preventing cuts and lacerations, controlling chemical and biological hazards, and maintaining safe production and sanitation operations.

Management should provide employees with the equipment, safeguards, training, PPE, and resources necessary to perform assigned work safely.

Managers, supervisors, and other designated personnel should:

• Identify workplace hazards.
• Conduct hazard assessments.
• Maintain applicable written safety programs.
• Evaluate ergonomic hazards.
• Maintain machine guards and safeguards.
• Maintain hazardous-energy-control procedures.
• Evaluate chemical exposures.
• Maintain refrigeration-system safeguards.
• Provide appropriate PPE.
• Conduct workplace inspections.
• Provide employee training.
• Correct unsafe conditions.
• Investigate injuries and near misses.
• Maintain applicable records.

Employees should follow established procedures, use required machine guards and PPE, follow Lockout/Tagout requirements, report unsafe conditions, and promptly report injuries and occupational exposures.

Poultry Processing Hazard Assessments

Poultry processing operations should be evaluated to identify ergonomic, mechanical, chemical, biological, electrical, physical, and other workplace hazards.

Hazard assessments may consider:

• Repetitive work.
• Awkward postures.
• High hand force.
• Knives and scissors.
• Powered cutting equipment.
• Conveyors.
• Hazardous energy.
• Wet environments.
• Live birds.
• Poultry blood and biological materials.
• Cleaning chemicals.
• Ammonia.
• Carbon dioxide.
• Liquid nitrogen.
• Noise.
• Cold environments.
• Forklifts.
• Confined spaces.

Assessments should be reviewed when equipment, processes, chemicals, production methods, or workplace conditions change significantly.

Poultry Processing Safety Inspections

Periodic safety inspections can help identify unsafe conditions and verify that established procedures are being followed.

Inspections may include:

• Machine guards.
• Emergency stops.
• Conveyors.
• Cutting equipment.
• Knives and scissors.
• Lockout/Tagout equipment.
• Electrical equipment.
• Walking-working surfaces.
• Drainage.
• Chemical-storage areas.
• Refrigeration systems.
• PPE.
• Forklifts.
• Racking.
• Emergency exits.
• Fire-protection equipment.

Identified deficiencies should be documented and corrected in a timely manner.

Job Safety Analysis (JSA/JHA)

A Job Safety Analysis (JSA/JHA) may be useful for poultry-processing tasks where a step-by-step hazard analysis can improve employee protection.

Potential JSAs/JHAs may address:

• Live bird receiving.
• Live hanging.
• Cutting and deboning.
• Knife sharpening.
• Machine setup.
• Clearing jams.
• Equipment cleaning.
• Sanitation.
• Chemical handling.
• Ammonia-related work.
• Flash-freezing operations.
• Forklift operation.
• Maintenance and repair.

JSAs/JHAs should reflect the equipment and work practices actually used at the facility.

Poultry Processing Ergonomics

Ergonomic hazards are a major concern in poultry processing because many jobs require employees to repeat the same motions rapidly throughout the work shift.

Risk factors may include:

• Repetition.
• Awkward postures.
• Bent wrists.
• Extended reaching.
• High hand force.
• Forceful gripping.
• Heavy lifting.
• Contact stress.
• Vibration.
• Cold temperatures.
• Prolonged standing.

The employer should evaluate jobs and workstations to identify opportunities to reduce unnecessary physical stress.

Repetitive Motion

Cutting, trimming, deboning, hanging, eviscerating, packaging, and other poultry-processing jobs may require highly repetitive hand and arm movements.

Potential controls may include:

• Workstation redesign.
• Adjustable work surfaces.
• Improved tools.
• Powered tools.
• Task variation.
• Job rotation where effective.
• Appropriate work methods.
• Equipment automation.

Job rotation should involve tasks that use meaningfully different muscle groups or motions when it is used as an ergonomic control.

Hand and Wrist Stress

Employees performing repetitive knife, scissor, and trimming work may experience significant stress on the hands, wrists, and forearms.

The amount of force required can be affected by:

• Tool design.
• Handle size.
• Blade condition.
• Product temperature.
• Glove fit.
• Wrist position.
• Cutting technique.
• Workstation height.

Tools and workstations should be selected and maintained to reduce unnecessary force and awkward wrist positions.

Awkward Postures

Employees may bend, reach, twist, or work with elevated arms because of improper workstation height or product positioning.

Potential controls include:

• Adjustable platforms.
• Adjustable workstations.
• Bringing product closer to employees.
• Tilting work surfaces.
• Repositioning containers.
• Reducing unnecessary reaching.

Employees should be able to perform work in a reasonably neutral posture where feasible.

High Hand Force

Dull knives, poorly designed tools, cold product, inappropriate handles, and repetitive gripping can increase the amount of force employees must exert.

Employers should evaluate:

• Knife sharpness.
• Handle size.
• Tool weight.
• Trigger design.
• Glove selection.
• Product positioning.
• Powered-tool alternatives.

Tools should be maintained so employees do not have to compensate for poor condition by using excessive force.

Workstation Design

Workstations should accommodate the tasks being performed and, where feasible, differences in employee size.

Potential improvements include:

• Adjustable platforms.
• Height-adjustable work surfaces.
• Appropriate reach distances.
• Product diverters.
• Tilted work surfaces.
• Sit/stand supports where appropriate.
• Adequate leg and foot clearance.

Employees should be encouraged to report workstation conditions that create persistent discomfort.

Ergonomic Tools

Tools should be selected according to the task and employee needs.

Potential ergonomic features include:

• Properly sized handles.
• Angled handles.
• Cushioned grips.
• Spring-assisted scissors.
• Powered scissors.
• Powered knives.
• Reduced-vibration tools.

Damaged or poorly functioning tools should be repaired or removed from service.

Knife Safety

Knives are widely used in poultry processing and can cause serious cuts and lacerations.

Employees should:

• Use the correct knife for the task.
• Keep knives sharp.
• Inspect knives before use.
• Maintain control of the knife.
• Keep body parts out of the cutting path.
• Use required cut-resistant PPE.
• Store knives safely when not in use.
• Report damaged knives.

Employees should receive task-specific knife-safety training before performing production cutting work.

Knife Sharpening

Sharp knives generally require less force than dull knives and can reduce both ergonomic stress and uncontrolled cutting motions.

Knife-sharpening procedures should address:

• Authorized personnel.
• Appropriate sharpening equipment.
• Safe hand positioning.
• Required PPE.
• Knife inspection.
• Removal of damaged knives.

Employees should not use improvised sharpening methods.

Scissor Safety

Scissors used for trimming and processing should be appropriate for the task and maintained in good condition.

Ergonomic options may include:

• Spring-assisted scissors.
• Pneumatic scissors.
• Cushioned handles.
• Offset handles.
• Properly sized grips.

Damaged or dull scissors should be repaired or removed from service.

Cut-Resistant PPE

Employees exposed to knife or cutting hazards should use appropriate cut-resistant protection based on the task and hazard assessment.

Protection may include:

• Cut-resistant gloves.
• Mesh gloves.
• Arm guards.
• Aprons.
• Other protective equipment.

PPE should fit properly and be maintained in serviceable condition.

Cut-resistant PPE does not replace safe cutting techniques, machine guarding, or hazardous-energy controls.

Machine Guarding

Poultry-processing machinery should be appropriately guarded to protect employees from moving parts and other machine hazards.

Potential hazards include:

• Cutting blades.
• Sprockets.
• Chains.
• Belts.
• Pulleys.
• Shafts.
• Gears.
• Nip points.
• Rotating equipment.
• Reciprocating parts.

Employees should not remove, bypass, defeat, or reach around required machine guards.

Processing Equipment

Processing equipment should be operated according to manufacturer instructions and established procedures.

Only trained and authorized employees should operate specialized equipment.

Employees should report:

• Missing guards.
• Damaged interlocks.
• Unusual vibration.
• Abnormal noises.
• Malfunctioning controls.
• Damaged emergency stops.
• Other unsafe conditions.

Conveyors

Conveyors can expose employees to caught-in, pinch-point, entanglement, and struck-by hazards.

Employees should:

• Keep body parts away from moving components.
• Avoid climbing or riding on conveyors.
• Keep guards in place.
• Follow established procedures for jams.
• Use required Lockout/Tagout procedures during servicing.

Conveyor emergency controls should remain accessible.

Clearing Jams

Employees should not reach into operating machinery to clear jams unless the task is specifically addressed by an applicable safe procedure that provides effective employee protection.

When clearing a jam exposes an employee to hazardous energy, appropriate energy-control procedures should be followed.

Production pressure should never justify bypassing guards or hazardous-energy controls.

Lockout/Tagout

Poultry-processing machinery may contain electrical, mechanical, hydraulic, pneumatic, thermal, gravitational, and other hazardous energy.

An appropriate Lockout/Tagout Program should address servicing and maintenance activities where unexpected energization, startup, or release of stored energy could injure employees.

Procedures should address:

• Equipment-specific energy sources.
• Shutdown.
• Isolation.
• Lockout or tagout.
• Stored energy.
• Verification.
• Group Lockout/Tagout where applicable.
• Shift changes.
• Return to service.

Authorized employees should receive appropriate training.

Machine Cleaning and Lockout/Tagout

Cleaning operations can expose employees to hazardous machinery when guards, covers, blades, or other components must be removed.

When cleaning exposes employees to hazardous energy, appropriate energy-control procedures should be followed.

Employees should not rely solely on:

• Stop buttons.
• Emergency stops.
• Control switches.
• Software controls.

unless the specific task and applicable requirements permit another effective means of protection.

Sanitation Worker Safety

Sanitation employees may be exposed to hazards throughout the poultry plant.

Potential hazards include:

• Moving machinery.
• Sharp blades.
• Hazardous energy.
• Cleaning chemicals.
• Wet floors.
• Hot water.
• High-pressure spray.
• Electrical equipment.
• Biological materials.
• Ladders.
• Open drains.

Sanitation employees should receive training appropriate to the equipment and hazards they encounter.

Sanitation and Equipment Cleaning

Before cleaning machinery, employees should determine whether the task requires removal of guards, entry into danger zones, or exposure to hazardous energy.

Required Lockout/Tagout procedures should be completed before employees begin work.

Guards and safety devices removed for cleaning should be properly replaced before normal operation resumes.

Cleaning Chemicals

Sanitation employees may use detergents, disinfectants, sanitizers, acids, caustics, and other hazardous chemicals.

Employees should:

• Follow labels and Safety Data Sheets.
• Use required PPE.
• Follow dilution procedures.
• Avoid unauthorized chemical mixing.
• Maintain container labels.
• Use ventilation where required.
• Report spills and exposures.

Chemical Mixing and Dilution

Chemical concentrates should be mixed or diluted only according to established procedures and manufacturer instructions.

Employees should understand the hazards associated with incompatible chemicals.

Automated dilution systems should be used as designed and maintained in safe operating condition.

High-Pressure Cleaning — When Applicable

High-pressure cleaning systems may expose employees to injection injuries, flying debris, chemicals, wet electrical equipment, slips and falls, and unintended contact with other employees.

Only appropriately trained employees should operate high-pressure cleaning equipment.

Employees should never direct high-pressure streams toward themselves or others.

Hot Water and Steam

Hot water and steam used during sanitation can cause burns.

Employees should use appropriate PPE and work practices.

Hoses, fittings, valves, and other equipment should be maintained to prevent uncontrolled releases.

Wet Electrical Environments

Electrical equipment used in wet processing and sanitation areas should be appropriate for the environment and maintained in safe condition.

Employees should promptly report:

• Damaged cords.
• Exposed wiring.
• Broken covers.
• Damaged plugs.
• Sparking.
• Electrical equipment exposed to inappropriate water contact.

Only qualified personnel should perform electrical repairs.

Hazard Communication

Poultry-processing facilities using hazardous chemicals should maintain an appropriate Hazard Communication Program.

The program should address applicable:

• Chemical inventories.
• Safety Data Sheets.
• Container labeling.
• Employee information and training.
• Non-routine tasks.
• Contractor communication.

Employees should understand the hazards of chemicals used in their work areas.

Poultry Processing Chemical Safety

Poultry-processing operations may involve chemicals used for sanitation, refrigeration, processing, water treatment, freezing, and other purposes.

Potential chemicals may include:

• Ammonia.
• Chlorine.
• Peracetic acid.
• Hydrogen peroxide.
• Carbon dioxide.
• Cleaning chemicals.
• Sanitizers.
• Acids.
• Caustics.

Chemical controls should reflect the substances and concentrations actually present.

Ammonia Refrigeration — When Applicable

Facilities using anhydrous ammonia refrigeration should evaluate employee exposure, equipment hazards, emergency conditions, and applicable regulatory requirements.

Procedures may address:

• Restricted access.
• Leak detection.
• Equipment inspection.
• Emergency communication.
• Evacuation.
• Respiratory hazards.
• Contractor activities.
• Maintenance.

Only appropriately trained and authorized personnel should operate, maintain, or repair ammonia refrigeration equipment.

Ammonia Exposure

Ammonia can cause serious respiratory, eye, and skin injury.

Employees should know how to recognize and report:

• Ammonia odors.
• Alarms.
• Suspected leaks.
• Refrigeration-system damage.
• Other abnormal conditions.

Employees who are not trained and equipped for emergency response should evacuate or otherwise follow the facility’s emergency procedures rather than attempting to stop a significant ammonia release.

Ammonia Leak Response

Emergency procedures should clearly distinguish between actions expected of ordinary employees and actions assigned to trained emergency responders.

Procedures may address:

• Alarms.
• Evacuation.
• Emergency notification.
• Assembly areas.
• Accountability.
• Isolation of affected areas.
• Coordination with emergency responders.

Employees should not enter a dangerous ammonia atmosphere without the required training and protective equipment.

Process Safety Management — When Applicable

Some ammonia refrigeration systems may be subject to OSHA’s Process Safety Management requirements.

Where applicable, the facility should maintain required PSM elements appropriate to the covered process.

These may include:

• Process safety information.
• Process hazard analysis.
• Operating procedures.
• Employee training.
• Mechanical integrity.
• Management of change.
• Pre-startup safety review.
• Contractor safety.
• Emergency planning and response.
• Incident investigation.
• Compliance audits.

PSM should not be treated as automatically applicable solely because ammonia is present.

Mechanical Integrity — When Applicable

Covered refrigeration processes should maintain appropriate inspection, testing, and preventive-maintenance procedures.

Equipment may include:

• Pressure vessels.
• Piping.
• Valves.
• Relief systems.
• Emergency shutdown systems.
• Controls.
• Pumps and compressors.

Deficiencies should be corrected according to applicable requirements and safe operating practices.

Chlorine — When Applicable

Facilities using chlorine-containing chemicals or chlorine systems should evaluate employee exposure and applicable requirements.

Controls may include:

• Ventilation.
• Closed systems.
• Appropriate storage.
• PPE.
• Leak or spill procedures.
• Employee training.

Employees should never mix incompatible chemicals that could release chlorine or other hazardous gases.

Peracetic Acid — When Applicable

Peracetic acid may be used in poultry-processing sanitation or antimicrobial applications.

Employees should be protected from potential inhalation, skin, and eye exposures through appropriate engineering controls, work practices, PPE, and training.

Spills and releases should be handled according to established procedures.

Hydrogen Peroxide — When Applicable

Employees using concentrated hydrogen peroxide products should follow applicable label and Safety Data Sheet precautions.

Controls should address:

• Eye and skin contact.
• Inhalation exposure.
• Chemical storage.
• Incompatible materials.
• Spill response.
• PPE.

Carbon Dioxide — When Applicable

Carbon dioxide may be used for cooling, freezing, processing, or other operations.

A release can displace oxygen and create a dangerous atmosphere, particularly in enclosed or poorly ventilated areas.

Controls may include:

• Ventilation.
• Equipment maintenance.
• Gas detection.
• Alarms.
• Restricted access.
• Emergency procedures.

Employees should not enter a suspected oxygen-deficient atmosphere unless properly trained, equipped, and authorized.

Liquid Nitrogen — When Applicable

Liquid nitrogen may be used in cryogenic or flash-freezing operations.

Potential hazards include:

• Oxygen displacement.
• Extremely cold temperatures.
• Cryogenic burns.
• Pressure buildup.
• Equipment failure.
• Large gas releases.

Facilities should maintain appropriate engineering controls, ventilation, alarms, operating procedures, maintenance, PPE, and emergency procedures.

Flash Freezing — When Applicable

Flash-freezing operations using liquid nitrogen or carbon dioxide should be evaluated for the possibility of significant gas releases.

Controls may include:

• Adequate ventilation.
• Gas monitoring.
• Alarms.
• Equipment interlocks.
• Preventive maintenance.
• Emergency shutdown procedures.
• Employee evacuation procedures.

Employees should understand the hazards associated with oxygen-deficient atmospheres.

Oxygen-Deficient Atmospheres

Nitrogen, carbon dioxide, and other gases can displace oxygen without providing adequate warning.

Employees should not rely on odor or physical symptoms to identify an oxygen-deficient atmosphere.

Where oxygen-deficiency hazards are reasonably foreseeable, appropriate atmospheric monitoring, alarms, ventilation, access controls, and emergency procedures should be considered.

Biological Hazards

Poultry-processing employees may be exposed to biological hazards associated with live birds, poultry blood, feces, dust, tissues, aerosols, and contaminated surfaces.

Controls may include:

• Hand hygiene.
• PPE.
• Ventilation.
• Cleaning and sanitation.
• Exposure-response procedures.
• Employee training.

Biological-hazard procedures should reflect the tasks and exposures present at the facility.

Live Bird Receiving

Employees working in live-receiving areas may encounter:

• Live animals.
• Dust.
• Feathers.
• Fecal material.
• Scratches.
• Moving cages or modules.
• Vehicles.
• Material-handling equipment.
• Ergonomic hazards.

Work areas should be designed and maintained to reduce unnecessary employee exposure.

Live Bird Handling

Employees handling live birds should use work practices appropriate to the operation.

Potential controls may include:

• Appropriate handling techniques.
• PPE.
• Ventilation.
• Hand hygiene.
• Equipment design.
• Employee rotation where appropriate.
• Exposure-response procedures.

Employees should promptly report scratches and other occupational injuries.

Live Hanging

Live hanging may combine repetitive lifting, elevated reaching, rapid work pace, bird movement, scratches, and biological exposure.

Workstations should be evaluated for:

• Shackle height.
• Reach distance.
• Work pace.
• Bird weight.
• Platform height.
• Employee posture.
• Available recovery time.

Engineering controls should be considered where feasible.

Avian Influenza — When Applicable

Facilities should evaluate occupational exposure when avian influenza is known or suspected among birds being handled.

Controls should reflect current public-health and occupational-health recommendations and may include:

• Exposure assessment.
• PPE.
• Respiratory protection when required.
• Hand hygiene.
• Cleaning and disinfection.
• Employee training.
• Exposure reporting.

Procedures should be updated when disease conditions or official guidance changes.

Poultry Blood and Body Materials

Employees may be exposed to poultry blood, tissues, feces, and other biological materials during processing.

Appropriate PPE and hygiene practices should be used to reduce exposure.

Ordinary poultry blood should not automatically be treated as human blood covered by OSHA’s Bloodborne Pathogens Standard.

Facilities should separately evaluate whether any employees have occupational exposure to human blood or other materials covered by applicable Bloodborne Pathogens requirements.

Hand Hygiene

Employees should have appropriate facilities and opportunities for hand hygiene.

Employees should wash their hands at appropriate times, including after handling contaminated materials and before eating, drinking, smoking, or leaving applicable work areas.

Eating and drinking should be limited to designated areas.

Personal Protective Equipment

PPE should be selected according to the hazards employees encounter.

Depending on the task, PPE may include:

• Cut-resistant gloves.
• Mesh gloves.
• Chemical-resistant gloves.
• Arm protection.
• Aprons.
• Safety glasses.
• Goggles.
• Face shields.
• Protective footwear.
• Hearing protection.
• Respiratory protection.

PPE should fit properly and be maintained in serviceable condition.

Hand Protection

Different poultry-processing tasks may require different types of hand protection.

Examples include:

• Cut-resistant protection for knife work.
• Chemical-resistant gloves for sanitation.
• Thermal protection for hot or cold materials.
• General protective gloves for material handling.

Glove selection should account for the task, chemical compatibility, dexterity, grip, and machine hazards.

Gloves should not be used in a manner that creates an entanglement hazard around moving machinery.

Eye and Face Protection

Employees should use appropriate eye and face protection when exposed to:

• Chemical splashes.
• Poultry blood or biological materials.
• Flying particles.
• High-pressure cleaning.
• Other splash or impact hazards.

Protection should be selected according to the anticipated exposure.

Protective Footwear

Wet floors, cutting tools, material handling, and cold environments may create foot hazards.

Appropriate footwear may include slip-resistant, waterproof, safety-toe, or other protective footwear depending on the hazard assessment.

Slips, Trips and Falls

Poultry-processing floors may become wet or contaminated with:

• Water.
• Fat.
• Poultry material.
• Ice.
• Cleaning solutions.
• Packaging materials.

Potential controls include:

• Effective drainage.
• Prompt cleanup.
• Slip-resistant surfaces.
• Appropriate footwear.
• Good housekeeping.
• Maintaining clear walkways.

Floor Drainage

Drainage systems should be maintained to reduce standing water and slippery conditions.

Drain covers should remain properly positioned except when removal is necessary for cleaning or maintenance.

Removed drain covers can create serious trip hazards and should be replaced promptly.

Walking-Working Surfaces

Floors, platforms, stairs, walkways, and elevated work areas should be maintained in safe condition.

Employees should not climb on processing machinery or other unsuitable surfaces to reach elevated areas.

Appropriate ladders or platforms should be provided.

Ladders and Platforms

Ladders and work platforms should be appropriate for the task and maintained in safe condition.

Employees should not improvise access using:

• Processing equipment.
• Boxes.
• Containers.
• Racks.
• Other unstable surfaces.

Occupational Noise

Poultry-processing machinery, conveyors, refrigeration equipment, compressors, packaging systems, and other equipment may expose employees to significant noise.

Noise exposures should be evaluated where employees work in high-noise areas.

Engineering and administrative controls should be used where required and feasible.

Hearing Conservation — When Applicable

Where employee noise exposures trigger applicable requirements, the facility should maintain an appropriate Hearing Conservation Program.

The program may include:

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

Hearing protectors should be selected and used according to the employee’s exposure.

Cold Work Environments

Poultry processing frequently involves refrigerated product and cold work areas.

Cold conditions may affect:

• Hand dexterity.
• Grip strength.
• Comfort.
• Musculoskeletal stress.
• PPE selection.
• Slip hazards.

Employees should receive appropriate protection for the conditions in which they work.

Cold Stress — When Applicable

Employees working in sufficiently cold environments may require additional controls.

Potential measures include:

• Appropriate clothing.
• Warming opportunities.
• Work practices.
• Employee training.
• Monitoring for signs and symptoms.

Cold protection should not unnecessarily interfere with safe machine operation or required dexterity.

Electrical Safety

Electrical hazards may be increased in wet processing and sanitation environments.

Electrical systems and equipment should be maintained in safe condition and appropriate for the location.

Employees should report:

• Damaged cords.
• Exposed wiring.
• Broken enclosures.
• Damaged plugs.
• Sparking.
• Shocks.
• Other electrical defects.

Only qualified personnel should perform electrical work requiring specialized training.

Confined Spaces — When Applicable

Poultry-processing facilities may contain tanks, vessels, pits, refrigeration-system areas, or other spaces requiring evaluation for confined-space hazards.

The employer should identify and evaluate confined spaces and determine whether applicable permit-required confined-space procedures are necessary.

Employees should not enter designated permit spaces unless authorized and properly trained.

Forklift and Powered Industrial Truck Safety

Poultry-processing and warehousing operations may use forklifts, pallet jacks, and other powered industrial trucks.

Only trained and authorized employees should operate powered industrial trucks.

Procedures should address:

• Pre-use inspections.
• Pedestrians.
• Intersections.
• Loading docks.
• Trailer entry.
• Load stability.
• Speed.
• Visibility.
• Parking.

Pedestrians should remain alert around powered equipment.

Material Handling

Employees may manually handle boxes, containers, pallets, ingredients, packaging, and other materials.

Potential controls include:

• Mechanical assistance.
• Carts.
• Conveyors.
• Team lifting.
• Improved storage heights.
• Appropriate work practices.

Employees should obtain assistance for loads they cannot safely handle.

Warehouse and Cold Storage Safety

Warehouse and refrigerated-storage operations may involve:

• Forklifts.
• Racking.
• Pallets.
• Cold exposure.
• Slips.
• Falling materials.
• Loading docks.
• Trailer traffic.

Storage systems should be maintained in safe condition and aisles kept clear.

Loading Dock Safety

Loading docks may expose employees to falls, trailer movement, forklifts, pedestrians, and material-handling hazards.

Procedures may address:

• Trailer securing.
• Dock plates.
• Dock edges.
• Communication with drivers.
• Lighting.
• Pedestrian control.

Emergency Exits and Egress

Emergency exits and exit routes should remain visible, accessible, and unobstructed.

Production equipment, pallets, packaging, product, carts, and other materials should not block required exits.

Employees should understand their assigned evacuation routes.

Fire Prevention

Fire-prevention procedures should address the hazards present at the facility.

Potential considerations include:

• Electrical equipment.
• Packaging materials.
• Hot work.
• Refrigeration systems.
• Flammable materials.
• Maintenance activities.

Required fire-protection equipment should remain accessible.

Emergency Action Plan

Employees should understand procedures for foreseeable emergencies.

The Emergency Action Plan may address:

• Fire.
• Ammonia releases.
• Carbon dioxide or nitrogen releases.
• Chemical spills.
• Severe weather.
• Power failure.
• Refrigeration emergencies.
• Medical emergencies.
• Evacuation.
• Shelter-in-place.

Employees should understand alarm methods, exit routes, assembly areas, accountability procedures, and assigned responsibilities.

Chemical Spill and Release Response

Employees should understand how to report chemical spills and releases.

Procedures should distinguish between incidental spills employees are trained and equipped to handle and releases requiring emergency response.

Employees should not attempt to control a hazardous release beyond their training, equipment, or assigned responsibilities.

Employee Sanitation and Restroom Access

Poultry-processing facilities should provide required sanitation facilities and permit employees reasonable access to toilet facilities when needed.

Drinking water, washing facilities, eating areas, and other sanitation provisions should be maintained according to applicable requirements.

Employees should follow hygiene procedures established for both occupational safety and production sanitation.

First Aid and Employee Injuries

Employees should promptly report occupational injuries and illnesses.

Particular attention should be given to:

• Cuts.
• Lacerations.
• Amputations.
• Musculoskeletal symptoms.
• Chemical exposures.
• Eye injuries.
• Slips and falls.
• Respiratory symptoms.

Prompt reporting allows appropriate medical evaluation and helps the employer identify conditions requiring corrective action.

Injury and Illness Reporting

Employees should be encouraged to report injuries, symptoms, and workplace hazards promptly without discouragement or retaliation.

Early reporting of musculoskeletal symptoms can help identify ergonomic problems before conditions become more severe.

Supervisors should not discourage reporting because of production goals or injury statistics.

Contractor Safety

Poultry-processing facilities may use contractors for refrigeration, electrical work, sanitation, maintenance, construction, pest control, equipment installation, and other specialized services.

Contractor activities should be coordinated with facility operations.

Relevant hazard information should be exchanged when required.

Additional contractor requirements may apply to covered PSM processes.

Poultry Processing Safety Training

Safety training should reflect each employee’s assigned duties and workplace exposures.

Depending on operations, training may address:

• Ergonomic hazards.
• Knife and scissor safety.
• Machine guarding.
• Lockout/Tagout.
• Sanitation.
• Chemical safety.
• Ammonia.
• PPE.
• Biological hazards.
• Slips and falls.
• Noise.
• Forklifts.
• Emergency procedures.

Employees should receive task-specific training before independently performing higher-hazard work.

New Employee Safety Orientation

New employees should receive appropriate safety orientation before beginning independent work.

Orientation may address:

• General poultry-processing safety.
• Machine hazards.
• Knives and cutting tools.
• Ergonomic risk factors.
• Lockout/Tagout awareness.
• Chemical hazards.
• PPE.
• Slips and falls.
• Emergency procedures.
• Injury reporting.

Entry-level sanitation and production employees should receive sufficient instruction and supervision to recognize the hazards associated with unfamiliar equipment and processes.

Poultry Processing JSA/JHA

Poultry-processing facilities can use JSAs/JHAs to document safe work practices for selected higher-hazard tasks.

Potential Poultry Processing JSAs/JHAs include:

• Live bird handling.
• Live hanging.
• Cutting and deboning.
• Knife sharpening.
• Clearing equipment jams.
• Equipment cleaning.
• Sanitation.
• Chemical handling.
• Ammonia refrigeration maintenance.
• Flash-freezing operations.
• Forklift operation.

Poultry Processing Safety Meetings

Periodic safety meetings can reinforce safe work practices and address current workplace concerns.

Potential topics include:

• Ergonomics.
• Knife safety.
• Machine guarding.
• Lockout/Tagout.
• Sanitation hazards.
• Chemical safety.
• PPE.
• Slips and falls.
• Noise.
• Forklifts.
• Emergency response.

Recordkeeping

Poultry-processing facilities should maintain occupational safety and health records required for their operations.

Records may include:

• Employee training.
• Safety inspections.
• Injury and illness records.
• Ergonomic evaluations.
• Lockout/Tagout inspections.
• PPE assessments.
• Noise records.
• Respirator records.
• Forklift training.
• PSM records where applicable.
• Equipment inspections.
• Other required program records.

Additional Safety Programs

Depending on poultry-processing operations, additional safety programs may be necessary for:

• Ergonomics.
• Lockout/Tagout.
• Machine Guarding.
• Hazard Communication.
• Personal Protective Equipment.
• Respiratory Protection.
• Hearing Conservation.
• Process Safety Management.
• Ammonia Safety.
• Confined Space.
• Forklift Safety.
• Walking-Working Surfaces.
• Slips, Trips & Falls.
• Manual Lifting and Material Handling.
• Electrical Safety.
• Emergency Action Plan.
• Fire Prevention.
• Spill Prevention and Response.
• Cold Stress.
• Hazardous Waste Management.
• Contractor Safety.

These programs should be included when employee activities, equipment, chemicals, or workplace hazards make them applicable rather than automatically adding programs unrelated to the facility.

Building a Poultry Processing Safety Manual

A useful Poultry Processing Safety Manual should reflect the actual facility rather than simply adapting a generic manufacturing or food-processing manual.

A poultry slaughtering facility may require a different combination of programs than a deboning operation, further-processing plant, packaging facility, or cold-storage operation.

The manual should consider:

• Live bird operations.
• Processing methods.
• Production equipment.
• Cutting and deboning.
• Repetitive work.
• Sanitation.
• Hazardous energy.
• Refrigeration systems.
• Chemicals.
• Biological exposures.
• Noise.
• Cold environments.
• Warehousing.
• Material handling.
• Emergency conditions.

Selecting the appropriate programs creates a manual that is comprehensive without filling it with procedures unrelated to the operation.

Customized Poultry Processing Safety Manuals

A Poultry Processing Safety Manual can be developed around the facility’s production processes, machinery, cutting operations, ergonomic exposures, sanitation methods, refrigeration systems, chemicals, biological hazards, warehousing activities, and other workplace exposures.

The finished manual may incorporate applicable programs for Ergonomics, Lockout/Tagout, Machine Guarding, Hazard Communication, PPE, Respiratory Protection, Hearing Conservation, Process Safety Management, Ammonia Safety, Confined Space, Forklift Safety, Emergency Action Planning, and other hazards present within the operation.

This provides poultry-processing employers with a practical safety manual organized around the work their employees actually perform.