A Newark, OH, food additive manufacturer’s failure to handle hazardous materials and respond properly to an emergency led to an explosion that injured four workers, including two contractors who scaled an 8-foot security fence topped with triple-strand barbed wire to escape the fireball.
An investigation by the Occupational Safety and Health Administration (OSHA) found Arboris LLC violated process safety management procedures for the handling of hazardous materials and did not have emergency shut-down procedures for the evaporator and rotary drum filter at the plant when the fire occurred Dec. 21.
The plant produces sterols, a renewable, non-genetically modified resource used in food manufacturing to lower cholesterol in products.
“Four workers were lucky to be able to escape with minor injuries after a fireball engulfed their work area,” said Vanessa Martin, OSHA’s area director in Columbus. “When employers fail to properly document procedures and control highly hazardous chemicals, there is a potential for unintentional releases which can cause explosions and fires. Companies must carefully monitor their processes to ensure safety in manufacturing facilities.”
OSHA issued Arboris one willful, 35 serious and five other-than-serious safety violations on June 17 and has proposed penalties of $180,180. Two Arboris workers suffered smoke inhalation and first-degree burns.
An investigation by the agency’s Columbus area office found Arboris failed to:
• Designate sufficient egress routes
• Develop operational procedures to maintain the ongoing integrity of equipment
• Develop procedures to prevent inadvertent startup or release of stored energy
• Document inspections and maintenance
• Follow standard operating procedures
• Review operating procedures annually
• Develop procedures for starting up the system after a turnaround
• Ensure piping and instrumentation diagrams are accurate
• Provide clear instructions to employees during service and maintenance
• Provide personal protective equipment necessary in the event of a fire
• Install handrails on stairs
• Enclose or guard electrical equipment
Atlas Industrial Contractors LLC employed the two workers hurt scaling the fence. OSHA cited that company for one repeated, one serious and one other-than-serious safety violation for failing to store gas cylinders properly and to provide flame-resistant clothing and other personal protective equipment. Atlas employees were working in the facility to decommission and demolish old process equipment. OSHA has proposed fines of $41,000 to the Columbus-based company.
Arboris has manufacturing plants in Savannah, Georgia, and Newark, to produce sterols — a natural compound produced by pine trees — used commonly in foods such as spreads, bread, milk and yogurt.
Columbus-based Atlas also operates facilities in Troy, Ohio; Lincoln, Alabama; and Longmont, Colorado.