ASL Mantua ISPESL USL Modena

Project:

“Risk profiles in the meat industry:

identifying and measuring effects”

TABLE OF CONTENTS

Preamble ………………………………………………………………….Page 1

Description of project ……………………………………………………..Page 5

Flow-chart – cattle ..................................................... .............................Page 18

Flow-chart – pigs......................................................... ...........................Page 20

SECTOR DOCUMENT

Geographic, historical and social background ………………………………Page 22

Outsourcing ……………………………………………………………….Page 30

External risk ………………………………………………………………Page 32

Equipment, machinery and plants ………………………………………… Page 35

Surveyed damage …………………………………………………………Page 43

General risks:

- Biological risk ……………………………………………………………Page 72

- Physical ergonomics: risks and preventive measures ………………………Page 94

- Microclimate ……………………………………………………………..Page 129

- Noise and vibrations ……………………………………………………..Page 137

- Personal protective equipment………………………………………….…Page 140

PHASE DOCUMENT

Preamble …………………………………………………………………..Page 151

Cattle butchery cycle ………………………………………………………Page 152

Pig butchery cycle …………………………………………………………Page 199

Bibliography ……………………………………………………………….Page 232

Preamble

Within the framework of the research plan “Risk profiles in the productive sectors of crafts and small and medium enterprises”, the I.S.P.E.S.L. Safety Department identified a specific research project regarding risk profiles in the meat industry: identifying and measuring effects.

The area comprising the provinces of Mantua and Modena stands out for having one of the highest concentrations of zootechnic pork and beef production in the country, and consequently one of the biggest meat processing industries.

This research has thus been entrusted to the Local Health Authorities (ASL/USL) of Mantua and Modena because of the importance of the sector in the area, the experience gained by the Occupational Prevention and Safety and Veterinary Departments of the ASLs and the need to raise the level of knowledge about Occupational Health and Safety.

With a view to providing guidelines for the assessment and prevention of risks, a working group was set up, formed by Public Service operators, prevention workers, company physicians and veterinary surgeons.

These guidelines envisage a particularly effective way of operating, making the most of local resources and experiences and turning them into general guidelines.

Special thanks for the cooperation provided with this research go to the Occupational Prevention and Safety Departments, which provided the research’s basic structure, and to the Veterinary Department, whose contribution enabled a form of interdisciplinary activity which it is hoped might be copied by Prevention Departments at a national level.

National INAIL data for the previous ten-year period show up high gravity and frequency indexes for meat industry workers, especially among younger workers, with a higher frequency for hand injuries, cuts and abrasions, involving knives in particular.

The study conducted by the Modena ASL in 142 slaughterhouses in the Modena region confirmed this data, although in recent years there has been a gradual reduction in the global number of injuries. This may partly be explained by the adoption of preventive measures tied up with work procedures and personal protective equipment.

As far as occupational diseases are concerned, national INAIL data for the period 1991 to 1995 showed an average of 25 cases per year in the meat industry. These figures are presumably under-estimated.

In the meat processing industry there is a proven relationship between technical innovation, productivity hikes and both positive and negative ergonomic effects, with a drop in the manual handling of loads offset by a rise in repetitiveness and work rates.

Nevertheless, these risks and relative effects on workers’ osteo-articular apparatus are undoubtedly underestimated in Italy, while they are the most frequent industrial pathology in other European countries and the United States.

There have been numerous cases of carpal tunnel syndrome, epicondylitis and tenosynovitis of the upper limbs among meat cutters, as can be seen by international literature and by a survey conducted by the Modena ASL on workers in the cutting, deboning and trimming units of a pork establishment.

Biological risk in the meat industry includes the risk of zoonosis. A number of monographs report possible occupational infections that can be picked up by workers.

Meat processing plants form part of “activities for which there is contact with animals and/or products of animal origin” - Legislative Decree 626/94, attachment IX, a biological risk because of the possibility of slaughtered animals being ill/infected or carriers of “biological” agents. Risk evaluation must expressly include the risk of zoonosis for workers. But this has led to difficulties for many firms owing to the complexity and specificity of the topic and to the shortage of specific technical knowledge.

Over the year in which the research was conducted, the working group looked in particular at problems relative to the risk of injury, biological risk and ergonomic difficulties in beef and pork slaughterhouses.

We wish to thank Assica, Assomeat, the Nomisma Agroindustrial Observatory, the magazines Agricole, Edagricole, Obiettivi Documenti Veterinari, the Cooperative Abattoir of Pegognaga, the Troni Abattoir, Mr Stefano Scacchetti and all other firms and workers that have helped with the gathering of useful data.

Project Head

Dr Emanuela Mossini

The following have participated in the initiative:

ASL of Mantua

Occupational Prevention and Safety Department

Alberto Tieghi

Anna Baccaglini

Emanuela Mossini

Gabriele Moi

Luca Pincella

Luciana Gatti

Maggiorino Spezia

Michele Agostinello

Monica Beruffi

Roberto Trinco

Sandro Tieghi

Saverio Potente

Stefania Bosio

Veterinary Service

Massimo Ghinzelli

Paolo Rasori

Industrial Medicine Resident

Sabrina Marcheselli

Trainee

Erik Tiengo

ASL of Modena

Occupational Prevention and Safety Department

Anna Goldoni

Annamaria Vandelli

Arcangelo Migliore

Claudio Buzzega

Filippo Ricchi

Guido Besutti

Lorenza Gandolfi

Paolo Galli

Rinaldo Ghersi

Roberto Poletti

Tiziana Festa

Industrial Medicine Resident

Gianluca Corona

DESCRIPTION OF PROJECT

The research project “Risk profiles in the meat industry: identifying and measuring effects”, promoted by the ISPESL Safety Department, has been entrusted to the ASL (Local Health Authority) of Mantua (Prevention and Safety at Work and Veterinary Departments), in collaboration with the ASL of Modena (Prevention and Safety at Work Department).

The area of the Provinces of Mantua and Modena stands out for having one of the highest concentrations of zootechnic, pork and beef production in the country, and consequently one of the biggest meat processing industries, that has developed in the same area.

The area’s geographic location, at the end of the Brenner motorway and crossed by the “Sun” motorway, is favourable for trading with countries in central Europe and with central and southern Italy.

On 9/9/99, in Gonzaga (MN) during the “Millenaria” trade fair, a seminar was held to present and discuss the project to which all firms in the meat industry in the provinces of Mantua and Modena were invited. The seminar was attended by representatives of employers and employers’ Associations, trade union organisations, heads of single companies’ Prevention and Protection Services, workers’ safety representatives and competent physicians.

During the seminar there was an illustration of the aims of the project and a presentation of data and experiences on industrial accidents, biological risk and ergonomics hazards.

Project aims:

ü to define critical elements through an analysis of the meat industry production process and cutting of cattle and pig meat;

ü to identify the sources of accident, biological and physical ergonomic risk, analysing accident trends and the prevention model pursuant to Legislative Decree 626/94;

ü to formulate measures to keep risk under control having identified and defined risks;

ü to arrange gathered material in standardised datasheets to be submitted to ISPESL as guidelines for the safety and health of workers in the industry;

ü to raise the knowledge levels of employers and workers’ representatives on risk evaluation criteria and the adoption of preventive measures;

ü to encourage adequate health monitoring for workers in the sector;

ü at the same time to show up occupational pathologies actually present in the sector and estimate the dimension of the phenomenon.

The project is broken down into three sub-projects:

1. Occupational safety in the cattle and pig butchery and meat cutting industry

2. Ergonomic analysis of work and evaluation of related pathologies

3. Protection against biological risk

1. Occupational safety in the cattle and pig butchery and meat cutting industry

Aims:

§ gathering and critical analysis of existing literature;

§ selection of a sample of firms for the survey chosen from different realities;

§ identification of critical points of the production process and of the sources of risk, through:

- processing of INAIL provincial data

- gathering and processing of data on injuries for the past 5 years from all survey contexts

- examination of risk evaluation documents drafted in compliance with the provisions of art. 4 of Legislative Decree 626/94

- inspections in some of the plants selected to conduct specific studies and assess more complex problems;

§ selection of feasible structural solutions pertaining to plants and machinery, the handling of vehicles, equipment and personal protective equipment, as well as organisational and procedural solutions, in an integrated, “continuous improvement” corporate management system, combining production needs with the protection of consumers and workers;

§ local discussion of solutions and national guidelines proposals.

2. Ergonomic analysis of work and evaluation of related pathologies

Aims:

§ ergonomic analysis of work, referring to repetitive tasks in full throughput slaughterhouses for cattle and pigs and in small slaughterhouses. The analysis method, proposed by the EPM research group, comprises:

- the reconstruction of the work cycle with the cooperation of company technicians and study of repetitiveness, breaks, postures, movements and muscular exertion for the upper limbs, through observation of the cycle and study of slow-motion film sequences

- on the basis of these assessments, concrete examples for guidelines, for application in different production contexts;

§ epidemiology of disorders and pathologies of the upper limbs among workers performing repetitive tasks, entailing:

- the gathering and processing of data from accident registers and competent physicians

- the training of competent physicians on methods for the health monitoring of workers performing repetitive tasks, especially with a view to standardising data gathering

- the conducting of prevalence studies directly by the PSAL Service by means of medical screening in some areas;

§ prevention recommendations, entailing:

- some prevention recommendations in the ergonomic sphere for repetitive tasks and aspects tied up with posture and the manual handling of weights in light of literature, ongoing experiences and studied situations, having consulted producers’ associations and trade union organisations;

- meetings with prevention workers (RSPP, RLS, competent physicians) with reference to the evaluation of work and prevention recommendations.

3. Protection against biological risk

Aims:

§ to identify the zoonoses that may be present in animals on the basis of the local epidemiological situation and among livestock of origin;

§ to analyse the various phases of the production process and work areas;

§ to identify any contaminating materials present and risks connected with the work area in each phase;

§ to identify prevention solutions, general health regulations, procedures and PPE needed to eliminate residual risk.

The survey was conducted during the course of the year 2000 in the provinces of Mantua and Modena, and involved firms operating in the cattle and meat butchery and meat cutting sectors.

The census on enterprises was performed through lists supplied by the Veterinary Service of the Public Health Department of the AUSL.

In August 1999 in the Province of Mantua there were 43 local units dealing in the butchery of cattle and pigs. In the Province of Modena the figure was 35.

Workers employed in the 78 surveyed firms totalled 2,557, of whom 363 office workers and 2,194 factory workers. This total did not include the workers of third-party enterprises that perform jobs within the same firms.

Firms employ an average of 28 workers. The range is from 1 to 381 employees.

There is a clear-cut prevalence of male workers.

All the firms surveyed were sent a questionnaire, drafted by the PSAL Service, with a view to gathering information in a standard and uniform manner needed for the cognitive survey on risk profiles in the butchery and meat cutting phases and to providing subsequent prevention recommendations aimed at improving measures to protect the health and safety of workers.

The data gathering questionnaire (attached) is split up into 7 parts:

1. General information sheet containing details about the firm and the firm’s representatives pursuant to Legislative Decree 626/94;

2. Working activity, with a brief description of the activity, incoming product and end product, ISTAT codes;

3. Machinery, Plants, with the type of machinery and plants, at 31/12/99, CE health marking and age;

4. Workers and hours worked, broken down by unit/work phase. Breakdown by factory and office workers, men/women and total for 1999 alone.

5. Health monitoring, indicating the year monitoring commenced, occupational diseases reported by the firm from 1995 to 1999. A copy of the most recent report drafted by the competent physician was requested.

6. Personal Protective Equipment in use, broken down by protection type (hearing, eyes and face, respiratory tracts, upper limbs, lower limbs, whole body, clothing, etc.) and by unit and job type.

7. List of third-party firms for contracted work, indicating the work type outsourced, the workers usually present, broken down by unit and hours worked in 1999.

This data was processed to show the following situation:

area	no. cattle slaughterhouses	no. pig slaughterhouses	no. mixed C/P slaughterhouses	no. pig meat cutting	no. cattle	no. pigs	no. workers
Mantua	17	17	9	-	139,835	1,504,935	817	108
Modena	9	8	-	18	281,920	991,695	1377	255
Total	26	25	9	18	421,755	2,496,630	2,194	363
	Total enterprises 78							Total workers 2557

ANNEXES

GONZAGA “PROCEEDINGS” 9/9/99

“ANALYSIS OF ACCIDENT PHENOMENON: PRELIMINARY DATA”

Report: A. Migliore

The report gives some information about the Modena experience. It refers in particular to the publication “ACCIDENTS IN THE MEAT INDUSTRY”, Veterinary Service data and available INAIL data.

The publication “ACCIDENTS IN THE MEAT INDUSTRY” of the AUSL of Modena, 1990, updated in 1996, summarises the survey conducted. It illustrates the materials and methods used, the epidemiological situation, regulatory framework and prevention strategies drawn up on the basis of emerging elements.

The “map” of the “Meat” industry of the province of Modena has been obtained by processing Veterinary Service data in relation to the number of plants and tons of meat processed.

Available INAIL data are examined and some considerations on critical points are raised for discussion.

In 1995, in the 7 districts of the province, there were 335 plants processing 743,451 tons of meat. The number of plants was not directly proportional to the tons of meat worked, since in mountain regions in particular (Pavullo) and in the lower plains (Mirandola), production was characterised by numerous small-scale establishment.

The highest concentration of enterprises and meat production was observed in the district of Vignola: in 1995 there were 2,800–3,000 workers in 167 production units (14 slaughterhouses, 42 meat cutting plants, 102 processing units, 6 cold storage units, 3 minced meat units and 3 by-product processing units). Fig. 1 and 2. In 1998 there were 41 slaughterhouses in the province (fig.3). Full throughput-scale slaughterhouses for cattle numbered 2, full throughput slaughterhouses for pigs 4, with 1 slaughterhouse accorded a temporary derogation and 27 low throughput slaughterhouses (butchery up to a maximum of 20 UGB (equivalent bovine units) per week, which for pigs corresponds to 100 pigs, and for processing up to 5 tons of meat a week).

During 1998 281,920 cattle, 991,695 pigs, 3,419 sheep, 6,402 horses, 1,421,963 poultry, 823,917 rabbits and 76 ostriches were butchered.

The analysis of accidents, conducted in 1990, refers to a sample of 142 firms (out of 148 surveyed) and looks at data for the years 1985-86-87. The 1996 update was concerned with activities to verify and monitor accident indexes, conducted in 5 representative firms of the previous sample in 1988-89-90-91-92-93-94.

In 1987 a total of 2,688 workers were employed in 142 firms for a total of 4 million working hours (4,001,665). From information acquired using an ad hoc questionnaire, the distribution of workers was as follows: 192 workers in slaughterhouses, 476 workers in full throughput plants, 837 workers in meat processing firms, 722 workers in sausage meat/salami producing firms, 298 workers in cured ham producing firms, 85 in fresh ham producing firms and 78 in gut processing plants.

Accidents for the three-year period, recorded in companies’ accident registers, totalled 1,850. They were classified according to the INAIL classification (seat and nature of the injury, form and material agent that caused the accident) and analysed using the following indexes:

· INCIDENCE INDEX (I.I.): NUMBER ACCIDENTS/NUMBER EMPLOYEES x 100

· FREQUENCY INDEX (F.I.): NUMBER ACCIDENTS/NUMBER HOURS WORKED x 1,000,000, for each year considered.

· GRAVITY INDEX (G.I.): NUMBER DAYS ABSENCE PER INJURY/NUMBER HOURS WORKED for each year considered. To be noted is the fact that in the index the numerator does not take into consideration the sum of accident-related invalidity scores multiplied by 75 days, since the information is not usually given in the injuries register. As a result, the indexes calculated appear lower.

· MEAN DURATION (M.D.): NUMBER DAYS INJURY/NUMBER INJURIES.

Values proposed as acceptable by the Clinica del Lavoro of Milan are 0.5 for the gravity index and 20 for the frequency index.

YEAR	I.I	F.I.	G.I.	M.D.
1985	23.1	156	3.1	21.4
1986	24.4	165	3.1	18.5
1987	25.2	169	3.6	21.3
AVERAGE (85-86-87)	24.2	164	3.3	20.4

Values were high and tending to rise. The average for the three-year period shows, in terms of incidence, that one worker in four suffered an injury, and in terms of frequency 164 accidents occurred every million hours worked. Comparing indexes with those for the same period (1987) in the pottery and building industry, the figure of 25 injuries/year per 100 workers was twice that of the pottery industry and about one and a half times that of the building industry.

Accident frequency far outweighed that of the other two sectors.

The gravity index was in line with that of the building industry and almost twice that of the pottery industry.

The mean duration of days’ absence from work due to injury (21 days/injury) compares with 30 days for the building industry and 26 days for the pottery industry.

The most frequent injuries were wounds from cuts, constituting about half of all injuries, followed by bruises, lacerated and contused wounds, sprains, injuries due to exertion, fractures, infections, and other types.

With reference to the material agent, 47% of injuries were caused by knives, followed by solid materials, bones, wheeled handling machines, floors, machinery, receptacles and other causes.

In 1991 a standard report giving relative instructions was drafted and sent to all firms:

1. Machinery and plants

2. Electric installations

3. Floors

4. Platforms and floor bases

5. Stairways

6. Raised workstations and mobile work platforms

7. Lift trucks

8. Overhead handling devices

9. Routine and preventive maintenance

10. Personal protective equipment

11. Information

The SPSAL Services of the province of Modena also started up a number of initiatives in the information and training spheres aimed at workers, unit heads and employers, as well as monitoring and supervisory activities.

Four years into the plan of action, a test was conducted on 5 firms of the sample, with 606 workers and 1,120,038 hours worked.

Index trends are given in the table below.

YEAR	I.I	F.I.	G.I.	M.D.
1988	43	246	3.9	16
1989	39	227	4.3	19
1990	44	250	4.4	18
1991	42	256	4.0	16
1992	34	188	4.3	23
1993	27	153	2.7	18
1994	19	103	2.2	21
AVERAGE (88,89,90,91,92,93,94)	35	203	3.3	19

In the sample of firms surveyed, there was a reduction in the number of accidents, particularly over the last three years, while the gravity of events was more in line with past trends.

Before going on to examine INAIL data, we should stress that SPSAL and INAIL data are not comparable.

SPSAL DATA

INAIL DATA

· Source: accident registers · Prevention aims (analysis of causes of accident) · Numerator: number of workers at risk · Hours worked by workers at risk · Highest indexes (actual) · Gravity index: does not take into account the after-effects of permanent invalidity (not given in accident registers) · Exclusion of accidents occurring on way to and from work · Specific data (from registers) · Mean Duration (of days’ absence from work due to accident)

· Source: Insurance database · Insurance purposes · Numerator: number of insured parties (including office workers) · Hours worked by insured workers (including office workers) · Lower indexes (diluted) · Inclusion of accidents on way to and from work · Data in INAIL group not broken down by sector · Mean Duration (average number of days’ absence due to accident; accidents to and from work are included)

INAIL receives about a million reports of accidents each year. This figure was constant for the years from 1994 to 1998 (from a minimum of 1,029,269 in 1997 to a maximum of 1,094,939 in 1994). Accidents for which benefits were accorded totalled roughly 600-700,000 per year in the years 1994-97.

In Emilia Romagna around 120,000 accidents a year are reported in the Industry/Crafts sectors.

In the province of Modena 25-27,000 accidents a year were reported. Accidents in the 1994-97 period for the INAIL group (Agricultural-industrial-foodstuff sectors) totalled 908, out of 7,964 workers, representing 6.5% and 3.4% of workers respectively. The mean duration (MD) was 20 and the incidence index (I.I.) was 11.4.

For the butchery subgroup, representing 7% of the larger group, the number of accidents totalled 156, 17% of the total for the Agricultural, Industrial and foodstuff sector. The mean duration of days’ absence was 15, while the Incidence Index totalled 28.

Over the four-year period the Incidence Index for all sectors amounted to 6 for all four years. for the major group Agric., Industrial and foodstuff manufacturing the index was 13 in 1994, 11 in 1995, 12 in 1996 and 10 in 1997. These values were very similar to those for the Construction and Earthmoving group in the engineering, mining and pottery sectors, which have notoriously high indexes.

To conclude, some critical points should be mentioned:

· the persistence and relevance of the problem of accidents, in particular in the “meat” industry;

· the aim of the National and Regional (Emilia Romagna) Health Plan is to cut the number of occupational accidents by at least 10%;

· radical ongoing legislative and institutional changes and changes to context of work organisation;

· positive impact of Legislative Decree 626: improvement from self-assessment of risks and implementation of preventive measures by company prevention representatives as per Legislative Decree 626/94. Negative impact: formal and bureaucratic obligations (“626 Tax”) in some areas;

· need to meet differing needs: production, safeguarding of quality and hygiene of products, health and safety of workers and protection of the environment;

· frequent outsourcing of work, contracting out, hiring of structures and equipment to service companies;

· difficulty in coordinating workers from different firms for prevention and safety activities;

· difficulty in providing safety-related information and training to non-EU workers.

QUESTIONNAIRE

Date

Ref. no.

Messrs (firm) ____________________

and c.c. To Workers’ Safety Representatives

c/o Firm ______________

RE: Cognitive survey on risk profiles in butchery and meat cutting plants.

Request for information in accordance with art. 64 of Presidential Decree 303/56.

The Occupational Prevention and Safety Service of the ASL of the Province of Mantua is conducting a cognitive survey on meat processing establishments with a view to looking in greater depth at risk problems in the sector and to issuing recommendations, in a subsequent phase, on protective measures to be adopted to improve the health and safety of workers.

This survey is being conducted in collaboration with the ASL of Modena and is part of a project promoted by ISPESL, “Risk profiles in the meat industry: identifying and measuring effects”.

The aim in particular is to acquire greater knowledge on the production unit/work phase of the production cycle listed below: lairage, butchery, tripery and cutting.

To this end the request is made, in accordance with art. 64 of Presidential Decree 303/56, to send to the undersigned Service, within 30 days of reception of this questionnaire:

· the information indicated on the attached sheets;

· a copy of the accident register for the years 1995-96-97-98-99, duly filled in. In particular it must indicate the production unit/work phase in which the accident occurred, as indicated in table 4.1, using if deemed to be simpler the numbering given in the first column.

We remain at your disposal for any further information of explanations.

Yours sincerely

For further information contact:

SPSAL HEAD

1. DETAILS OF COMPANY

· company name __________________________________________

· addresses:

registered office ____________________________________________________________________

venue of local unit (production unit) ____________________________________________

________________________________________________________________________

· telephone ________________________________ fax _________________________________

· business activity (brief description of activity) _________________________________________

· ISTAT 91 codes (from chamber of commerce registration) ________________; ______________; _____________;

· for 1999 indicate surname and name of the following company officers:

Legal representative ___________________________________________________________

Head of Prevention and Protection Service ____________________________________

Competent Physician (if present) _____________________________________________________

Workers’ Safety Representative(s) ___________________________________________

2. WORKING ACTIVITY

The firm must list all the products that arrive at the production unit in the form of raw material and all products processed at the plant

INCOMING PRODUCT

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

END PRODUCT AFTER PROCESSING

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

3. MACHINERY AND PLANTS

The firm must list the type and number of all machines and installations present in the production unit, giving an approximate indication of their age and possession of CE certification at 31.12.99, as in the following example:

	conveyor belt	5	1	3	1	yes 1 no 4
	machine type	total No.	less than 5 years No.	between 5 and 10 years No.	over 10 years No.	CE certification No. No. yes no
1						yes no
2						yes no
3						yes no
4						yes no
5						yes no
6						yes no
7						yes no
8						yes no
9						yes no
10						yes no
11						yes no
12						yes no
13						yes no
14						yes no
15						yes no
16						yes no
17						yes no
18						yes no
19						yes no
20						yes no

4. WORKERS AND HOURS WORKED

4.1. The following table should be used to indicate the number of workers (including production partners) and hours worked, broken down by production unit and workers for the years 1995/99.

Production unit		1995		1996		1997		1998		1999
		No. workers	hours worked	No. workers	hours worked	No. workers	hours worked	No. workers	hours worked	No. workers	hours worked
1	Lairage
2	Butchery
3	Tripery
4	Cutting
5	Chilling
6	Porterage
7	Cleaning
8	Maintenance
9	Other Processing
10	Office workers
	Total

4.2 For the year 1999 the number of production workers, office workers and total workers must be broken down by gender.

	production workers	office workers	total
men
women
total

5. HEALTH MONITORING

5.1 if health monitoring is carried out by the Competent Physician, indicate since which year: ____.

5.2 send a copy of the latest health report drafted by the Competent Physician containing the anonymous and collective results of controls effects

5.3 list the occupational diseases reported in the firm for the period 1995/99

occupational disease

production unit

job

name and surname

report date

6. LIST OF PERSONAL PROTECTIVE EQUIPMENT (PPE) IN USE, BROKEN DOWN BY TYPE, MAKE AND MODEL

	type of protection	production unit and job	make	models
head
hearing
eyes and face
respiratory tracts
hands and arms
feet and legs
whole body
trunk
other

7. LIST OF EXTERNAL ENTERPRISES

Indicate those enterprises to which work is contracted out and that operate inside the firm, indicating the work and units for which they perform their activity, filling in the following table.

Name or Company name

Address and telephone no.

Work contracted out

hours worked (in 1999)

For each enterprise there must be an indication, using an additional sheet of paper if necessary, to be attached hereto, the average number of workers present in the firm, broken down by production unit.

Date of compilation ________________________

Stamp of the firm Signature of Legal Representative

FLOW-CHART

CATTLE

PHASES	OPERATIONS
LAIRAGE	1. reception of cattle 2. unloading 3. lairage and walk to stunning box ante-mortem examination
BUTCHERY	4. stunning 5. jugulation and bleeding 6. removal of hind hooves 7. dehiding and removal of milk gland 8. removal of front hooves and head 9. completion of dehiding 10. evisceration of abdomen 11. opening of breastbone 12. evisceration of chest 13. side splitting 14. finishing 14a – meat health marking
PROCESSING OF OFFAL (“TRIPERY”)	12a processing of thoracic offal 12b processing of abdominal offal
CUTTING	16. meat cutting
CHILLING	15. chilling 17. cold storage
PORTERAGE	19. handling and shipment of goods · miscellaneous
CLEANING	· cleaning and sanification of work environments · cleaning and sanification of mobile equipment
MAINTENANCE	· maintenance
OTHER PROCESSING	18. packing · other processing
“OFFICE WORKERS”	· administration · sales · veterinary inspection and supervision

STANDARD LAYOUT OF WORKING AREAS

AND FLOW OF GOODS IN FULL THROUGHPUT PLANTS

[flow chart p19]

External yard – reception of cattle

Quarantining

Lairage

Butchery room

Evisceration room

Head processing room

Hide processing room

Offal room

Tripery

Administrative offices and veterinary service

Analysis laboratory

Materials storeroom

Cleaning of equipment

Staff changing rooms

Cold storage units

Sorting room

Frozen storage units

Packing room

Shipping room

Shipping – outside yard

FLOW-CHART

PIGS

PHASES	OPERATIONS
LAIRAGE	1. reception of cattle 2. unloading 3. rest pens and washing ante mortem examination
SLAUGHTER	4. stunning 5. jugulation 6. bleeding 7. scalding 8. depilation 9. removal of claws 10. singeing 11. finishing 12. evisceration 13. side splitting 14. removal of heads 15. finishing 16. meat health marking
PROCESSING OF OFFAL (“TRIPERY”)	12a processing of thoracic offal 12b processing of abdominal offal
CUTTING/DEBONING	17. meat cutting
CHILLING	18. cold storage
PORTERAGE	19. handling and shipment of goods · miscellaneous
CLEANING	· cleaning and sanification of working environments · cleaning and sanification of mobile equipment
MAINTENANCE	· maintenance
OTHER PROCESSING	19. packing · other processing
“OFFICE WORKERS”	· administration · sales · veterinary inspection and supervision

STANDARD LAYOUT OF WORKING AREAS

AND FLOW OF GOODS IN FULL THROUGHPUT PLANTS

[flow chart p21]

External yard – reception of pigs

Quarantining

Lairage

Butchery room

Evisceration room

Scraps room

Tripery

Utility rooms

Administrative offices and veterinary service

Analysis laboratory

Materials storeroom

Cleaning of equipment

Staff changing rooms

Hot sorting room

Cold storage units

Cold sorting room (Hams)

Frozen storage units

Packing room

Shipping room

Shipping – outside yard

SECTOR DOCUMENT

GEOGRAPHIC, HISTORICAL AND SOCIAL BACKGROUND

Over the past two decades the number of red meat processing plants in Italy has fallen considerably due to a number of factors. Technological innovation in the sector starting in the 1980s led to a rationalisation of slaughterhouses, with a rise in production capacity and consequent fall in numbers. In the 1990s new national and Community laws in the sphere of health and hygiene and intra-Community trading of fresh meat (EEC Directives 91/497 and 91/498) introduced strict rules on enterprises, causing numerous small units and state-owned plants to exit the market.

In 1982 there were 1,900 municipal slaughterhouses in Italy. This figure fell to 706 in 1992 and to just 376 in 1999.

The table below shows the distribution of red meat slaughterhouses referring to 1999 by animal and degree of specialisation, data coming from ISTAT. In 1999 2,561 slaughterhouses were operating in Italy, 75% of which in northern regions.

In Lombardy alone there were 1,010 units, 39.4% of the national total. 85.3% of slaughterhouses were private. Slaughterhouses accorded EEC meat health marking totalled 402, representing only 15.7% of the total. This shows that despite technological change and legislative constraints, Italy’s slaughterhouses are still mainly low throughput plants well spread over the territory.

Another point to emphasise is that among private undertakings 16.8% of slaughterhouses comply with EEC standards, compared with 9.3% in the public sphere.

Considering those slaughterhouses that handle more than one type of animal, cattle are handled in 2,173 slaughterhouses, 84.8% of the total, and pigs in 1,440 units (56.2%).

Specialist slaughterhouses, butchering one animal only, totalled 952, 37.2% of the total.

In Italy there were therefore 1,609 non-specialist units that handled two or more animal types at the same time.

Number of slaughterhouses by type and region – 1999

	private slaughterhouses		state-owned slaughterhouses
REGION	EEC health Marking -	total	EEC health marking	total	general TOTAL
Piedmont Aosta	57	386	3	9	395
Lombardy	70	989	1	21	1010
Trentino-Alto Adige	3	88		5	93
Veneto	41	147	2	4	151
Emilia Romagna	36	132	3	25	157
Tuscany	19	47	3	23	70
Abruzzo	14	43	4	27	70
Campania	28	62	4	34	96
Sicily	8	10	3	61	71
Other	91	494	12	167	448
ITALY	367	2185	35	376	2561
North	210	1852	10	71	1923
Centre	60	102	11	85	187
South	97	231	14	220	451

Butchery of cattle

Italy’s beef industry stands in third place in Europe in terms of volume, with a 14.6% share of butchered cattle.

In the Community ranking Italy is preceded only by France (21.4%) and Germany (17.9%).

Butchery of cattle in Europe

	1998 %	EU 15
France	1,630	21.4
Germany	1,367	17.9
Italy	1,113	14.6
United Kingdom	705	9.2
Spain	630	8.3
Ireland	590	7.7
Netherlands	535	7.0
Other	1,054	13.8
EU15	7,624	100

Net production; thousands of tons.

The Italian industry stands out for the prevalent butchery of calves and bullocks.

Looking at leading EU producers the first thing to note is the different number of production units, with Italy having 16 times more slaughterhouses than the Netherlands and seven times more than Ireland.

Italy, moreover, has the lowest degree of EEC health marking in the Community in relation to the number of meat processing plants, indeed only 15% of slaughterhouses are in possession of Community certification. This fact can only be viewed as a weakness of the sector as a whole, since it acts against the competitiveness of the meat industry and may cause biased price policies. It also creates inefficiencies both upstream, affecting farming, and downstream, affecting the degree of consumer health protection.

Data given refer to the period prior to the production crisis deriving from the BSE outbreak.

It should be noted that since then the consumption of beef has fallen in nine member States, by 20% in France and 50% in Germany.

The beef sector is an important socio-economic reality for the entire country.

The meat industry is a technical-economic link for the economy, uniting cattle farming with commerce and consumption.

In occupational terms the approximately 320,000 workers are employed within the beef economy.

In terms of size of production, the sector underwent alternating fortunes in the 1970s and 80s, production peaking in 1992, with over 5 million animals butchered and over 1.2 million tons of meat produced. Since then numbers have fallen, resulting in 1999 in a general fall of 13% in animals butchered and a 9% drop in production volume.

This trend reflects the saturation that has now been reached by the consumer market, but it also reveals the indirect effects of a Common Agricultural Policy that penalises Italian cattle farming. The effects of this were also felt at an industrial level.

In absolute terms, in 1999 4.4 million animals were butchered, with a corresponding carcass weight of 1.11 million tons. Bullocks and ox-beef were the main type of animals butchered, constituting 43.9% of production units 55.7% of overall carcass weight.

These were followed by calves (24.9% of all butchered animals, obviously with a much lower volume), cows (15.4% of animals) and heifers (14.3% of animals).

Focusing on the industrial (or full throughput) structure, estimates for 1999 show the existence of 2,173 beef producing enterprises, in which roughly 10,200 workers are employed.

Although it is still based on a large number of production sites, the beef industry has rapidly declined in recent years in terms of numbers, going from almost 6,000 slaughterhouses in 1993 to 3,000 in 1996 and 2,173 in 1999. This sharp decline has combined with growing market competition and veterinary and health constraints imposed on activity.

Cattle slaughterhouses are more numerous and often more specialist than those dealing with other animals.

Number of cattle slaughterhouses, total and specialist, by region – 1999

	total		specialist
REGIONS	EEC health marking-	total	EEC health marking	total
Piedmont-Aosta	41	343	12	96
Lombardy	52	872	27	399
Trentino Alto Adige	2	86		8
Veneto	34	130	10	21
Emilia Romagna	22	122	8	43
Tuscany	11	48	2	4
Abruzzo	5	38
Campania	26	84	1	2
Sicily	11	70
Other	69	380	12	27
ITALY	273	2173	62	600
North	154	1666	57	589
Centre	36	128	4	8
South	83	379	1	3

There are both private and State-owned slaughterhouses. In just a few years the latter have fallen in number by over 2,000 units. There are currently about 450 such units nationwide, handling less than 20% of total butchered meat. It is likely that the number of these slaughterhouses will fall further in the future, since most of these units are operating through national derogations to Community directives.

The remaining national slaughterhouses, all private, are made up of very different enterprise types.

There is the segment of slaughterhouses operating on behalf of third parties. These are often of significant economic proportions and attain high levels of efficiency, with cases of absolute or prevalent subcontracting activities (from 80% to 100%) and other enterprises for which subcontracting takes up a relevant but not majority percentage of production.

Number of cattle slaughterhouses total by animal class and region –1999

REGIONS	less than 500	from 500 to 999	from 1,000 to 4,999	from 5,000 to 9,999	from 10,000 to 19,999	20,000+	total
Piedmont Aosta	249	34	45	5	6	4	343
Lombardy	781	42	23	5	14	7	872
Trentino-Alto Adige	78	5	3				86
Veneto	54	36	13	3	8	16	130
Emilia Romagna	87	13	12	1	1	8	122
Tuscany	25	8	11	1	3		48
Abruzzo	21	9	8				38
Campania	36	18	25	3	2		84
Sicily	26	27	13	3	1		70
Other	220	73	75	10	2		380
TOTAL	1577	265	228	31	37	35	2173

Number of specialist cattle slaughterhouses total by animal class and region –1999

REGIONS	less than 500	from 500 to 999	from 1,000 to 4,999	from 5,000 to 9,999	from 10,000 to 19,999	20,000+	Total
Piedmont Aosta	73	9	11	1	1	1	96
Lombardy	363	10	10	2	10	4	399
Trentino-Alto Adige	8						8
Veneto	9	1	1			10	21
Friuli-Venezia Giulia	7		1				8
Liguria	11	2	1				14
Emilia Romagna	32	3	2			6	43
Tuscany	1		3				4
Other	2	2	3				7
TOTAL	506	27	32	3	11	21	600

At the other end of the scale are the extremely numerous “micro-slaughterhouses”, which handle only tens or hundreds of animals a year. These firms will find it increasingly difficult to face up to market competition, especially in light of rigid health, sanitary and quality requirements.

As can be seen in the table below, the sector has a relevant but not dominant concentration of firms.

The top 10 cattle slaughterhouses, including the leading cooperatives in the sector, control almost 22% of the global market. The figure exceeds 12% for the three leading enterprises in our territory.

Number of slaughterhouses by enterprise type, number of workers and butchered animals – 1999 data

	Enterprises	Workers		Butchery
	no.	no.	%	.000 animals	%
Top 10	10	1900	18.6	950	21.6
Public	440	2,310	22.6	800	18.2
Other	1,723	5,990	58.7	2,650	60.2
Total	2,173	10,200	100	4,400	100

The great majority of Italian cattle slaughterhouses (around 84%), declared a butchery volume of fewer than 1,000 bovine animals a year. This exempted them from having to conform to Community legislation on hygiene-sanitary standards (EEC “health marking”, Directive 64/433/EEC).

By virtue of the technical-productive ties linking animal farming with the butchery sector, the geographic distribution of meat processing capacity by and large mirrors that of cattle farming.

72% of animals are butchered in just four Italian regions: Lombardy (21.7%), Veneto (19.7%), Emilia Romagna (18.1%) and Piedmont (12.5%). The situation is similar if expressed in terms of carcass weight, but quite different if one considers the number of processing plants.

Number of cattle slaughterhouses by region

chart p25

Veneto

Lombardy

Other

Piedmont

Emilia Romagna

Tuscany

Campania

Sicily

This data shows up major structural differences between the 4 regions dedicated to the butchery of bovine animals. In Veneto and Emilia Romagna the average size of slaughterhouses is higher (approximately 6,000 animals/year per slaughterhouse). Slaughterhouses in Piedmont, and in Lombardy in particular (approximately 1,200 animals/year per slaughterhouse), are smaller-scale and more numerous.

In the remaining areas of the country, full throughput structures are “dispersed”, with operating capacity below the national average.

Concluding the overview of the national beef industry, one must stress the importance of meat cutting plants, which complete sector ties with the consumer market.

The beef Observatory conducted a second survey on the national meat industry in the spring of 1999, using ad hoc structured questionnaires aimed at a sample of slaughterhouses. The sample is absolutely representative, since the output of selected enterprises constitutes around 1/3 of all national production.

Enterprises in the sample posted turnover in 1998 of Lire 3,330 billion and butchered 1,395,000 animals, producing 378,000 tons of meat (carcass weight).

In terms of employment, enterprises in the sample, including leading national cooperatives, employed 2,908 permanent or seasonal workers.

Pig butchery

In the European Union through December 1999 a total of 124.3 million pigs were butchered.

Community production of pig meat in the 15 member States of the European Union rose in 1999 to 18,026 million tons, 2.2% up on 1998.

Number of pigs in European Union (thousands of animals)

	December 1999	% EU
Germany	25,793	20.7
Spain	22,597	18.2
France	15,991	12.9
Netherlands	13,139	10.6
Denmark	11,914	9.6
Italy	8,403	6.7
Belgium	7,376	5.9
United Kingdom	7,037	5.7
Other	12,018	9.7
TOTAL EUR 15	124,268	100

As far as Italy is concerned, the economic state of pig farming in 1999 followed on from the slump of 1998, with butchered meat prices down 7% and feed costs up 4.6%.

Italy had a little over 8,403,000 pigs in 1999, 2.2% up on the previous year. Italian pork production rose significantly in 1999 to 1,120,000 tons (+4.6%, worth Lire 3,250 billion) because of the larger number of butchered animals and a higher carcass weight.

According to the list of Italian slaughterhouses and production units processing pig meat products, supplied by the Health, Foodstuffs, Nutrition and Veterinary Public Health Department of the Health Ministry, the national structure is formed by 3,679 production units (through February 2000), approved by the European Community for the production of meat-based products.

Plants butchering pigs in Italy numbered 1,440, with 63.6% (917 out of 1,440) located in northern regions.

Number of pig slaughterhouses, total and specialist, by region – 1999

	total		specialist
REGIONS	EEC health marking	total	EEC health marking	total
Piedmont Aosta	27	174	17	47
Lombardy	30	452	20	120
Trentino-Alto Adige	3	57	1	4
Veneto	22	89	9	20
Emilia Romagna	25	76	16	33
Tuscany	14	52	7	17
Abruzzo	14	53	9	20
Campania	27	82	3	6
Sicily	12	63	1	2
Other	83	342	23	34
ITALY	257	1,440	106	303
North	100	917	64	227
Centre	52	144	26	40
South	95	379	16	36

The Lombardy region housed 31.4% of Italy’s pig slaughterhouses; in Emilia Romagna 43.4% of production units specialise in pig meat production.

Number of pig slaughterhouses by region – 1999

chart p28

Sicily

Campania

Tuscany

Emilia R.

Piedmont

Veneto

Lombardy

Other Regions

Compared with the beef sector the size of pig abattoirs by class is distributed more among medium/small-sized units: 63.8% of plants butchered fewer than 500 animals a year, and 88.8% fewer than 5,000; there were 75 plants that butchered over 20,000 animals a year, 61.3% of which in northern regions. With regard to specialisation too the pork sector differs from the beef sector in terms of size distribution: 32.3% of pigs were butchered in plants handling up to 550 animals, 25.7% in units handling from 1,000 to 4,999 animals and 19.8% in units butchering 20,000+ animals. 70% of large-sized specialist abattoirs (20,000+) were concentrated in the north.

Number of pig slaughterhouses total by animal numbers and region – 1999

	animal class
REGIONS	fewer than 500	from 500 to 999	from 1000 to 4999	from 5000 to 9999	from 10000 to 19999	20000 and over	total
Piedmont Aosta	132	8	21	3	2	8	174
Lombardy	362	33	29	5	2	21	452
Trentino Alto Adige	45	6	4	1	1		57
Veneto	58	11	11	0	5	4	89
Emilia Romagna	31	6	17	7	4	11	76
Tuscany	14	2	25	7	2	2	52
Abruzzo	26	8	10	2	3	4	53
Campania	42	9	19	3	4	5	82
Sicily	39	8	10	5	1	0	63
Other	169	56	68	16	13	20	340
TOTAL	918	147	214	49	37	75	1440

Number of specialist pig slaughterhouses by animal numbers and region – 1999

animal numbers

	animal class
REGIONS	fewer than 500	from 500 to 999	from 1000 to 4999	from 5000 to 9999	from 10000 to 19999	20,000 and over	total
Piedmont Aosta	13	5	17	2	2	8	47
Lombardy	60	18	19	3	0	20	120
Trentino Alto Adige	1	0	1	1	1	0	4
Veneto	5	4	4		3	4	20
Friuli-Venezia Giulia	1		1		1		3
Emilia Romagna	7	1	10	2	4	9	33
Tuscany	4		6	4	1	2	17
Abruzzo	4	2	7	1	2	4	20
Other	3	5	13	3	3	12	42
TOTAL	98	35	78	16	16	60	303

Slaughterhouses with EEC-authorised meat cutting plants numbered 448.

48% of these units were in Emilia Romagna, Lombardy, Piedmont and Veneto.

Worthy of mention is the fact that the highest concentration of slaughterhouses was to be found in those Regions where animal farming was practised most intensely.

There were roughly one thousand low throughput slaughterhouses authorised by the respective Regions.

These data showed up the considerable fragmentation of structures in the butchery sector. The majority of these enterprises were indeed family-run.

1996 census data supplied by ISTAT bear witness to the predominant medium-small size of enterprises: the number of workers was between 2 and 9 at 53% of these firms.

Enterprises employing 50 or more workers made up just 5% of the total.

OUTSOURCING

The Beef Observatory conducted a survey in 1999 on a sample made up of 53 slaughterhouses. Enterprises included in the sample butchered a total of 1,395,000 animals in 1998, about 1/3 of all national production. In job terms they employed 2,908 workers. An interesting point is that 620 of these workers, 21% of the total, were “indirect” labour, i.e. workers operating in the enterprise but maintaining contractual relations with other enterprises (often workers’ cooperatives).

This fact is part of a more general trend regarding the outsourcing of some work phases (e.g. butchering, deboning, porterage, etc.), with a view to achieving flexible management and worker specialisation.

It should be stressed that the sample gave a representative geographic distribution of the national picture as a whole. Of the enterprises studied, 39 (74%) were located in the four main beef regions: Lombardy, Emilia Romagna, Veneto

and Piedmont, while the remaining 14 enterprises were from other regions, especially in the centre-south.

This type of organisation was present in enterprises representing the most advanced types of industrial model, based on higher quality standards and approved by the Community.

In smaller plants productivity was a lot lower than average levels, with 40% fewer animals butchered.

Data gathering by the ASLs of Mantua and Modena confirm the results of this study. Enterprise types are characterised by productivity in excess of 100,000 animals butchered/year. Work contracted out, regarding more or less all working phases, was represented by:

· cattle butchery:

- animal procurement

- butchery

- cutting and deboning

- tripery

- hides

- porterage

- cleaning

· pig butchery:

- animal procurement

- cutting

- offal

- porterage

- cleaning.

Animals are usually procured with the vehicles of external road haulage companies that have specific procurement contracts with the slaughterhouse or with the animal seller.

Transport workers are seldom employees of the slaughterhouse. This is the case only in small craft-based firms when the enterprise purchases limited amounts of animals to be butchered directly from local farmers.

Over the past two years however the procurement process has undergone a swift transformation, with the decline of “indirect” channels (go-betweens) and a more direct relationship with farmers.

The butchering of bovine animals concerns both the industrial-scale cycle and smaller-scale production. Animals are usually butchered by operators possessing specific professional competence and experience on the basis of the provisions of Legislative Decree 333/98.

Tripery and offal activities, together with porterage and cleaning, are the work phases most often contracted out to external firms because of the special nature of the work and personnel operating costs.

This type of work organisation has made it possible to optimise costs, but it has also led to difficulties regarding safety management, especially in small and medium enterprises where the employer/customer is not given adequate training on the firm’s prevention system and is thus unable to deal effectively with safety coordination as set forth in art. 7 of Legislative Decree 626/94.

Art. 7 of Legislative Decree 626/94 sets obligations for all employers involved (customer, contractor, self-employed worker, etc.) for the enactment of measures to prevent risks and provide protection, if works in the production unit are contracted out to contractors or self-employed workers.

· The employer is required to:

- check the qualifications of contractors

- supply information on specific risks and measures

- foster and enact intercompany cooperation and coordination.

· The employer of the contracting firm (contractor, subcontractor, self-employed workers, etc.) is required to:

- enact cooperation

- supply information

- enact coordination with the customer and other contractors.

We should point out that another negative aspect relating to these organisational choices is the existence of forms of labour organisation in which pay (amount received per job order) is directly proportional to work rates/speeds and amounts produced. It is believed that this system of pay may have a negative impact on the organisation of prevention and on safety levels, which in practice are subject to productivity, due to the fact that “company control” of work organisation is lowered, and also to pay methods.

A long-term outlook cannot fail to ignore the medium/long-term costs deriving from the lack of safety: costs for the contractor and possibly for the customer in terms of insurance premiums, legal costs, possible compensation; consequent increases in rates for the contractor; costs for society in general in terms of our health and social security system. Economic damage too, affecting workers, be they employees, partners or self-employed, owing to functional disability and a consequent drop in earning capacity or loss of job because of an injury or cumulative overload, rendering the worker unfit for duty.

EXTERNAL RISK

The establishment of a butchery brings with it a number of potential environmental risks capable of having an impact on the surrounding area. We should recall that it is one of the most insalubrious industries according to the Consolidation Act of Health Laws of 1934 (art. 216 of R.D. 1265/34). Borrowing the expressions of the legislator of that time, we might say that never more so than in this case should this type of establishment be “ISOLATED IN THE COUNTRY”, since even if correct risk containment systems are in place, its impact is considerable, for instance the smells that emanate from faeces storage areas or possible leaks of ammonia from the chilling plant.

Water

One should first raise the problem of managing wastewater, which can come from all units and all production phases. This chiefly consists of washwater, which may contain blood, grease, meat residues (organic compounds), as well as a moderate load of chemical compounds, relating to routine washing and sanification operations. The prevention system consists of the use of a water purifier, complete with biological removal activated sludge plant, ensuring discharge in surface waters in compliance with existing legislation.

One should stress the need for this plant to be constantly monitored to avoid operating imbalances. In this sense it should be remembered that the reliability of such a system usually rises according to the size of the served installation. This is because industrial-scale structures can better sustain relative operating costs, and their production cycle is usually a lot more uniform than that of small slaughterhouses.

The sludge originating from a full throughput slaughterhouse’s purifying plant must be disposed of, once a month on average, as special waste, by an authorised firm. Discharge in surface waters must of course be authorised. To run the plant a reference laboratory is needed (usually present in industrial-scale plants), as well as suitably trained personnel. The discharge must be analysed regularly and in representative conditions.

Incinerator

Butchery facilities usually have an incinerator serving quarantine butcheries. This need has grown since the latest outbreak of BSE, since all specified risk materials (SRM) of animals over the age of 30 months must be incinerated, i.e. intestinal lining, cranium, brain, eyes, spinal cord, tonsils, backbone.

The incinerator must usually have a combustion chamber operating at approximately 900°C and a post-combustion chamber in the smoke-stack, operating at 1,200° C. It must also have dust removal systems in the smoke-stack, normally using cross-current flow scrubbing. The resulting ashes are disposed of by an authorised firm after the waste has been classified. In this case too incinerator emissions are subject to prior authorisation granted by the competent authorities (Regions or Provinces).

Faeces and rumen

The faeces of animals, from pens and pathways, are stored in muck-heaps on impervious soil. Muck-heaps also receive materials from emptied stomachs and intestines. Everything is disposed of via muck spreading after it has matured according to an agronomic plan of use authorised in advance by the competent authority (Province).

Blood

Blood originates from the initial phase of the butchery process (jugulation and bleeding) and is collected in different troughs according to its destination and whether or not it comes from animals undergoing BSE testing. In the latter case it should be noted that all by-products of animals undergoing the test (including blood) can only leave the production unit after tests have proved negative.

The blood from bullocks is treated with anticoagulant and chilled to be used in the cosmetics and pharmaceutical industries. Blood from other animals (cows) is collected in a trough and disposed of without any special treatment, serving the fertiliser industry. Tanks for storing blood are endowed with filters on air outlets to avoid smells.

Noise

Noise that may impact on the outside is produced by the compressors of the chilling plant. The problem is best resolved by installing the cold store facility in an adequately soundproofed and isolated room and appropriate silencers on the vent pipes of compressors. Other sources of noise may be equipment and installations used in the butchery cycle, such as automatic circular splitting saws, or pneumatic equipment for handling hides, which “shoot” the material and generate high noise levels.

With regard to these risks, which usually have important effects on worker exposure to noise, it is believed that the best solution is to replace these systems with others (handheld band saw for splitting and mechanical transportation of hides) that can drastically reduce noise-related risk.

Ammonia leakage

Leaks of ammonia that may originate from the chilling plant must be pre-routed. In other words, safety valves must be in place so that in the event of malfunctioning or excess pressure, the gas must be able to escape. These leaks must be conveyed to ad hoc water knockout tanks. The chilling plant must of course be managed by adopting a good number of technical, organisational and procedural measures established by legislation and by specific risk evaluation, which includes the full-time on-site presence of personnel qualified to use toxic gases, as well as personnel specially trained to act in emergency situations.

Drain oil

Drain oils derive from the periodical substitution of machine lubricants and from the cleaning of refrigerating circuits. The amount of oil from ammonia compressors that is dragged into the gas stream is considerable. Drain cocks are therefore required, appropriately positioned and to be used on a regular basis. This simple and routine operation poses a significant risk for workers, since oil flows out of the cocks when opened, or ammonia exits when the oil is depleted. The cleaning operation should accordingly be carried out from a protected position. Drain cocks should be of the “instant close” (spring) type and have a relative upstream safety cock.

Depleted oils are disposed of using a skip authorised by the Consorzio Obbligatorio Olii Usati (Compulsory Depleted Oils Consortium).

Sundry waste

Other sundry waste is produced by the industrial unit. This includes packaging made from cardboard, plastic, polystyrene, ferrous residues, etc. which must be collected separately within units. Disposal procedures appear to be sufficiently well established.

EQUIPMENT, MACHINERY AND PLANTS

Existing technical legislation

In 1996 Presidential Decree 459 (the so-called “Machinery Directive”) came into force, establishing minimum safety requirements for the production and sale in EU member States of machinery and safety devices.

The “Machinery Directive” makes CE marking compulsory (manufacturer self-certification being allowed) for all machines, to ensure that the good in question has been manufactured after having carefully assessed and observed safety and good practice standards available at that time.

Application of the Machinery Directive has not produced sudden improvements to newly manufactured machines, rather it has set in motion a process by which manufacturers have a greater awareness and knowledge of safety aspects.

In the meantime the national framework of good practice norms (UNI standards) has evolved considerably, with the drawing up of harmonised standards increasingly applicable to specific machinery.

UNI standards are broken down into three main categories, type A, type B and type C standards.

Type A standards are general ones, containing general machine safety requirements. UNI EN standards 292 and 292-2 establish general safety requirements for all types of machines but do not make specifications about single machines.

Type B standards establish safety requirements applicable to special categories of devices. Standard UNI EN 294 for example refers to requirements for permanent guards, specifying manufacturing characteristics and safety distances for the correct installation of permanent guards; type B standards prevail over type A standards since they deal with specific aspects of questions that apply to a range of machines and provide more detailed indications.

Type C standards are specific standards that give detailed indications as to correct manufacturing techniques for a specific machine; UNI EN standard 1974 of 31/05/99 “Machinery for the food industry – Slicing machines – Safety and hygiene requirements” is currently the only available type C standard for machines in the butchery and meat processing sector.

To facilitate the job of persons required to verify the correctness of the safety devices of a machine or installation, a non-exhaustive list is given of UNI standards to be considered for more correct evaluations.

Standard	Publication	Title
UNI EN 292-1	November 92	Machine safety. Basic concepts, general design principles. Terminology, basic methodology.
UNI EN 292-2	November 92	Machine safety. Basic concepts, general design principles. Specifications and technical principles.
UNI EN 292-2 FA 1-95	December 1995	Machine safety. Basic concepts, general design principles. Specifications and technical principles.

Standard	Publication	Title
UNI EN 294	July 93	Machine safety. Safety distances to prevent upper limbs from entering dangerous zones.
UNI EN 349	June 1994	Machine safety. Minimum spaces to prevent body parts from being crushed.
UNI EN 414	January 93	Machine safety. Rules for drafting and drawing up safety standards.
UNI EN 418	June 1994	Machine safety. Emergency stop devices, functional aspects. Design principles.
UNI EN 457	January 93	Machine safety. Audio warning signals. General requirements, design and testing.
UNI EN 547/1	September 1998	Machine safety. Measurement of human body. Principles for determining size of opening required for whole body to enter the machine.
UNI EN 547/2	September 1998	Machine safety. Measurement of human body. Principles for determining size of openings.
UNI EN 547/3	September 1998	Machine safety. Measurement of human body. Anthropometric data.
UNI EN 563	June 1995	Machine safety. Temperatures of contact surfaces. Ergonomic data to establish threshold temperature values for hot surfaces.
UNI EN 574	December 1998	Machine safety. Two handed control devices. Functional aspects. Design principles.
UNI EN 614/1	March 1997	Machine safety. Ergonomic design principles. Terminology and general principles.
UNI EN 626/1	September 1996	Machine safety. Reducing health-related risks deriving from dangerous substances released by machines. Principles and specifications for machine manufacturers.
UNI EN 811	February 1998	Machine safety. Safety distances to keep lower limbs away from dangerous zones.
UNI EN 842	May 1997	Machine safety. Visual warning signals. General requirements, design and testing.

Standard	Publication	Title
UNI EN 894/1	November 1998	Machine safety. Ergonomic requirements for the design of information and control devices. General principles for interaction.
UNI EN 894/2	November 1998	Machine safety. Ergonomic requirements for the design of information and control devices. Information devices.
UNI EN 954-1	December 1998	Machine safety – Parts of safety-related control systems – general design principles.
UNI EN 981	March 1998	Machine safety – Warning signal systems and audio-visual information systems.
UNI EN 982	July 1997	Machine safety. Safety requirements for systems and their components for hydraulic and pneumatic transmission. Hydraulics.
UNI EN 1033	April 1997	Vibrations transmitted to hand-arm system. Laboratory measurement of hand-held machine vibrations. General aspects.
UNI EN 1037	April 1997	Machine safety. Prevention of unexpected start-up of machine.
UNI EN 1050	November 1998	Machine safety - Risk evaluation principles
UNI ENV 1070	December 1994	Machine safety. Terminology.
UNI EN 1088	November 1997	Machine safety. Guard-related interlock devices. Design and choice principles.
UNI EN 1093-3	June 1997	Machine safety. Evaluation of the release of dangerous substances into the air. Emission capacity of a specific machine.
UNI EN 1093-4	June 1997	Machine safety. Evaluation of the release of dangerous substances into the air. Plant collection capacity/performance.

Standard	Publication	Title
UNI EN 1299	October 1998	Mechanical vibrations and impacts – Insulation for machine vibrations –Information for the installation of source insulation.
UNI ISO 4413	May 89	Hydraulics. General rules for the application of installations in transmission and control systems.
UNI ISO 4414	September 92	Pneumatics. General rules for the application of installations in transmission and control systems.
UNI EN ISO 4871	October 1998	Acoustics – Declaration and testing of noise emission values of machines and equipment.

Specific standards for the safety of machinery used in the food industry

Standard	Publication	Title
UNI EN 1672-2	October 1998	Machines for the food industry – Basic concepts – Health requirements.
UNI EN ISO 7287	February 1997	Graphic signals for thermal cutting equipment.

Data were gathered in firms operating in the butchery and meat processing sector on the age of machines and plants and the presence of CE marking.

The data, concerning a total of 798 machines, provided a gloomy picture: the number of old machines over the age of ten years was significantly higher than those less than five years old that can guarantee a greater degree of safety.

Below are general data regarding the machines examined.

Characteristics of machines in the butchery sector

Total machines examined 798

Machines with declared age 791

Machines less than 5 years old 205

Machines aged between 5 and 10 years 315

Machines over 10 years old 271

Age of the sample of machines examined

chart p39

machines less than 5 years old

machines aged between 5 and 10 years old

machines over 10 years old

age not declared

With reference to the above graph showing the entire surveyed sample, it can be seen that there is a prevalence, in absolute terms, of machines and installations over the age of 10 years or between 5 and 10 years compared with more recent machines. Unfortunately investments in the sector have not been as intense as in other productive sectors.

Older machines were installed mainly in smaller enterprises where the speed of butchery was not of vital importance, and where older machines, despite being less competitive than modern machines, were able to perform the job asked of them.

For industrial-scale butchery activities the greater use of machines and installations and the need for greater productivity/competitiveness prompted a much higher turnover of machinery, due in part to the greater use and wear and tear. An industrial butchery chain cannot afford to interrupt work because of the breakdown of a machine caused by a lack of maintenance or the age of the machine.

Below are data regarding only CE marked machines out of all machines present in the butchery industry.

Total machines examined 798

Machines with declared marking 795

CE marked machines 272

Non-declared 3

Non-CE marked machines 523

CE marking of the sample of examined machines

chart p39

CE marked machines

Non-declared

Non-CE marked machines

In this case there is an even wider gap between machines manufactured and purchased prior to 21 September 1996 (date on which the Machinery Directive came into force) and machines prior to that date still operating. 66% of machines still used do not have CE marking, and are thus pre-Machinery Directive.

Breakdown by “homogeneous” machines

Data sent by the USL authorities of Modena proved difficult to process, since larger enterprises in particular did not follow the scheme given in the questionnaire. In many cases bulky attachments were sent in which machines and equipment were named and listed with code numbers and abbreviations that were difficult to understand. It has thus only been possible to make an estimate of the age of machines and of CE marking.

Below are percentage-based disaggregated data pertaining to significant machine classes for the butchery and meat processing sector in the Province of Mantua.

Hoisting and transportation equipment

Figures refer to the absolute number of machines in the survey.

Age of surveyed hoisting and transportation equipment

chart 2 p39

hoisting gear

conveyor belts

lift trucks and pallet trucks

machines less than 5 years old

machines aged between 5 and 10 years

machines over 10 years old

CE marked machine

In this case too it can be seen that the total number of machines aged between 5 and 10 years was higher than more recently manufactured machines and equipment.

Bone saw – splitting saw

The main meat processing machine is undoubtedly the band saw.

In the butchery industry there are usually two machine types: the splitting saw and bone saw.

In the former case the saw type is usually a “portable” band saw, used to split the carcass into two via a longitudinal cut down the spinal column. Machines of this type are generally endowed with a suspension aid to limit the physical exertion of the machine operator by eliminating the weight of the equipment. The machine usually has two handles for gripping the saw; the equipment should have two-handed controls, with a simultaneous operating device, thus making it impossible to switch on the machine using a single control button on a single handle.

Special care should be taken during machine cleaning and maintenance. At the end of the shift the machine needs to be opened and cleaned inside. The machine guard, which is usually movable, must be endowed with a position sensor, so that once the cover is removed the machine cannot be switched on accidentally.

As to the choice of sensor, refer to standard UNI EN 1088 “Machine safety. Guard-related interlock devices. Design and choice principles”, it is possible to use, in accordance with the provisions of the standard in question, position sensors controlled magnetically providing there is automatic control for every commutation cycle and overcurrent protection. The magnet must of course have an encrypted code to prevent easy tampering.

This interlocking system is undoubtedly less cumbersome, and easy to keep clean, while respecting specific norms for the sanification of machines.

The graph below shows the ages of bone saw and splitting saw machines.

Age of bone saw and splitting saw machines in survey

chart p41

splitting saw

bone saw

machines less than 5 years old

machines between 5 and 10 years old

machines over 10 years old

Guideways

Guideway installations are the most important of the butchery chain. All jobs involving the “disassembly” of the butchered animal are indeed performed interacting with the overhead guideway.

Guideways must be endowed with a system to prevent the butchered animal from falling, which could cause a serious injury were it to strike an operator.

It is therefore forbidden to move below the guideways. One should also verify that hooks are endowed with a device to prevent the guideway from becoming unhooked. This may for instance occur when there are sudden changes of direction or close to a rail crossroads.

The production unit must be endowed with procedures to verify the state of maintenance and preservation of the guideway and to act by protecting the areas where the risk of unhooking is greatest, such as bends and crossroads. It should be remembered that the guideway is subject to considerable stress, requiring at least careful and regular controls.

Below are data on the “length of service” of this equipment.

Age of surveyed guideways

chart 2 p41

less than 5 years old

between 5 and 10 years

over 10 years old

SURVEYED DAMAGE

INDUSTRIAL ACCIDENTS

The survey focused on enterprises in the Province of Modena. The same area was the subject of a previous study in the 1980s, and the phenomenon is still monitored over time.

The sample consisted of 35 enterprises, 9 of which butcher cattle, 8 butcher pigs and 18 perform the cold cutting of pigs. The sample initially surveyed did not include enterprises performing “other processing”, mixed type firms dealing chiefly in trading, individual enterprises and (to a small extent) some mixed type firms that have delayed replying to questionnaires or supplied incomplete responses.

In 1999 the number of workers in the 35 surveyed firms totalled 1,632, of whom 255 office workers and 1,377 production workers. This total did not include workers from other firms performing work inside the firms in the survey.

The sample of 35 enterprises was split up into 3 homogeneous sub-groups: Cattle butchery and meat cutting (9 enterprises), Pig butchery and meat cutting (8 enterprises) and Pig cold cutting (18 enterprises).

The number of injuries for the 5 years in all 3 “sectors” totalled 1,691, the number of days absence from work totalled 33,603.

Indexes

In the description of data gathered in the current study, the previous study referred to in the bibliography for the three-year period 1985-87 is used as reference and a means of comparison.

Incidence index (I.I.): number injuries/number workers by 100.

Indicates the percentage of workers exposed to risk that are injured in a given period (one year in our study).

The table shows values for the five-year period considered (1995-99).

The global mean incidence index (for the three-year period 1985-87) was 24, the mean incidence index (for the three-year period 1985-87) for complete cycle enterprises was 43, and the mean incidence index (for the three-year period 1985-87) for butchery enterprises was 27.

Values obtained in the current study were below values observed in the previous study with reference to both the complete cycle and slaughterhouses, while global index values were practically the same.

For the pig butchery and hot cutting sector the value, while coming down, was constantly higher than 24 (global incidence index for 1985-87 period) and lower than 43 (mean incidence index, 1985-87, for slaughterhouses).

For the cold cutting of pigs the value was constantly lower.

For the cattle butchery and cutting sector values were lower and variable.

Higher values were observed in 1996 for pig butchery and (hot and cold) cutting, while for cattle the index was higher in 1998.

INCIDENCE INDEX

Distribution by sector

SECTOR	1995	1996	1997	1998	1999	Average 1995/99
Cattle butchery and meat cutting	19	23	21	25	20	22
Pig butchery and meat cutting	33	38	30	26	26	31
Pig cold cutting	14	21	19	17	19	18
Global	23	27	23	23	22	24

INCIDENCE INDEX

Cattle butchery and meat cutting

chart p44

Global sector

Other processing

Maintenance

Cleaning

Cutting

Tripery

Butchery

1995 1996 1997 1998 1999 average 1995-99

Frequency index (F.I.): number of injuries/number hours worked per 1,000,000.

Indicates the ratio number of injuries and hours worked over a period of time (one year in our study).

The frequency index for the 1985-87 was 164, as mean global index, 181 as index in butchery enterprises, 249 in complete cycle enterprises. The tendency was one of growth, notwithstanding fluctuations, over the years.

The frequency index for the five-year period 1995-99, as global index, showed quite steady values (139…143), with the exception of 1996, which had a distinctly higher value of 171.

For the butchery and hot cutting of pigs values were constantly higher (also compared with complete cycle data, which in the period 1985-87 was 249). For the (cold) cutting of pigs the index ranged from a minimum of 86 to a peak of 125 in 1996.

For the butchery and cutting of cattle values were lower; the highest value was recorded in 1998.

FREQUENCY INDEX

Distribution by sector

SECTOR	1995	1996	1997	1998	1999	Average 1995/99
Cattle butchering and cutting	104	132	120	149	125	126
Pig butchering and cutting	234	269	226	194	198	224
Pig cold cutting	86	125	104	108	114	107
Global	139	171	143	148	143	149

GRAVITY INDEX

Cattle butchery and meat cutting

chart p45

Global sector

Other processing

Maintenance

Cleaning

Cutting

Tripery

Butchery

1995 1996 1997 1998 1999 average 1995-99

Gravity index (G.I.): number days absence from work due to injury/number hours worked by 1,000.

Indicates the ratio: number of days absence from work (temporary unfitness) owing to injury and number of hours worked in a given period (one year in our study). As for the previous study, the formula adopted does not include the indicative factor of permanent after-effects of injuries, taken as the sum of invalidity points resulting from injuries, multiplied by 75 days. These data were not recorded in accident registers.

In the previous study the global gravity index (average for three-year period 1985-87) was 3.3, the index of the complete cycle was 4.1, the index for slaughterhouses was 4.4.

In the current study the mean index for the five-year period is 2.9, a little less than previous values, varying from a peak of 3.4 in 1996 to a low of 2.5 in 1999.

For the butchery and hot cutting of pigs higher values were recorded, 4.16 as mean value for the 5 years and the highest value in 1997, with 3.9.

For the cold cutting of pigs the mean 5-year value was 2.1.

For the butchery and cutting of cattle the mean 5-year value was 2.3, with the highest value of 3.3 in 1996 and 3.7 in 1998.

GRAVITY INDEX

Distribution by sector

SECTOR	1995	1996	1997	1998	1999	Average 1995/99
Cattle butchery and cutting	2,3	3,3	2,3	3,7	2,2	2,8
Pig butchery and cutting	4,2	4,6	4,9	3,9	3,2	4,2
Cold cutting of pigs	2,0	2,4	1,8	2,1	2,2	2,1
Global	2,8	3,4	2,8	3,2	2,5	2,4

GRAVITY INDEX

chart p46

1995 1996 1997 1998 1999 Average 1995-99

Cattle butchery and cutting

Pig butchery and cutting

Cold cutting of Pigs

Global

Mean Duration (M.D.): number days absence owing to injury/number of injuries.

Indicates the mean duration, expressed as an arithmetic average, of the number of days absence owing to any injury occurring.

The Mean Duration for the study pertaining to the period 1985-87 was, as global index, 20.4, as index for the complete cycle 16.1, and as index for the butchery sector 24.9.

In the period 1995-99 the value of the Mean Duration was, as global mean value, 19.8.

For the butchery and hot cutting of pigs the highest value recorded was 22 in 1997, compared with 16 in 1999.

For the cold cutting of pigs the highest value was recorded in 1995 (23), compared with a low of 17 in 1997.

For the cattle butchery and cutting sector the highest value for the Mean Duration was 25 in 1996 and in 1998, the lowest value was 17 in 1999.

INDEXES for work phase/production unit.

The tables below show indices by work phase/production unit in the three sectors, compared with the respective global index for the sector and the global index for the entire sample.

MEAN DURATION

Distribution by sector

SECTOR	1995	1996	1997	1998	1999	Average 1995/99
Cattle butchery and cutting	22	25	19	25	17	17
Pig butchery and cutting	18	17	22	20	16	16
Cold cutting of pigs	23	19	17	19	19	19
Global	20	20	20	22	17	17

MEAN DURATION

chart p47

1995 1996 1997 1998 1999 Average 1995-99

Cattle butchery and cutting

Pig butchery and cutting

Cold Cutting of Pigs

Global

CATTLE BUTCHERY AND MEAT CUTTING

INCIDENCE INDEX: the mean global index for the 5-year period was 22. The classification was headed by the cutting sector, with 42, followed by the butchery sector, with 37; the tripery sector had an index of 36, maintenance 20. In the tripery sector values ranged from 59 in 1995 to 8 in 1999.

This fact appears to be due to the outsourcing of this production phase in recent years rather than to any “real” improvement.

INCIDENCE INDEX

Cattle butchery and meat cutting

PRODUCTION UNIT	1995	1996	1997	1998	1999	Average 1995/99
Lairage
Butchery	45	41	37	31	33	37
Tripery	59	48	32	34	8	36
Cutting	41	61	36	36	36	42
Porterage
Cleaning	0	0	0	38	0	8
Maintenance	15	13	20	33	19	20
Other processing	10	12	13	19	15	14
Global index Sector	19	23	21	25	20	22
Global index Total	23	27	23	23	22	24

INCIDENCE INDEX

Cattle butchery and meat cutting

chart p48

Global sector

Other processing

Maintenance

Cleaning

Cutting

Tripery

Butchery

1995 1996 1997 1998 1999 average 1995-99

FREQUENCY INDEX: the highest values were in the cutting sector with 253, the butchery sector with 211 and the tripery sector (191). Considerations expressed for incidence hold good for frequency too. In the tripery sector the 1995 figure of 307 fell to 49 in 1999. The maintenance sector showed a mean index of 104. The value was high throughout the 5-year period.

FREQUENCY INDEX

Cattle butchery and meat cutting

PRODUCTION UNIT	1995	1996	1997	1998	1999	Average 1995/99
Lairage
Butchery	253	232	205	175	188	211
Tripery	307	244	171	183	49	191
Cutting	230	336	233	225	241	253
Porterage
Cleaning	0	0	0	256	0	51
Maintenance	79	72	105	161	101	104
Other processing	52	70	74	112	90	80
Global index Sector	104	132	120	149	125	126
Global index Total	1399	171	143	148	143	149

FREQUENCY INDEX

Cattle butchery and meat cutting

chart p49

Global sector

Other processing

Maintenance

Cleaning

Cutting

Tripery

Butchery

1995 1996 1997 1998 1999 average 1995-99

GRAVITY INDEX: the global mean value for the five-year period was 2.9. The tripery sector

ranked first with a value of 5.5, followed by the butchery sector (4.6) and the cutting sector (4.5). The maintenance sector came in last with 1.3. For the tripery sector the 1999 figure was very high (7.2), probably due to the occurrence of serious accidents.

GRAVITY INDEX

Cattle butchery and meat cutting

PRODUCTION UNIT	1995	1996	1997	1998	1999	Average 1995/99
Lairage
Butchery	5.0	5.6	5.0	3.8	3.4	4.6
Tripery	8.9	4.2	4.0	3.1	7.2	5.5
Cutting	3.8	8.7	2.9	3.4	3.9	4.5
Porterage
Cleaning	0.0	0.0	0.0	13.7	0.0	2.7
Maintenance	2.5	1.1	0.8	1.2	0.8	1.3
Other processing	1.2	2.0	1.5	4.0	1.2	2.0
Global index Sector	2.3	3.3	2.3	3.7	2.2	2.7
Global index Total	2.8	3.4	2.8	3.2	2.5	2.9

GRAVITY INDEX

Butchery and cutting of cattle

chart p50

Global sector

Other processing

Maintenance

Cleaning

Cutting

Tripery

Butchery

1995 1996 1997 1998 1999 average 1995-99

MEAN DURATION: the mean value was 20. The tripery sector ranked first with a value of 47, followed by the butchery sector (22) and the cutting sector (17). The maintenance sector had a mean value of 14, with 32 in 1995 and 8 in 1999.

MEAN DURATION

Cattle butchery and meat cutting

PRODUCTION UNIT	1995	1996	1997	1998	1999	Average 1995/99
Lairage	0	0	0	0	0	0
Butchery	20	24	24	22	18	22
Tripery	29	17	23	17	148	47
Cutting	17	26	12	15	16	17
Porterage	0	0	0	0	0	0
Cleaning	0	0	0	53	0	11
Maintenance	32	15	8	8	8	14
Other processing	22	28	21	36	13	24
Global index Sector	22	25	19	25	17	22
Global index Total	20	20	20	22	17	20

MEAN DURATION

Butchery and cutting of cattle

chart p51

Global sector

Other processing

Maintenance

Cleaning

Cutting

Tripery

Butchery

1995 1996 1997 1998 1999 average 1995-99

BUTCHERY AND HOT CUTTING OF PIGS

INCIDENCE INDEX: the 1995-99 average for the sector butchery and hot cutting of pigs saw the phase “other processing” top the ranking with 47, followed by “cutting” (33) and then “butchery” (30). For the “maintenance” phase the mean index for the 5-year period was 21.

INCIDENCE INDEX

Pig butchery and meat cutting

PRODUCTION UNIT – 1995	1996	1997	1998	1999	Average 1995/99
Lairage	0	14	22	56	30	24
Butchery	34	40	32	29	17	30
Tripery	27	0	11	0	0	8
Cutting	40	41	30	27	28	33
Porterage	12	4	11	3	24	11
Cleaning	0	20	10	20	0	10
Maintenance	8	26	15	25	32	21
Other processing	29	55	65	32	52	47
Global index Sector	33	38	30	26	26	31
Global index Total	23	27	23	23	22	24

INCIDENCE INDEX

Butchery and Cutting of pigs

chart p52

Global sector

Other processing

Maintenance

Cleaning

Porterage

Cutting

Tripery

Butchery

Lairage

1995 1996 1997 1998 1999 average 1995-99

FREQUENCY INDEX: in terms of frequency the phase “other processing” came out on top with 279, followed by the “butchery” sector (261) and then the cutting sector (242). For the maintenance sector there was a mean value of 143.

FREQUENCY INDEX

Pig butchery and meat cutting

PRODUCTION UNIT	1995	1996	1997	1998	1999	Average 1995/99
Lairage	0	107	179	472 – 246	201
Butchery	272	320	319 – 243	149	261
Tripery	171	0	71	0	0	48
Cutting	281	291	225	203	209	242
Porterage	72	25	69	21	162	70
Cleaning	0	188	86	174	0	90
Maintenance	53	170	98	172	223	143
Other processing	181	344	360	198	314	279
Global index Sector	234	269	226	194	198	224
Global index Total	139	171	146	148	143	149

FREQUENCY INDEX

Pig butchery and meat cutting

chart p53

Global sector

Other processing

Maintenance

Cleaning

Porterage

Cutting

Tripery

Butchery

Lairage

1995 1996 1997 1998 1999 average 1995-99

GRAVITY INDEX: in terms of gravity was the butchery sector with 5.0, followed by other processing (4.9) and the cutting sector (4.4). For the maintenance phase the mean value was 2.5. Figures for the cleaning, tripery and lairage phases fluctuated from year to year, probably because work is mostly contracted out to the workers of external enterprises.

GRAVITY INDEX

Pig butchery and meat cutting

PRODUCTION UNIT	1995	1996	1997	1998	1999	Average 1995/99
Lairage	0.0	1.7	4.0	11.9	2.6	4.0
Butchery	5.1	5.1	6.7	5.5	2.4	5.0
Tripery	1.8	0.0	0.5	0.0	0.0	0.5
Cutting	5.0	5.2	4.4	3.8	3 .6	4.4
Porterage	0.7	0.3	4.6	0.7	2.0	1.7
Cleaning	0.0	5.6	3.1	2.4	0.0	2.2
Maintenance	1.3	1.6	4.1	3.5	2.2	2.5
Other processing	3.0	5.8	7.2	3.7	5.0	4.9
Global index Sector	4.2	4.6	4.9	3.9	3.2	4.2
Global index Total	2.8	3.4	2.8	3.2	2.5	2.9

GRAVITY INDEX

Pig butchery and meat cutting

chart p54

Global sector

Other processing

Maintenance

Cleaning

Porterage

Cutting

Tripery

Butchery

Lairage

1995 1996 1997 1998 1999 average 1995-99

MEAN DURATION: the global index for the sector was 20. For single phases porterage posted the highest number with 27, followed by maintenance (21), butchery (19) and cutting (18).

MEAN DURATION

Pig butchery and meat cutting

PRODUCTION UNIT	1995	1996	1997	1998	1999	Average 1995/99
Lairage	0	16	23	25	11	15
Butchery	19	16	21	23	16	19
Tripery	11	0	7	0	0	4
Cutting	18	18	20	19	17	18
Porterage	10	10	66	35	12	27
Cleaning	0	30	36	14	0	16
Maintenance	24	9	42	20	10	21
Other processing	17	17	20	19	16	18
Global index Sector	18	17	22	20	16	19
Global index Total	20	20	20	22	17	20

MEAN DURATION

Pig butchery and meat cutting

chart p55

Global sector

Other processing

Maintenance

Cleaning

Porterage

Cutting

Tripery

Butchery

Lairage

1995 1996 1997 1998 1999 average 1995-99

COLD CUTTING OF PIGS

INCIDENCE INDEX: the global mean index was 18. This value was close to that for the phases “other processing” (20) and “cutting” (19).

INCIDENCE INDEX

“Cold” cutting of pigs

PRODUCTION UNIT	1995 – 1996	1997	1998	1999	Average 1995/99
Cutting	17	22	19	15	22	19
Porterage	13	0	0	0	0	3
Cleaning	0	0	7	0	0	1
Maintenance	0	9	9	8	0	5
Other processing	14	22	23	22	18	20
Global index Sector	14	21	19	17	19	18
Global index Total	23	27	23	23	22	24

INCIDENCE INDEX

“Cold” cutting of pigs

chart p56

Global - sector

Other processing

Maintenance

Cleaning

Porterage

Cutting

1995 1996 1997 1998 1999 average 1995-99

FREQUENCY INDEX: the mean global index for the 5 years was 107, for the cutting phase 116, for other processing 105. Porterage peaked at 116 in 1995, compared with a mean value of 23, due to the fact that in the subsequent 4 years the number of hours worked were few, and no accidents occurred. The same was true for the cleaning phase.

FREQUENCY INDEX

“Cold” cutting of pigs

PRODUCTION UNIT	1995 – 1996	1997	1998	1999	Average 1995/99
Cutting	96	134	122	93	136	116
Porterage	116	0	0	0	0	23
Cleaning	0	0	126	0	0	25
Maintenance	0	72	71	63	0	41
Other processing	80	123	90	135	97	105
Global index Sector	86	125	104	108	114	107
Global index Total	139	171	146	148	143	149

FREQUENCY INDEX

“Cold” cutting of pigs

chart p57

Global sector

Other processing

Maintenance

Cleaning

Porterage

Cutting

1995 1996 1997 1998 1999 average 1995-99

GRAVITY INDEX: the mean index value for the 5-year period was 21. Top ranked was porterage with 2.9 (14.3 in 1995), followed by maintenance with 2.6 (10.7 in 1998) and then cutting with a value of 2.3.

GRAVITY INDEX

“Cold” cutting of pigs

PRODUCTION UNIT	1995	1996	1997	1998	1999	Average 1995/99
Cutting	2.3	2.7	1.8	1.6	2.9	2.3
Porterage	14.3	0.0	0.0	0.0	0.0	2.9
Cleaning	0.0	0.0	0.6	0.0	0.0	0.1
Maintenance	0.0	2.0	0.5	10.7	0.0	2.6
Other processing	1.4	2.2	2.0	2.3	1.6	1.9
Global index Sector	2.0	2.4	1.8	2.1	2.2	2.1
Global index Total	2.8	3.4	2.8	3.2	2.5	2.9

GRAVITY INDEX

“Cold” cutting of pigs

chart p58

Global sector

Other processing

Maintenance

Cleaning

Porterage

Cutting

1995 1996 1997 1998 1999 average 1995-99

MEAN DURATION: the global index was 19 days absence from work on average. The ranking was headed by the maintenance phase with 41 days, followed by porterage (25) and cutting (19).

Indices are high despite the fact that values close to zero were observed in some cases. This may mean, observing both the Gravity Index and Mean Duration, that accidents are not very frequent, but when they happen are serious.

MEAN DURATION

“Cold” cutting of pigs

PRODUCTION UNIT	1995	1996	1997	1998	1999	Average 1995/99
Cutting	24	20	14	18	21	19
Porterage	123	0	0	0	0	25
Cleaning	0	0	5	0	0	1
Maintenance	0	28	7	170	0	41
Other processing	18	18	22	17	17	18
Global index Sector	23	19	17	19	19	19
Global index Total	20	20	20	22	17	20

MEAN DURATION

“Cold” cutting of pigs

chart p59

Global sector

Other processing

Maintenance

Cleaning

Porterage

Cutting

1995 1996 1997 1998 1999 average 1995-99

Nature of injury

The table and graph show that wounds continued to be the most common injury (315 injuries in the pig butchery and cutting phase, 237 in the cattle butchery and cutting phase and 207 in the pig cold cutting phase). They were followed by bruises, injuries caused by over-exertion, fractures, lacerated and contused wounds, infectious agents, foreign matter, injuries caused by other agents and burns. Anatomical loss was involved in two injuries, 1 in the butchery phase and 1 in the pig cutting phase.

Nature of injury

NATURE of Injury	Cattle- BC (butchery and cutting) no. inj.	Pig BC no.inj	Pig C (Cutting) no.inj.	Total- no. inj.	% inj.	% cases with abs.> 30 days	Days abs	MD
Wounds	237	315	207	759	44,9	10.0	12026	16
Bruises	187	182	84	453	26,8	17.0	8528	19
Injuries caused by Exertion	74	71	43	188	11,1	20.7	4508	24
Dislocation Distortion Sprain	4	78	17	99	5,9	30.3	2658	27
Fractures	19	21	9	49	2,9	69.4	3056	62
Lacerated and Contused Wounds	5	29	15	49	2,9	10.2	727	15
Agents Infectious	7	27	14	48	2,8	20.8	1304	27
Foreign matter	10	3	4	17	1,0	0.0	128	8
Injuries caused by Other Agents	4	4	2	10	0,6	30.0	201	20
Burns	5	2	2	9	0,5	0.0	138	15
Anatomical loss	1	1	0	2	0,1	50.0	99	50
Electrocution	0	1	0	1	0,1	0.0	14	14
Not defined	2	4	1	7	0,4	42.9	216	31
Total	555	738	398	1691	100,0	33603

Global % of injuries giving rise to absence from work above 30 days: 16.4

Global MD = 20

Distribution of injuries by Seat of Injury

chart p60

Wounds

Injuries caused by exertion

Fractures

Infectious agents

Injuries caused by Other Agents

Anatomical loss

% Injuries

Form and agent

The table and graph shows the distribution of injuries by material agent for the three sectors under review.

Material Agent

MATERIAL AGENT	Cattle BC no. inj.	Pigs BC no. inj.	Pigs C no. inj.	Total no. inj.	%	Days abs.	MD.
Knife	215	238	194	647	38	10,518	16
Solid Materials	97	99	42	238	14	4,218	18
Collectors/Trolleys	38	114	28	180	11	2,958	16
Flooring	50	66	19	135	8	3,976	29
Repetitive Movements/Exertion	15	61	32	108	6	2,606	24
Machinery	31	53	23	107	6	2,246	21
Animals	25	21	0	46	3	923	20
Infectious Agents	7	26	13	46	3	1,275	28
Overhead transport	20	2	3	25	1	424	17
Truck	6	6	13	25	1	803	32
Stairways and Walkways	9	10	4	23	1	1,003	44
Maintenance Tools	7	12	4	23	1	303	13
Splinters	15	4	3	22	1	278	13
Lift trucks	4	4	8	16	1	655	41
Pallet trucks	2	5	3	10	1	235	24
Fire	5	0	0	5	0	101	20
Gases, Vapours, Fumes	1	2	2	5	0	114	23
Squirts	3	1	0	4	0	31	8
Non defined	5	14	7	26	2	936	36
TOTAL	555	738	398	1691	100	33603	20

Global MD = 20

Distribution of injuries by

Material Agent

chart p61

Knife

Solid Materials

Collectors/Trolleys

Flooring

Repetitive Movements /Exertion

Machinery

Animals

Agents Infectious

Air transport

Truck

Stairways and Walkways

Maintenance Tools

Splinters

Lift trucks

Pallet truck

% Injuries

The three tables given below show the distribution of injuries occurring over the 5 years, combining “Form” and “Material Agent”, for each of the sectors under review.

The first 15 items of the three tables cover 89.9% of injuries occurring in the cattle butchery sector, 81.8% of injuries in the pig butchery sector and 76.5% of injuries in the pig cold cutting sector, i.e. for each table more than 3/4 of total injuries.

The item “self-inflicted”/“knife” was the most common cause of injury in all three sectors (approximately one quarter of all events), followed by “cumulative traumas”/“Repetitive Movements-Exertion knife” (roughly 10% of events) and falls on floors (9% of events).

Injuries caused by Collectors and Trolleys were uneven in the three sectors: 7% circa in the Cattle and Pig Butchery sectors and 3% in the Pig Cutting sector.

Injuries caused by lift trucks and pallet trucks were infrequent but posted high values in terms of mean duration.

FORM MATERIAL AGENT

Cattle butchery and meat cutting

FORM	MATERIAL AGENT	no. inj.	%	% cum.	days abs.	MD
Self-inflicted	knife	132	23.8	23.8	2289	17
Cumulative traumas	repet. movements exertion knife	52	9.4	33.2	1909	37
Hit by	solid materials	54	9.7	42.9	659	12
Falls	flooring	50	9.0	51.9	1843	37
Crushed/Knocked down by	collectors/trolleys	38	6.8	58.7	631	17
Hit by	knife	31	5.6	64.3	530	17
Strain moving with exertion	solid materials	30	5.4	69.7	570	19
Hit by	animals	25	4.5	74.2	576	23
Hit by	pulleys	17	3.1	77.3	208	12
Hit by	knife	16	2.9	80.2	226	14
Hit by	splinters	15	2.7	82.9	198	13
Crushed by	machinery	12	2.2	85.0	423	35
Made contact with	machinery	10	1.8	86.8	207	21
Falls	stairways and pathways	9	1.6	88.5	234	26
Self-inflicted	maintenance tools	7	1.3	89.7	62	9
Made contact with	fire	6	1.1	90.8	121	20
Crushed by	lift trucks	3	0.5	91.4	289	96
Hit by	squirts	3	0.5	91.9	23	8
Hit by	machinery	2	0.4	92.3	146	73
Crushed by	pallet truck	2	0.4	92.6	17	9
Foot trapped	lift trucks	1	0.2	92.8	56	56
Crashed against	Fittings	1	0.2	93.0	8	8
	Other	39	7.0	100.0	1015	26
	Total	555	100.0		12240

Global Mean Duration = 22 days

FORM MATERIAL AGENT

Pig butchery and meat cutting

FORM	MATERIAL AGENT	no. inj.	%	% cum.	days abs.	MD
Self-inflicted	knife	198	26.8	26.8	2900	15
Crushed by	collectors/trolleys	105	14.2	41.1	1618	15
Cumulative traumas	repet. movem. exertion knife	79	10.7	51.8	1545	20
Falls	flooring	68	9.2	61.0	1725	25
Strain moving with exertion	solid materials	53	7.2	68.2	1003	19
Hit by	solid materials	22	3.0	71.1	302	14
Hit by	knife	15	2.0	73.2	263	18
Crushed by	machinery	15	2.0	75.2	320	21
Hit by	animals	10	1.4	76.6	170	17
Fall	stairways and walkways	10	1.4	77.9	552	55
Hit by	knife	7	0.9	78.9	76	11
Self-inflicted	maintenance tools	7	0.9	79.8	90	13
Made contact with	machinery	6	0.8	80.6	211	35
Crushed by	pallet truck	5	0.7	81.3	132	26
Hit by	splinters	4	0.5	81.8	58	15
Strain moving with exertion	animals	3	0.4	82.2	33	11
Knocked down by	animals	3	0.4	82.7	22	7
Hit by	pulleys	2	0.3	82.9	92	46
Crushed by	lift trucks	1	0.1	83.1	7	7
Hit by	squirts	1	0.1	83.2	8	8
Hit by	machinery	1	0.1	83.3	8	8
Foot trapped	lift trucks	1	0.1	83.5	7	7
	Other	122	16.5	100.0	2523	21
	Total	738	100.0		13665

Global Mean Duration = 19 days

FORM - MATERIAL AGENT

Cold cutting of pigs

FORM	MATERIAL AGENT	no. inj.	%	% cum.	days abs.	MD
Self-inflicted	knife	161	40.5	40.5	2741	17
Cumulative traumas	repet. movem. exertion knife	32	8.0	48.5	629	20
Hit by	solid materials	22	5.5	54.0	330	15
Fall	flooring	20	5.0	59.0	476	24
Solid materials	crushed by	12	3.0	62.1	369	31
Crushed by	collectors/trolleys	12	3.0	65.1	214	18
Strain moving with exertion	solid materials	12	3.0	68.1	185	15
Crushed by	machinery	7	1.8	69.8	93	13
Truck	slipped	6	1.5	71.4	155	26
Hit by	knife	5	1.3	72.6	77	15
Crushed by	lift trucks	4	1.0	73.6	181	45
Self-inflicted	maintenance tools	4	1.0	74.6	64	16
Hit by	splinters	3	0.8	75.4	22	7
Hit by	knife	2	0.5	75.9	70	35
Crushed by	pallet truck	2	0.5	76.4	65	33
Hit by	pulleys	2	0.5	76.9	11	6
Foot trapped	lift trucks	1	0.3	77.1	16	16
Hit by	machinery	1	0.3	77.4	4	4
	other	90	22.6	100.0	1996	22
	Total	398	100		7698

Global Mean Duration = 19 days

The final part of the analysis of injuries is that of identifying the working phases/units in which risk determinants are high in terms of frequency and/or gravity so as to come up with special prevention recommendations.

In conclusion, we describe 5 main causes of injury, identified with the agent, form, nature, seat of injury or a combination of factors that have had the greatest bearing in the cause of events.

Ø Knife wound

Knife wounds were the cause of the highest number of injuries (35% of total) in all three sectors reviewed. The average number of days absence from work was 16 days.

From an analysis of trends it emerged that in 87% of cases the cause was “self-inflicted”.

The worker self-inflicted the wound with the knife he used to perform his job. In 9% of cases the cause was “hit by”. In this case the knife, hitting against hard surfaces (bones) caused the knife to slip from the hand gripping it, causing a slash wound. In the remaining 4% of cases the cause was “hit by”. The worker was hit by a colleague working in a neighbouring work area.

Knife/self-inflicted

PRODUCTION UNIT/WORK PHASE					Total
Sector	Butchery	Cutting	Tripery	Other Processing		Other Units	No. inj.	Days abs.	MD
Cattle Butchery & Cutting	46	56	10	20		0	132	2289	17
Pig Butchery & Cutting	45	138	0	14		1	198	2900	15
Cold cutting of pigs	-	89	-	70		2	161	2741	17
Total	91	283	10	104		3	491	7930
% of production unit	(18%)	(58%)	(2%)	(21%)		(1%)	(100%)

Global MD = 16

Knife/hit by

PRODUCTION UNIT/WORK PHASE					Total
Sector	Butchery	Cutting	Tripery	Other Processing		Other Units	No. inj.	Days abs.	MD
Cattle Butchery & Cutting	17	9	2	0		0	31	530	17
Pig Butchery & Cutting	0	14	0	1		0	15	263	18
Cold cutting of pigs		5		0		0	5	77	15
Total % Production Unit	17 (33%)	28 (55%)	2 (4%)	1 (2%)		0	51 (100%)	870

Global MD = 17

Knife/hit by

PRODUCTION UNIT/WORK PHASE					Total
Sector	Butchery	Cutting	Tripery	Other Processing		Other Units	No. inj.	Days abs.	MD
Cattle Butchery & Cutting	1	8	1	6		0	16	226	14
Pig Butchery & Cutting	0	6	1	0		0	7	76	11
Cold cutting of pigs	2	0	0	2		70	35
Total % Production unit	1 (4%)	16 (64%)	2 (8%)	6 (24%)		0	25 (100%)	372	15

Global MD = 15

To prevent such injuries the following protective measures should be adopted:

· Knives endowed with ergonomic handles and with hilt to prevent the knife from slipping out of one’s hand, with blades kept in efficient state (regular sharpening), and knife being replaced when the blade becomes too narrow (less than 12.5 mm). The use of blades of less than 6 mm is forbidden (blade height measurement is taken to be over 20 mm from the tip);

· Working spaces and surfaces must be of sufficient width to perform the assigned task;

· Suitable PPE to protect those parts of the body exposed to the risk of cuts and slashes (upper limbs – chest abdomen - lower limbs). For correct choices refer to the specific chapter on PPE.

· Adequate worker training and controls on the correct use of PPE

Ø “Falls” on flooring, stairways and pathways

The study of injuries shows that this type of event is common and present in all units, causing in the 5 year period 157 injuries and 4,830 working days lost.

The units most affected are Cutting (26%) and Other Processing (30%). These are followed by Butchery and Tripery (13% and 8% of events respectively).

It should be stressed that the global mean duration was high, at more than 30 days absence from work per injury.

The causes of falls are Slipperiness (lack of friction/resistance) and Obstructions (difficult to move) on Floors.

Slipperiness of the floor is due to:

· the material with which it has been constructed: compliant with health standards (impermeable and smooth) but not with accident prevention norms (low friction coefficient);

· the presence of water, blood and high-fat waste materials produced during processing.

Obstructions are due to the excessive crowding of machines, platforms, materials of all sorts placed on workers’ walkways.

Clearly the most effective protective measures to eliminate the danger of falls should be sought in the design phase.

The designer of the new production unit or work environment should design new flooring taking into due account reference laws and standards concerning the problem of falls. The designer (pursuant to art. 6 of Legislative Decree 626/94) must accordingly comply with:

· Regional Building Regulations (e.g. Bollettino Regionale E.R. part two no. 83 of 08/05/95, mandatory requirements);

· design constraints pursuant to M.D. 236 of 14/06/89;

· good practice standards (B.C.R.A.; DIN 51130, etc.).

Flooring - Stairways and Walkways/falls

PRODUCTION UNIT/WORK PHASE					Total
Sector	Butchery	Cutting	Tripery	Other Processing		Other Units	No. inj.	Days abs.	MD
Cattle Butchery & Cutting	8	9	12	21		9	59	2077	35
Pig Butchery & Cutting	12	25		18		23	78	2277	29
Cold cutting of pigs		9		8		3	20	476	24
Total % of production unit	20 (13%)	43 (27%)	12 (8%)	47 (30%)		35 (22%)	157 (100%)	4830

Global MD = 31

For flooring already constructed, the analysis of risk may be carried out by measuring the “Dynamic Friction Coefficient” of the floor surface area using the method recommended by the British Ceramic Research Association Ltd (B.C.R.A.) (M.D. 236 of 14/06/1989 point 8.2.2 Flooring):

The floor is “nonslip” when the dynamic friction coefficient is above:

· 0.40 per hide slippery element, on dry flooring;

· 0.40 per standard hard rubber slippery element, on wet flooring.

In order to evaluate risks pertaining to obstructions, it is necessary to study the way work is organised in the enterprise, pinpointing the most dangerous pathways with reference to obstacles (steps, pallets, crates/boxes, etc.) and exposure to risk (how many persons and how long they walk on these pathways).

To prevent such injuries the following preventive measures should be adopted:

· plan changes to flooring using materials conforming to safety requirements;

· use suitable PPE (shoes with nonslip soles);

· remove grease and waste from floors adequately and regularly;

· avoid the risk of tripping up by removing obstructions and keeping the work setting tidy.

Ø ”Injuries caused by exertion”

Injuries caused by over-exertion affecting the upper limbs are usually the result of Repetitive Movements and efforts relating to the use of knives. This type of event for all three sectors under review is most common in the Cutting units (66% of total), followed by Other Processing (17%) and Butchery (13%).

Injuries caused by exertion affecting the backbone are usually due to the exertion of manually handling loads. These injuries are most common in the Other Processing units (59%) followed by Cutting (26%).

Upper limbs / Repet. Movem.-Exertion Knife

PRODUCTION UNIT/WORK PHASE					Total
Sector	Butchery	Cutting	Tripery	Other Processing		Other Units	no. inj.		days abs.	MD
Cattle Butchery & Cutting	3	28	2	19		0		52	1909	17
Pig Butchery & Cutting	18	54	0	2		5		79	1545	20
Cold cutting of pigs	0	25	0	7		0		32	629	20
Total % of production unit	21 (13%)	107 (66%)	2 (1%)	28 (17%)		5 (3%)		163 (100%)	4436

Global MD 27

Backbone/Movement of Solid Materials

PRODUCTION UNIT/WORK PHASE					Total
Sector	Butchery	Cutting	Tripery	Other Processing		Other Units	No. inj.	Days abs.	MD
Cattle Butchery & Cutting	1	7	1	40		3	52	1909	37
Pig Butchery & Cutting	12	26	0	13		2	53	1003	19
Cold cutting of pigs		3		28		1	32	629	20
Total % of production unit	13 (9%)	36 (26%)	1 (1%)	81 (59%)		6 (5%)	137 (100%)	3541

Global MD 26

To prevent such injuries it is necessary to adopt the preventive measures analysed in detail in the specific section.

Ø ”Lift trucks and Pallet trucks”

The lift truck is one of the most common hoisting and transportation machines used in warehousing/storage work. Choice of the model and power supply (diesel or electric) depends on the various working and environmental needs. The main trait of this equipment is that the harness of the load (fork) prevents workers from standing below the suspended load during both hoisting and transportation.

The pallet truck is a very common piece of hoisting and transportation equipment and is used for the same purposes as the lift truck. It is usually electric powered. The various types differ in the following ways:

· on-board or ground-based manoeuvring;

· hoisting of the load to several metres in height or just a few centimetres.

Pallet trucks endowed with on-board manoeuvring and hoisting at heights have safety problems similar to lift trucks.

Injuries relating to these machines are not very frequent, but are present in all sectors under review. In terms of gravity the average duration of absence from work exceeds 30 days.

In greater detail, the table shows the seriousness of:

· knock-downs caused by lift trucks in the phases Butchery of Cattle (MD 96) and Cutting of Pigs (MD 45);

· knock-downs caused by pallet trucks in the phase Cold cutting of Pigs (MD 33);

· stumbles/trips, caused by the operator climbing on/off the machine, in the Cattle butchery and cutting phases (MD 56).

Knock-downs caused by these machines may cause workers very serious and permanent invalidity.

Injuries caused by Lift trucks and Pallet trucks

MEAN DURATION

SECTOR	Crushed by/Forklift truck	Crushed by/ Pallet truck	Tripped up/Lift truck
Cattle Butchery and Cutting	96 (3 injuries)	9 (2 injuries)	56 (1 injury)
Pig Butchery and Cutting	7 (1 injury)	26 (5 injuries)	7 (1 injury)
Cold cutting of Pigs	45 (4 injuries)	33 (2 injuries)	16 (1 injury)

To prevent such injuries the following technical and organisational preventive measures should be adopted:

· safety measures pertaining to machines;

· codes of behaviour (traffic circulation rules);

· signalling;

· worker training/information;

· conditions of pathways.

Ø Collectors and Trolleys

Collectors and trolleys are portable metallic pieces of equipment endowed with surfaces or hooks to store and transport cut meat. They are moved manually by workers when the equipment is endowed with wheels or are hoisted and transported with the aid of pallet trucks or lift trucks.

The wheels enable workers to move these structures manually even when they are fully loaded. Injuries occurring with collectors and trolleys are caused by the worker’s hands being crushed (between the means itself and other trolleys or stationary structures). The table below shows that most of these accidents occur in the Pig butchery and cutting sector (68%): 42% in the Cutting unit, 15% in the Other Processing phase and 5% in Butchery. In the other two sectors the number of accidents is lower: 24% in the Cattle butchery phase and 8% in the Cold cutting of pigs phase.

Collectors-Trolleys/Crushed by

PRODUCTION UNIT/WORK PHASE						Total
SECTOR	Butchery	Cutting	Tripery	Other Processing	Porterage		Other Units	No. inj.	Days abs.	MD
Cattle Butchery & Cutting	1	9	8	19	0		1	38	631	17
Pig Butchery & Cutting	8	65	0	23	9		0	105	1618	15
Cold cutting of pigs	0	7	0	5	0		0	12	214	18
Total % of production unit	9 (6%)	81 (52%)	8 (5%)	47 (30%)	9 (6%)		1 (1%)	155 (100%)	2463

Global MD = 16

To prevent such injuries it is necessary to make changes to the organisation of work:

· avoiding the manual handling of fully laden collectors, using only pallet trucks for this purpose;

· adequately training workers;

· for unavoidable and occasional manual handling, endowing workers with suitable PPE (anti-crush gloves).

OCCUPATIONAL DISEASES

Health monitoring in the butchery industry generally appears to be inadequate in terms of the quality of actions performed. This reflects the general approach adopted by competent physicians, still basing their activity on the identification of “traditional” risks.

Health monitoring protocols are often proposed that are limited to traditional instrumental tests (audiometry/spirometry), relegating the study of the osteo-articular apparatus and especially of Repetitive Movements of the upper limb.

A high percentage of enterprises do not have a competent physician. This demonstrates the still modest awareness of problems pertaining to the health of workers. This is probably due to efforts concentrating on the wholesomeness of the foodstuff produced, deemed to be a priority need or even an exclusive need by employers, who are subject to daily veterinary controls.

The “bovine” sector is that most affected, while there are signs that in the pig butchery and cutting sector the search for “emerging” pathologies such as diseases caused by CTD is more developed.

The risk indeed seems greater in this sector. This probably means competent physicians are being called on to make more “limited fitness” judgements.

In the chapters devoted to physical risks (noise) and in the chapter on ergonomics there are detailed accounts of risk sources and possible corrective measures.

Many enterprises still fail to carry out health monitoring of any sort (especially “bovine” enterprises). There is, consequently, a general underestimation of risks and occupational diseases. This situation is acute in the Province of Mantua, where enterprises carrying out health monitoring are in a small minority.

Summarising the data in our possession, the following picture emerges:

Total butchery and meat cutting enterprises: 78

Of which:

1) chiefly or exclusively cattle butchery and cutting 35 (competent physicians 6)

2) pig butchery and hot cutting 25 ( “ “ 14 )

3) pig cold cutting 18 ( “ “ 11 )

The total number of workers is an estimated 2,500 persons (in 1999).

The competent physician has been appointed only in 31 enterprises (40%), which are mostly large-sized. It has not been possible to acquire an exhaustive health report for all these activities.

Analysing reported diseases there is a clear-cut prevalence of pathologies caused by CTD, followed by hypacusia, verrucas and sporadic reports of brucellosis.

The table summarises reports contained in the health reports sent by enterprises for the period 1995-1999. Points worthy of mention:

ü only three reports (1 hypacusia, 1 osteo-articular pathology and 1 allergopathy) were sent by the competent physicians of enterprises operating in the territory of the Province of Mantua;

ü data refer almost exclusively to reports from the Modena area;

ü pathologies caused by infectious agents are always reported in accident registers;

ü for pathologies not listed a specific insurance investigation procedure is in place in accordance with the provisions of Legislative Decree 38/2000.

	1995/1999
PATHOLOGIES CAUSED BY CTD (not listed)	84*
HYPACUSIA AND NOISE RELATED HEARING LOSS	14
VERRUCAS	10
BRUCELLOSIS	2
ALLERGIES (contact-related dermatitis)	1
NON DEFINED BRONCHOPATHIES	1

* (65 of which in pig butchery and cutting enterprises)

GENERAL RISKS

It was decided to unite the description of some risks in the sector document, since a correct analysis of risks and of procedures and preventive measures is to be dealt with at a general level: the management of work spaces to prevent accidents, and the ergonomics involved in design and correction phases, for instance, cannot be limited to the analysis and adoption of measures in single phases without having a clear overall vision.

The following risks will thus be dealt with in separate chapters:

ü biological risk

ü non-ergonomic aspects

ü noise and vibrations

ü microclimate

At the end of the sector document some information is given on personal protective equipment to steer relative choices.

BIOLOGICAL RISK

1. Biological risk and zoonosis

The problem of occupation-related infectious diseases has been well known for a long time, but it is only after Legislative Decree 626/94 that the issue has been dealt with systematically, with enterprises required to prevent biological risk in the workplace.

Work in the animal husbandry and butchery sectors entails in particular the risk of contracting zoonosis. The term zoonosis indicates diseases that can be transmitted from man to animals, and vice versa. There are many known zoonoses, but only a few of them constitute an occupational risk. Prevention of zoonoses at the source must be conducted on animals, and is entrusted to Veterinary Services.

Prevention and actions to combat zoonosis are traditionally one of the main tasks of the public veterinary services of ASLs. They consist of actions to improve health conditions and controls on livestock, the inspection of foodstuffs of animal origin and more recently veterinary urban hygiene.

The direct link between the preventive action of veterinarians in relation to these pathologies and public health has been the main argument in favour of the category coming under the National Health Service with the health reform of 1978.

The Work Environment Prevention and Safety Services are responsible for occupational prevention for workers and for checking measures adopted by employers.

Zoonosis diseases thus represent common ground for professional figures managing risk. Interdisciplinary cooperation alone will make it possible to tackle the problem rationally.

It should be noted that the veterinarian shares with butchery workers the same biological risks regarding contact with the same potentially infectious matrices and presence in the same structures.

The Veterinary Inspector is an ASL employee and thus enjoys the same employee protection as a worker. The two positions of the veterinarian (protected and at the same time a prevention actor) are thus closely interdependent. The position of the veterinarian is comparable to that of the hospital physician, who on the one hand is protected and on the other is one that identifies risks with the diagnosis of patients (in our case animals) and works to combat infectious diseases.

2. Occupational zoonoses among butchers

The category of butchery and meat processing workers is particularly exposed to the danger of coming into contact with pathogenic agents present in animals and thus to the risk of contracting a zoonosis of professional origin. This type of activity entails a vast range of possible contacts with potentially infectious materials: livestock, faeces, urine, blood, organs, entrails and tissues.

The International Labour Conference defined occupational diseases as ”diseases caused by exposure, during processes, activities or productions, to substances or inherent risks” (International Labour Office Convention no.121, 1980). The same Conference drew up a list of occupational diseases, at point 29 citing: “Infectious or parasitic diseases contracted in a work setting in which there is a specific risk of contamination”..(omission)… c) Work involving the dressing of animals, carcasses or parts thereof...(omission).

The WHO, defining “occupational populations and groups exposed to a high risk of zoonosis infection” in the group “animal product manufacture” listed: “butchers, workers in slaughterhouses and meat storage plants; handlers of meat, eggs, milk, hides, carcasses, dead animals, etc.”(source Schwabe, 1981, adapted from WHO, 1982). The world’s leading health organisation defined at the same time a list of zoonoses that may affect this category: “anthrax, brucellosis, erysipeloid, salmonellosis, campilobacteriosis, leptospirosis, tubercolosis, tularaemia (rabbit fever), yersiniosis, psittacosis-ornithosis, Q fever, contagious ecthyma, Newcastle disease, glanders, etc.”.

Italian legislation on the subject of worker insurance recognises as injuries those infectious diseases contracted through work (Presidential Decree 1124/1965). With the recent introduction of Legislative Decree 38 of 23.02.2000, the legislator decided to set up a Scientific Commission for the drawing up and periodical review of the list of diseases as per art. 139 of Consolidation Act 1124/65. Art. 13 of the same Decree introduces the concept of “biological damage”, to be handled by the same insurance institute.

Apart from the so-called tabular system as per above, diseases that are not present in the above tables are also considered as occupational diseases. The worker must however be able to demonstrate the professional origin, the so-called “burden of proof” (ruling 179/1988 and subsequent rulings of Constitutional Court).

Not all the pathologies reported by the WHO are of course present among animals in our country. The frequency of contagion is furthermore closely related to the working conditions of workers affected. Improvements made over the years to the health conditions of animals by Veterinary Services has significantly reduced the incidence of clear-cut zoonosis pathologies among butchers. Some of these, such as glanders or anthrax, have practically disappeared.

Other risks are however real and topical, such as brucellosis and TBC, in the butchery of cattle, or leptospirosis and erysipeloid, contracted by pig butchers.

3. Biological risk in Legislative Decree 626/94

Legislative Decree 626 of 19 September 1994 obliges employers to undertake specific prevention for “all working activities in which there exists a risk of exposure to biological agents” (art. 73).

In attachment IX of the Decree there is an illustrative list of activities that may entail the presence of biological agents. This list expressly includes “activities in which there is contact with animals and/or products of animal origin”.

All activities placed under the control of ASL Veterinary Services fully come under this provision. These include: the breeding of animals, their transportation, veterinary treatment and prophylaxis, butchery, the processing of meat and other products and by-products of animal origin, collection and treatment of the waste produced by zootechnic activities and related industries, etc.

Slaughterhouses therefore come under the governance of the legislator and are subject to evaluations on biological risk. It may be stated that biological risk is significant in this category of factory in terms of the kind of manual skills required, the type of contact with animals, organs, entrails and by-products, environmental conditions, work rates and the lack of perception of risk of many workers.

dida p73

Failure to observe basic rules of hygiene exposes workers to contact with biological agents and causes meat contamination.

When assessing risk in these plants, carried out pursuant to art. 4, § 1, the employer should expressly consider biological risk and “keep in mind (art. 78 - Legislative Decree 626/94) all available information regarding the characteristics of the biological agent and working methods.

Once risks have been evaluated, the employer must draw up preventive measures appropriate for the situation in hand.

Biological risk in slaughterhouses mainly consists of the possibility of contracting zoonosis-related diseases, and one should not underestimate the extremely high incidence of verrucas, probably due to interhuman contagion of papillomavirus.

Attachment XI of Legislative Decree 626/94 (amended on several occasions) lists many zoonosis agents among classified biological agents. Of these agents many are to be considered as “exotic”, since they have never affected animals kept in Italy, while other classified agents have caused serious problems in the past but are now seldom present in our territory (for instance Glanders or Anthrax agents). Finally, there is a group of biological agents that are frequently present among productive livestock and that can be transmitted when animals or meat are handled (Brucella spp, Leptospira spp, Mycobacteria, Erysipelothrix rhusiopathiae, etc.).

There are some question marks over “emerging” agents such as transmissible encephalopathies, coli going to produce verocytotoxin or Streptococcus suis II, which are duly defined as being transmissible on account of professional causes.

Biological agents are classified in Legislative Decree 626 in four different groups (art. 75) on the basis of risk of human infection, the possibility of propagation in the community, the seriousness of contracted diseases and the availability of preventive or therapeutic measures.

The classification of biological agents is based on the effect of such agents on healthy workers. It does not take into account special effects on workers whose sensitivity may have been altered by other causes such as past diseases, the use of medicines, lowered immunity levels, state of pregnancy or breast-feeding, during which the law forbids women workers from performing butchery or cutting work. These factors have been taken into account in health monitoring as per art. 95.

The lists of classified biological agents are given in attachment XI, and include only those agents known to be able to cause infectious diseases in humans.

For each group there are various measures and levels of control, reported in attachment XII.

The tables given list some zoonosis agents classified in attachment XI (as amended by the Decree of 12 November 1999) that may be present in animals in the Italian territory. This is not sufficient to constitute a professional risk, since effective exposure in the working environment must be verified. With regard to parasites, they should be considered as “infesting” only in some stages of their development.

Only productive livestock normally reared and butchered in Italy are considered. Operations on exotic animals and especially primates expose workers to agents classified by Law but not listed here.

Table with some of the zoonosis agents classified by the decree

BACTERIA	Classification
Bacillus anthracis	3
Borrelia burgorferi	2
Brucella abortus	3
Brucella melitensis	3
Brucella suis	3
Burkholderia pseudomallei	3
Campylobacter spp	2
Chlamidya psittaci (ceppi aviari)	3
Chlamidya psittaci (ceppi non aviari)	2
Clostridium botulinum	2
Clostridium perfringens	2
Clostridium tetani	2
Coxiella burnetii	3
Erysiphelothrix rhusiopathiae	2
Escherichia coli (ceppi verocitotossigenici)	3
Francisella tularensis (tipo a)	3
Francisella tularensis (tipo b)	2
Haemophilus spp	2
Helicobacter pylori	2
Leptospira interrogans	2
Listeria monocytogenes	2
Mycobacterium avium/intracellulare	2
Mycobacterium bovis	3
Mycobacterium tubercolosis	3
Mycobacterium paratubercolosis	2
Salmonella	2
Salmonella thypi	3
Staphylococcus aureus	2
Streptococcus spp	2
Streptococcus suis	2
Yersinia	2
Yersinia pseudotubercolosis	2

PARASITES	Classification
Ascaris suum	2
Echinococcus granulosus	3
Echinococcus multilocularis	3
Fasciola haepatica	2
Taenia saginata	2
Taenia solium	2
Toxoplasma gondii	2
Trichinella spiralis	2

FUNGI	Classification
Cryptococcus neoformans	2
Histoplasma capsulatum	3
Microsporum spp	2
Tricophyton spp	2

VIRUS	Classification
Respiratory syncytial virus	2
Rift valley fever virus	3
Newcastle disease virus	2
Milkers’ node virus	2
Rabies virus (not currently present)	3

NON-CLASSIC AGENTS ASSOCIATED WITH TRANSMISSIBLE SPONGIFORM ENCEPHALOPATHIES

Classification

Bovine spongiform encephalopathy and other animal TSEs 3

4. The difficulties involved in assessing biological risk in slaughterhouses

The prevention system should be based on the identification of dangers, the quantification of likely damage and the likelihood of undesired events occurring, which in the case in point cover: contamination, infection, illness and death.

Assessing biological risk in these contexts is more complex than for others types of risk. In the absence of certain reference data, indeed, quantitative appraisals are impossible, and even simple qualitative appraisals are difficult.

To assess biological risk in slaughterhouses we should indeed have at our disposal data such as: number of occupational zoonoses occurring over the years, broken down by sector, disease, job type, and know the type of exposure relating to the infection, damage caused in terms of days off work, number of deaths and cases of invalidity, etc.

This type of approach cannot currently be applied to biological risk owing to the lack of basic data on which the assessment should be based.

A qualitative-type approach is however possible, based on:

- epidemiological data on the spread of zoonoses among animals for slaughter and by-products;

- an examination of production processes and identification of contacts with potentially infecting materials;

- scientific knowledge of the means of transmission of biological agents;

- epidemiological surveys conducted on workers in the sector.

5. Identification of dangers

The Veterinary Services of ASLs are technically and legally responsible for diagnosing the zoonosis diseases of animals and for managing the information flows needed to assess biological risk.

Animals arrive at the slaughterhouse accompanied by health certificates issued during the animal farming phase. They undergo an ante-mortem health inspection at the slaughterhouse, a necroscopic inspection of organs and entrails (post mortem examination) and possibly laboratory analyses. These procedures are fixed by law and are aimed at protecting consumers and controlling diffusive animal diseases. Health data on zoonosis diseases detected during these operations must by law be reported, and should constitute the basis for structuring risk appraisals. The methods of inspection and analysis established by veterinary legislation set out to guarantee the wholesomeness of meat, and are therefore effective in detecting some pathologies rather than others. It should also be borne in mind that an animal’s sickness may be symptomatic or asymptomatic, the animal my be infectious or simply a carrier of the zoonosis-related agent.

For some zoonoses subject to specific health plans (TBC and bovine brucellosis) there are epidemiological data for almost all animals reared in Italy, while for other pathologies just a few elements are available.

The collaboration of the Veterinary Officer is in any case a fundamental step towards identifying the dangers arising from biological agents present in a slaughterhouse. In this way it is possible to narrow down the list of biological agents to be considered in the appraisal.

Each biological agent has its own means of transmission during working activity, according to the pathogenesis of diseases considered, elimination through animal excretion or secretion or its focalisation in particular organs or tissues. It is for this reason necessary to define the list of agents potentially present in the specific working activity so as to be able to adopt preventive measures focusing on the identified risk. By way of example: leptospirosis is very common in intensive pig farming. Pigs eliminate leptospira in their urine. In pig slaughterhouses it is therefore necessary to identify the points where the worker comes into contact with pig urine and to come up with solutions compatible with the job performed.

Animal epidemiology is thus a focal point of the problem, and depends on:

1) species, category and age of butchered animals

2) territory of origin of animals

3) epidemiological state of the livestock of origin

4) state of health of the single animal

The animal epidemiology of the territory where the slaughterhouse is located is irrelevant.

diagram p78

Agents listed in attachment XI of Legislative Decree 626/94

Agents described in literature for animal species present in working activity

Agents potentially present in the slaughterhouse under review

6. Butchery worker exposure to biological agents

The existence of a danger does not necessarily mean the presence of a significant risk. To have a zoonosis-related biological risk two conditions must occur at the same time:

1) the presence of the biological agent in the animal or in by-products;

2) working methods and conditions favouring effective exposure to the risk.

dida p78

The material seized by the Veterinarian during inspections must only be handled using suitable PPE. In the photograph a kidney affected by leptospirosis is incorrectly removed without precautions.

Effective exposure is taken to mean contact sufficient to cause penetration in the organism of an infecting load sufficient to cause biological effects.

The general and specific immunity conditions of the organism play a key role in the initial phases of the pathogenetic process.

Biological agents can penetrate through nasal, buccal and ocular mucous, digestive channels, through skin soaked by contact with water, through wounds or abrasions.

In some cases agents carried by dust or aerosol may enter through the respiratory tract.

EXHALED AIR

SALIVA

GASTRIC REGURGITATION

SKIN

MILK

URINE

FAECES

FOETAL ENVELOPE

BLOOD

ORGANS AND ENTRAILS

Effective exposure?

SKIN

MUCOUS

DIGESTIVE TRACT

RESPIRATORY TRACT

Exposure thus depends on the manual work performed, the level of plant automation, the use of Personal Protective Equipment (PPE), the general level of environmental and occupational hygiene and the health training of workers. Each single biological material is capable of conveying some agents and not others. For example urine can convey Leptospira spp, faeces Clostridium tetani or Erysipelpthrix rhusiopathiae, the skin fungus, the uterus or mammary tissue of the cow brucella, etc.

Exposure can in part be estimated by observing contacts between the operator and potentially infecting biological materials.

dida p79

The production chain of full throughput plants involves contacts with biological materials from a large number of animals.

Analysis of the production process is thus the first step towards verifying the degree of exposure to the potentially infecting biological material in different jobs.

The analysis of the production process should consider:

- the activity phase;

- the type of manual skills required;

- the procedures adopted;

- actual compliance with general hygiene rules;

- the use of PPE;

- work organisation (chain, stationary workstation, etc.).

dida p80

Manual errors may cause the biological contamination of meat and worker exposure to risk.

In this context a critical point may be defined as a situation involving the possible presence of a pathogenic agent and sufficient worker exposure.

A solution must be adopted for each critical point identified.

Since contacts with animal biological materials are continuous and very frequent in slaughterhouses, critical points must be identified on the basis of assumptions regarding the possible presence of some biological agents, according to information on the health conditions of butchered animals. The observance of rules on the subject of industrial hygiene and of veterinary rules to protect the hygiene of meat may be vital in reducing exposure levels.

7. Epidemiological studies

Epidemiological studies on butchers offer important scientific findings to be taken into consideration when evaluating risk. Unfortunately, despite the economic and social importance of the meat producing and processing industry in some areas of the country, few studies have been conducted on this category of workers that are available in literature. The bibliography herein lists some of these studies, which provide relevant evidence of the existence of the problem.

It is necessary to take care when drawing up conclusions regarding these studies, especially those conducted in other countries, since they are directly related to the epidemiological conditions of animals located in a particular geographic context.

For a summary of leading scientific evidence on this subject, we refer the reader to the introductory chapter of the ISPESL Monograph “Definition of the risks of exposure and safety and health protection measures in the animal farming, butchery, meat processing and distribution sectors”.

8. Preventive measures and solutions

Once dangers have been identified (list of biological agents potentially present) it is necessary to estimate risks. As it is impossible to undertake a quantitative appraisal, risks should be estimated adopting prudent principles.

In addition to adopting general collective health measures it is necessary to come up with solutions and corrective measures for the various identified critical points.

Prevention actions should be based on the following areas:

· - Collective prevention

· - Health measures

· - Procedures

· - PPE

· - Training

Collective prevention is undertaken through animal prophylaxis and therapy in the animal farming phase, Veterinary Policing measures, the isolated butchery of suspect cases, veterinary inspections, etc. Prevention at source should be conducted on animals during the farming phase. Efforts to combat zoonosis in that phase reduce biological risk in all subsequent transformation phases. At the slaughterhouse ante- and post-mortem examinations make it possible to diagnose some pathologies that can be transmitted to humans, and are essential in identifying dangers and adopting all other preventive measures for workers in the sector as well as veterinarians.

General health measures are those fixed by Legislative Decree 626 (art. 80) and are partly the same as those required by veterinary regulations for the wholesome production of meat. On this point Legislative Decree 286 of 18 April 1994, governing the butchery sector, lays down health measures to reduce environmental contamination, such as the sanification of work settings and instruments, actions to combat infesting elements, observance of pathways and filter zones (observing correct working sequence), procedures for the management and removal of waste of animal origin. Health permits for slaughterhouses are granted only if these conform to construction principles designed to ensure healthy conditions in these structures. Provisions regarding the hygienic handling of meat provide for the use of complete work clothing, changing rooms endowed with two-compartment lockers, the banning of smoking in work areas, the use of non-hand operable wash basins, with liquid soap and disposable towels, etc. Controls on the observance of the provisions of Legislative Decree 286/94 are entrusted to the Veterinary Officer, but clearly the observance of such rules has significant effects in favour of workers.

Procedures are established by the employer after having assessed risks present, and he must indicate correct methods for performing jobs. In practice, the worker must always be aware of the correct way of going about his job so as to avoid occupational risk. Procedures should be drawn up on the basis of the type of risk involved and the type of action to be performed. Legislation and veterinary good practice standards establish many elements for different zoonoses. Here we recall the ban placed on butchering animals affected by specific pathologies and the obligation of butchering in isolation those animals suspected of carrying a zoonosis detected in the farming phase or during slaughterhouse inspections. This is a measure adopted by the Veterinary Officer (Legislative Decree 286/94, art. 8, point 2) and should be accompanied by additional preventive measures (PPE, sanification, etc.) to be implemented by the employer. Also, the butchery of animals within the context of “corrective” operations (i.e. animals testing positive in intradermic reaction tests for the diagnosis of TBC or in serological tests for brucellosis) must be accompanied by special precautions. The observance of procedures established by the Veterinary Officer on the subject of the segregation of pathological material seized during the inspection and management of waste of animal origin are also of interest to the protection of workers’ health. The centralised washing of workers’ clothing prevents biological materials from being taken to workers’ vehicles and homes and guarantees the uniform sanification of clothing.

Although it is an indispensable prevention tool, PPE (title IV) is not the only solution adopted for first-choice intervention (art. 3, § 1 - letter g). The use of extended passive protection in all production phases may appear to be the ideal solution, since it prevents contact of the organism with any potentially infected animal tissue and thus any possibility of exposure.

This solution is however often demanding on workers because of:

- the climatic conditions of some units (animal pens, scalding baths, etc.)

- the impediment this creates when performing certain operations

- the subjective aggravation they can create

- workers not being used to wearing them

- the low individual perception of risk

dida 1 p82

Workers often claim that the use of PPE is incompatible with some operations.

PPE must be supplied by the employer and be suitable for the type of activity performed. It must be replaced when it is worn out or no longer fully functional. PPE must protect the skin, eyes, nose and mouth from any possible contact with infecting organic material. This equipment includes: gloves, working clothes, plastic-coated aprons, rubber boots, face masks (full or partial), eye screens and goggles. Equipment must be provided after having analysed risks for the various workstations on the basis of the type of contact to be avoided or specific moments during working activity. Their utilisation, sanification and replacement must be established according to precise company instructions. Although it is necessary to encourage the increasing use of PPE to tackle residual risk, the use of such equipment cannot replace other types of preventive measures. With regard to PPE identified to prevent exposure to the prions of BSE, see attachment 1.

dida 2 p82

Cattle carcasses may be split into two using the traditional axe method or a band saw. In both cases there is the danger of exposure to the nerve tissue of the spinal cord.

Worker training on the subject of safety must be provided by the employer (Legislative Decree 626/94, art. 22 and art. 85), who is also required to undertake similar initiatives on the subject of meat hygiene, with the participation of the Veterinary Officer (Legislative Decree 286/94, art. 15). It may be rational and desirable to unite training initiatives on the subject of hygiene and biological risk owing to the similarity of topics tackled and the behaviour required of workers.

Training should aim to get workers involved in safety initiatives, moving beyond the “familiar” attitude shown by workers, since detecting animal diseases is an event considered as very common and usual. Training must also encourage workers to comply with the firm’s health procedures, with special reference to personal hygiene measures and the use of PPE.

Training instructors should take into due account the social origin and cultural tools at the disposal of workers and the linguistic difficulties of many workers in the sector that come from outside the European Community.

9. Role of Prevention Services

Despite the difficulties involved in expressing the statistical likelihood of a butchery worker undergoing damage from infectious agents for occupational reasons, it is possible to make some general considerations.

1) The improved health conditions of livestock and preventive measures adopted by veterinary services to combat some infectious diseases over the years have reduced the incidence of some important zoonoses among farm animals, thus reducing occupational risk for all related activities.

2) Actions to bring national regulations into line with Community legislation have led to general structural and operational improvements in slaughterhouses.

3) industrial hygiene in slaughterhouses has gradually improved owing to the need to conform to meat hygiene standards.

Despite these successes, other considerations lead one to believe that the risk of exposure remains high. These concerns include:

· the particular environmental and working conditions in this type of plant;

· continuous contact with livestock, blood, tissues and other organic fluids;

· the type of tasks performed on animals and on meat, which limits the use made of PPE;

· the lack of awareness of the problem on the part of prevention operators;

· workers’ difficulty in perceiving biological risk;

· the organisation of work in full throughput slaughterhouses, with single operators daily handling hundreds or thousands of animals or carcasses, multiplying the likelihood of contact with infected animals;

· the fact that some serological tests on these workers have revealed antibodies for different zoonoses.

These brief reflections lead us to believe that there is a real public health problem, with a need to afford greater protection to workers in the sector in relation to occupational zoonoses and a need to remove any technical uncertainty on the subject. In our opinion these are tasks that are legally and technically the responsibility of public prevention services.

As regards the desirability for these Services to play a bigger role, we wish to recall:

· the existence of adequate professional profiles in the public service;

· the extensive presence of veterinary services in the productive contexts under review;

· the existence of the legal preconditions (and obligations) required to intervene;

· the possibility of interdisciplinary action between physicians and veterinarians with a view to coordinating and optimising actions that are already performed on humans and animals;

· the existence of a demand for the service on the part of enterprises seeking explanations and

guidelines for the application of Legislative Decree 626 with regard to biological risk.

ATTACHMENTS

I. BSE and other transmissible encephalopathies

The emergence of bovine spongiform encephalopathy (BSE) is a serious public health problem owing to possible human transmission via food intake of the “prions” that carry the disease in the animal. The juvenile variant, Creutzfeldt-Jacob (vMCJ) disease, an extremely serious neurodegenererative disease, can be contracted by consuming nerve tissue from cattle infected with BSE.

To prevent the transmission to human by food intake Community veterinary legislation has enforced increasingly rigid measures, including the removal and destruction of Specified Risk Materials (SRM) and the systematic conducting of the “rapid test” on the encephalic tissue of some categories of animals.

The bibliography does not contain proven cases of the occupational transmission of this pathology, and scientific knowledge in this area is being acquired all the time. It is in any case necessary to consider with the utmost urgency the need to prevent exposure to this infectious agent.

On this point the following elements should be borne in mind:

1) The Decree of 12 November 1999, amending Attachment XI of Legislative Decree 626/94, expressly considers in group 3 “bovine spongiform encephalitis (BSE) and other related animal TSEs”;

2) Routine cattle and sheep butchery operations sometimes entail the need to handle nerve tissue or other tissues defined by the SRM law;

Preventive measures established by veterinary regulations entail the need for the further handling of SRM to cut out, remove, store, transport, deposit and destroy such materials (Decree of 29 September 2000, “Protective health measures to combat transmissible spongiform encephalopathies”).

The taking of cerebral material samples on the part of Veterinary Officers also constitute phases of potential risk.

Potentially infectious biological materials for the transmission of prions

Animal tissues deemed to be highly infectious are the brain, spinal cord and eyes. Less infectious are considered: amygdala, ileum and colon, cephalo-rachidian liquid, spleen, peripheral nerves, placenta and lymph glands. The following are not considered infectious: blood, muscular tissue, milk, faeces, etc.

Pursuant to the Decree of 29 September 2000, attachment I (amended by the Ministerial Decree of 27 March 2001) the following SRMs must be removed and cannot be offered to consumers:

a) the cranium, including brain and eyes, tonsils, backbone, excluding tail-bones but including spinal ganglions, and the spinal cord of cattle over the age of 12 months and the entire intestine, from the duodenum to the rectum, of cattle of all ages.

b) the cranium, including brain and eyes, tonsils, spinal cord of sheep and goats over the age of 12 months having at least one permanent incisor and the spleen of sheep and goats of all ages.

Operations involving the handling of SRMs are to be considered as being at potential risk of exposure to prions. The use of PPE is compulsory, as per attachment IV of the Decree of 29 September 2000.

Productive sectors where there is the risk of exposure to prions

On the basis of the presence of animal tissues deemed to be infectious and the type of operations related to the activity in question it is possible to draw up a list of productive sectors in which it is necessary to prevent exposure to hazardous biological material:

ü Butchery of cattle and sheep

ü Transportation of SRM

ü SRM storage, treatment and incineration plants

ü Public veterinary services

ü Zooprophylactic institutes

Occupational exposure to prions

Despite the absence of precise scientific evidence, we can, as a precautionary step and considering similarities with known means of transmission for other spongiform encephalopathies (including iatrogenic transmission for Creutzfeldt-Jacob disease and transmission to workers responsible for post-mortem examinations), put forward possible means of entry into the organism in the aforementioned occupational environments:

ü Inoculation (wounds, injections)

ü Mucous (ocular, nasal and buccal)

ü Inhalatory (via aerosol and dust)

ü Cutaneous (greater risk if skin intact)

A WHO document (WHO Infection Control Guidelines for Transmissible Spongiform Encephalopathies, Report of a WHO Consultation, Geneva, 23-26 March 1999) suggests some measures to be adopted following contact with potentially infected tissues:

ü Contamination of intact skin: wash thoroughly with warm water and soap (do not brush), rinse and dry.

ü Possible inoculation caused by deep cut or wound: encourage bleeding, wash thoroughly with warm water and soap (do not brush), rinse, dry and cover with waterproof gauze.

ü Contamination of ocular mucous: rinse thoroughly with physiological saline.

Potentially hazardous operations during the butchery of cattle and sheep

ü Stunning with captive bolt gun

ü Removal of head (SRM)

ü Evisceration

ü Side splitting

ü Removal of spinal cord (SRM)

ü Removal of intestinal pack (SRM)

ü Removal of backbone (SRM)

ü Taking of brain matter for testing

ü Colouring, storage and shipment of SRM

ü Cleaning and decontamination operations

Prevention of exposure to prions

Below are some suggested preventive measures based on current knowledge of the problem.

ü Inform workers as to the precise focalisation of infectious tissues.

ü Draw up written procedures and train workers.

ü Butcher separately those animals at greatest risk in terms of age, medical history, etc.

ü Limit the number of workers performing jobs at risk.

ü Concentrate removal of SRM at specific times, possibly at the end of the butchery cycle.

ü Define spaces in which to perform risky handling and SRM removal operations.

ü Identify the equipment, instruments and receptacles to be used solely for hazardous operations.

ü Minimise contamination of the working environment.

ü Immediately sanitise the working environment and instruments after handling SRM.

ü Use the PPE laid down in attachment IV of the Decree of 29 September 2000.

ü Rigidly enforce the fundamental hygiene rules established by legislation.

Personal Protective Equipment

The specific legislative reference for PPE to be used to handle SRM is Attachment IV of the decree of 29 September 2000, which lists:

Gloves – must have CE marking, as third category PPE, and conform to the provisions of technical standard EN 374, to be ascertained from appropriate documentation and certification issued by the manufacturer and the notified authority.

Protective clothing – must be classifiable as PPE and have CE marking, the manufacturer must be able to provide documentation certifying that clothing has undergone tests providing in the analysis methodology for the deployment of the bacteriophage Phi X 174 (an example of analysis methodologies are those pertaining to ASTMs F 1670-97, F 1671-97d, F 1819-97).

Protective equipment for eyes and face – must be of mask type and be classified as PPE, have CE marking as devices for “protection against liquid drops and squirts”, in compliance with technical standard EN 166, to be ascertained from appropriate documentation and certification issued by the manufacturer and the notified authority.

Protective equipment for respiratory tracts – must be classified as third category PPE and, as regards the possession of essential safety and health requirements, as per attachment II of Legislative Decree 475/1992, they must in particular perform the job of protecting against infectious agents. On this point manufacturers must provide users with specific documentation.

Decontamination of environments, instruments and equipment

Prions have shown themselves to be particularly resistant to common disinfecting procedures adopted in slaughterhouses. It is accordingly necessary to follow to the letter the disinfecting procedures known to be scientifically effective regarding the inactivation of the agent. In view of instruments usually present in slaughterhouses, the application of sodium hypochlorite 2% (20,000 ppm of active chloride) for at least 1 hour and possibly by immersion appears to be practicable. The hypochlorite solution must be prepared just prior to use to avoid inactivation. The employer must adopt any necessary procedures to manage chemical risks connected with the use of this chemical substance and inform workers exposed to contact and to inhalation of its vapours.

II. Verrucas suffered by meat processing/butchery workers

Verrucas are fleshy and hard outgrowths, benign in nature, caused by viral infections deriving from agents of the Papovavirus family. In particular, the verruca virus is called HPV: Human Papilloma Virus, a specific species for human and classified in group 2 of Attachment XI of Legislative Decree 626/94.

It is very common for verrucas to focalise on the hands. Transmission is especially by direct means. The squame of the verruca is however able to transmit the viral infection through those instruments and objects commonly used by different persons. Solutions of continuity of the skin or abrasions favour transmission. Self-inoculation of the contagion in various parts of the sufferer’s hands is common. The state of the sufferer’s immunity system has a strong bearing on the pathogenesis of the disease. The most common treatment for this disease is cryotherapy, but relapses are very common.

Epidemiological data from various sources have shown a high incidence of verrucas among workers in the meat industry, in particular among those handling fresh meat.

Transmission probably occurs through simple contact with working tools, but it is likely that cuts of meat, handled sequentially by several operators on production lines, may convey exfoliated cells containing the virus.

The skin, in continuous contact with the humid environment, loses a part of its immunity defences. This favours viral attacks and self-infection.

To prevent contagion the following is suggested:

- use of photoelectric or pedal-based taps and soap dispensers;

- compulsory use of disposable towels;

- use of systems for opening of doors using elbows;

- strictly personal use of knives and PPE;

- sanification of knives (handles in particular) and instruments;

- preference for photoelectric or pedal-based control of machine tools.

III. Flow of health data for identification of dangers

Actions to combat zoonoses are an example of interdisciplinary cooperation within the Prevention Department. Below are some proposed elements of an organisational model to be set up at the Department to coordinate preventive actions to combat zoonosis-related biological risk in pursuance of Legislative Decree 626/94 (M.Ghinzelli and F.Pezza No.3/1997 of Obiettivi e documenti veterinari - Edagricole-Bologna).

ASL Veterinary Services are technically and legally responsible for activities in which animals or products of animal origin are used and which are subject to zoonosis-related biological risks. These include:

ACTIVITIES MONITORED BY THE VETERINARY SERVICE AND EXPOSED TO BIOLOGICAL RISK

Owing to the presence of animals

· Breeding of animals, animal trading establishment, shows, trade fairs and markets, hippodromes, dog-racing tracks, etc.

· Breeding farms and seminal matter production centres

· Kennels

· Pounds

· Veterinary Surgeries, clinics and laboratories

· Zooprophylactic analysis laboratories, research centres and Institutes

Owing to the presence of animal by-products

· Butchery

· Meat processing

· Collection and transportation of milk

· Production of cheeses and dairy products

· Production, sale and use of feed

· Collection, transportation and processing of carcasses, waste of animal origin, butchery by-products and material at specific risk of BSE.

Existing legislation on health control exercised by the public administration on these activities is largely concerned with veterinary legislation. One objective is the prevention of zoonosis diseases, to be achieved through the health control of possible sources of infection, i.e. animals and relative products. The reporting of zoonoses is a legal obligation for the veterinarian.

A rational organisation of public prevention services should provide for a system for the flow of data from the veterinary service to other responsible organisations, putting at everyone’s disposal those elements needed to carry out one’s task.

To encourage and improve the dissemination of health data acquired by public veterinarians, below is a standard form proposed (O.D.V. No. 3/1997) for the reporting of zoonosis diseases detected in slaughterhouse and animal farming enterprises.

REGION ................................. U.S.S.L corporation No...........

VETERINARY MEDICINE SERVICE

To Head

of Veterinary Medicine Service

Forwarded for allowed purposes

REPORTING OF INFECTIOUS ZOONOSIC DISEASE

(Provisions as per articles 1 and 5 of Presidential Decree 320/54 and subsequent amendments, art. 254 of T.U.LL.SS. R.D. 1265 of 27/07/34, art 16 and attachment I chap. VIII point 42 b of Legislative Decree 286 of 18/4/94, and art. 4 of Presidential Decree 264 of 11/2/61 and communications to subjects obliged to enforce Legislative Decree 626 of 19 September 1994)

Disease reported: .............................................................……........ Suspected . Ascertained .

Enterprise............................................in Municipality of ........................................................

Slaughterhouse

No. animals/carcasses affected................. species and category ............................................................................... .....

of a delivery consisting of No. ............. animals from the animal farm enterprise........................................................ ...

...........................................................in the Municipality of ................................................................................................

Measures taken: seizure and destruction of ................................................................................................

delayed butchery of..................................................................................................

separate butchery of..................................................................................................

Other special measures

Animal farm

No. animals affected..................... species and category .........................................................

No. animals present in farm...........................

Animals recently introduced by........................................................ in Municipality of ..............................................

Measures adopted:

Seizure of farm

Quarantining of infected animals

Disinfection of pens

Other special measures

Analytical appraisals

It has not been deemed necessary to undertake further analytical appraisals

It has been deemed necessary to undertake the following appraisals via sending to.......................................................................

of the following material ...........................................................................................................

for the following reasons: .......................................................................................................

findings have not yet been received, but will be forwarded to the Veterinary Service as soon as they become available.

findings of further appraisals................................................................................……………

...............................................

Observations of use to the epidemiological study .....................................................................

.................................................

...........................................................

.......................................

The Head of the Prevention and Protection Service of the above enterprise, Mr..............................................

was immediately informed of the actions to take immediately within his jurisdiction.

Conducted at.................................. on ....../........../...........

The Veterinary Officer

Attachments No. ................ .............................................................................

The form contains an overview of regulations obliging the veterinarian to report the zoonoses.

The diagram below shows the possible recipients of the communication of the Head of the Veterinary Service and the flow of information to other authorities. The mutual zoonosis communication between the veterinary and public health services is a legal obligation.

Flow of health data for zoonoses detected by veterinarians

[flow chart p89]

Veter. Office

area B

Vet. Office

area A and C

Veterinary surgeon

Head of Veterinary Service

Regional epidemiological Observatory

Ministry of Health

Head of Enterprise’s prev. and prot. service

Enterprise’s competent physician

Public Health Service

Head of AUSL Veterinary Service

Industrial Medicine Service

Industrial Medicine Service (other AUSL)

Public Health Service (other AUSL)

Competent physician of AUSL staff

Head of AUSL prev. and prot. service

Competent physician of enterprise

Head of prev. and prot. service of enterprise

For animals or products from different AUSL

Immediate verbal communication *

Reporting to the Head of the Prevention and Protection Service of USL corporation is desirable because veterinary service staff are also exposed to the identified biological risk.

The diagram does not show the flow of health data for zoonoses detected in humans by physicians (hygienists, hospital physicians, GPs and competent physicians), which must be forwarded to Veterinary Services to search for the source of the contagion.

Reports from physicians and veterinarians must flow into a single database kept by the Prevention Department so as to gradually acquire elements pointing to the incidence of zoonosis diseases in the territory.

Also of fundamental importance is the acquisition of aggregate health data from regional organisations and the Ministry of Health to enable local prevention organisations to fix priorities for action and assess the state of human and animal health in their own area in relation to broader contexts.

With special reference to the application of Legislative Decree 626, industrial medicine services will obtain elements by which to judge biological risk evaluations prepared by enterprises in the sector and to request any corrective measures. When it acquires global information on the state of health of animals, Veterinary Services can intensify or ease off controls on given pathologies in farms or slaughterhouses, planning for further diagnostic studies, secondary surveys, analytical sampling and additional inspections.

[flow chart p91]

Health Ministry

Regional Services

Epidemiological Observatory

Industrial medicine services

Veterinary Services

International Organisations

General Medicine

Hospital Services

Universities, bibliographical research

Information and training given to prevention heads of enterprises

Control of risk evaluations supplied by enterprises

Assistance to enterprises

Worker information and training

Production of training and informative material

Information to GPs

Special inspections, serological surveys, etc.

Supervision

DEPARTMENT

Planning of actions

Ranking of priorities

IV. The Veterinary Officer and regulations on the subject of occupational health and safety

(Summary from Occupational Safety and Health: biological risk in Legislative Decree 626/94 and the role of Veterinary Services. - M. Ghinzelli, S. Pezza, il Progresso Veterinary no. 9/96)

Legislative Decree 626/94 entrusts employers with the task of developing the evaluation of biological risk and prime responsibility for prevention activity. ASL veterinarians are under the protection/supervision of their employer (the Director General) and subject to worker obligations fixed by regulations. In the same way the employer in control of plants subject to veterinary control shall assume responsibility for risks to which his employees are exposed.

Preventing the transmission of zoonoses from animals to humans is one of the main reasons for the presence of Veterinary Services in the National Health Service. The legislator has constantly reiterated veterinary jurisdiction in this sector and assigned consequent responsibilities. In particular, the obligation of reporting zoonoses is fixed in the Veterinary Police Regulations, by Legislative Decree 286/94, by the Consolidation Act for Health Laws, etc.

Legislative Decree 626 does not expressly assign to the Veterinary Officer any obligation or responsibility for its implementation. The obligations and responsibilities of the veterinarian for the prevention of zoonoses as provided for in existing regulations are not modified, but are now placed within a broader and more complex organisational context involving other protagonists in the sphere of prevention: employers, competent physicians and public supervisory services.

Without prejudice to the responsibilities assigned to each interested party by law, the Veterinary Officer should perform preordained tasks with the utmost care so as to enable other persons to fulfil their own role.

Briefly, the Veterinary Officer shall:

1) Identify risk

The Veterinary Officer that suspects or diagnoses a zoonosic disease in the animal farm, at the slaughterhouse or during any other phase of supervisory and inspection activity shall report it to the Head of the Service, notify the owner of the farm enterprise or production unit and carry out all the investigations needed to define the epidemiology of the event.

2) Prevent transmission to humans

The Veterinary Officer that detects a zoonosis or receives a report of a zoonosis in the territory under his jurisdiction shall act to prevent it from being transmitted to humans or other animals. Firstly he shall take any necessary Veterinary Police measures or adopt measures prompted by his experience and knowledge and by the rules of good veterinary practice. Once informed of the biological risk, the employer shall act. If he believes actions taken to be technically inadequate, the Veterinary Officer may notify Industrial Medicine services. Faced by a serious and immediate danger, he shall in any case adopt preventive measures, impeding the handling of animals or infected products or setting in place precautionary measures.

3) Supply information to other actors

When biological risk is assessed or reviewed by the prevention and protection services of enterprises in the sector, the Veterinary Service shall supply those elements in its possession regarding the epidemiological state of zoonoses in the territory, with special reference to past reports and information received from regional organisations, Zooprophylactic and scientific institutes report on the question.

These elements of appraisal can also be transmitted to Industrial Medicine Services, which are responsible for gauging the relevance of risk appraisals and preventive measures drawn up by enterprises. It may be desirable to forge continuing cooperation with the Industrial Medicine Service in order to express an opinion on biological risk appraisals.

4) Collaborate with physicians

The cooperation of the Veterinary Service with public medical services as regards specific preventive actions for different production contexts or for the handling of epidemiological investigations for cases of human zoonoses enables the ASL to optimise available human resources and perform global and qualified actions.

The competent physician appointed to carry out health monitoring on a firm’s workers may make use of elements supplied by Veterinary Services to steer his investigations on the basis of elements of zoonosic risk identified that production context.

5) Be involved in worker training

Legislative Decree 626/94 obliges employers to organise worker training on the subject of biological risk prevention. The veterinarian may be involved in the organisation and staging of meetings with workers by virtue of his specific technical knowledge and constant presence in production processes where there is a biological risk in terms of zoonosis.

The Veterinary Officer has no technical or legal jurisdiction for occupational risks other than biological risk, but may cooperate with authorities in a capacity as expert of the production sectors relating to the processing and conversion of products of animal origin.

PHYSICAL ERGONOMICS: RISKS AND PREVENTIVE MEASURES

Below are summaries of:

· some assumptions of field appraisals carried out in the sphere of research

· results of the ergonomic analysis in table form

· main lines of prevention.

The phases listed in the tables are described in successive risk profile datasheets, in which some ergonomics topics will be referred to.

The critical bibliography at the end of this volume seeks to guide the reader to sources and in-depth analyses.

EVALUATION OF RISK RELATING TO REPETITIVE MOVEMENTS AND EXERTIONS OF UPPER LIMBS

The acronym CTD (Cumulative Trauma Disorders) is used to collectively define musculo-skeletal syndromes of the cervical-brachial zone, characterised by fatigue, awkwardness, disability or persistent pain in the joints, muscles, tendons and other soft tissues with or without evident organic injuries. These cover a number of diseases or syndromes such as tendinitis and tenosynovitis, carpal tunnel syndrome, Guyon’s canal syndrome, epicondylitis, tendinitis of the rotator cuff and thoracic outlet syndrome. These alterations gradually evolve over periods of months or years as a result of repeated stress affecting a particular part of the body. The term “cumulative” is based on the theory that each repetition of an activity produces a trauma or the wear and tear of tissues and joints. CTDs have proved to be more frequent among certain categories of workers in which the working condition may be a primary, concausal or aggravating cause.

It should not however be forgotten that in the pathogenesis of such disorders some non-professional factors should be taken into account, such as traumas and fractures, some chronic, peripheral, circulatory pathologies, past neuropathies, age and anthropometric structure. The main factors relating to working activity are over-exertion, highly repetitive work, incorrect posture, insufficient recovery/rest times and/or, in association with previous factors, incentive systems based on production speed, the vibration of equipment, hand contact with cold or humid surfaces. Butchery and meat cutting activities typically have many of the above risk factors. The area of the provinces of Mantua and Modena has one of the highest concentrations in the country of animal farms and slaughterhouses. This has made it possible to conduct a detailed study on risks relating to the biomechanical overload of the upper limbs in this sector.

The study was conducted using an analytical appraisal method (estimate of the OCRA index, synthetic indicator of cumulative overload for the upper limb) proposed in light of international experiences and research by the EPM (Ergonomics, Posture and Movement) Research Unit of Milan, formed by specialists from the University Polyclinic and Polytechnic, the ASL and the Istituto don Gnocchi.

The analysis of Repetitive Movements was based on film taken of working phases, subsequently analysed in slow motion using a video recorder.

Cattle slaughterhouses

This section of the study took into consideration 2 types of cattle butchery activity: one “full throughput”, where production capacity is approximately 120,000 animals/year, the other “low throughput”, which despite having a relevant production of approximately 20,000 animals/year may be likened to the activity of the traditional slaughterhouse, at least with regard to the problem of Repetitive Movements.

It was possible to produce a schematic picture of appraisals in terms of synthetic risk index in both industrial-scale and low throughput slaughterhouses for each of the butchery phases. With regard to the cutting phase it should be pointed out that this activity is usually entrusted to workers doing piece-work, who work for themselves or in cooperatives.

The cutting of single butchered animals by small-scale dealers cannot be considered as an activity for assessing CTD owing to the limited nature of operations performed. It is however possible that incorrect postures, inadequate instruments and the lack of physiological recovery times may facilitate the emergence of such disorders also among these workers.

The OCRA index can only be applied for repetitive jobs in which insufficient recovery times constitute the main danger. Clearly the evaluation undertaken is indicative, non-exhaustive and non-generalisable, since it was assumed that each task was performed during the entire shift by the same operator. In practice, there is a rotation of workers doing different jobs, and this fact should be borne in mind when making appraisals of specific contexts.

The aim is to provide an example for evaluating main physical ergonomic aspects for different working tasks.

Special attention should be paid to the work of “piece-workers”. This activity is in itself very high risk and, as the analysis shows, is probably fatiguing in a short time because of work rates and the lack of adequate recovery times.

The synthetic chart shows the butchery production cycle for the phases in which the risk of CTD is believed to exist, comparing the full throughput with the low throughput slaughterhouse.

The first thing to note is that the high degree of automation involved in the transportation of animals or parts thereof has reduced or even totally eradicated risks deriving from the handling of loads. It should be stressed that working activity studied in the low throughput slaughterhouse does not entail repetitive tasks for the whole working shift, but only for half of it. Butchering indeed is only performed in the morning, for a duration of about 4 hours, while in the remaining 4 hours other activities are performed (cleaning, storage, loading). Deboning activity is not performed.

To better illustrate all operations requiring the repeated use of the upper limbs, the entire butchery production cycle is followed (numbered sheets), giving a brief description based on the “Borg scale” administered to surveyed workers. Using the Borg scale the worker describes and quantifies perceived exertion in the single actions of a task (technical actions) without the interpretation of external observers.

An additional risk factor comes from the microclimate. Measurements were taken in the full throughput slaughterhouse in the cutting unit and in a number of butchery workstations. Observations made in the specific report emphasise the influence exerted by the humidity of these environments on perceived heat comfort. Such working conditions may add to the risk of contracting CTD-type diseases.

It should be noted that in full throughput slaughterhouses OCRA indexes were in some cases higher than those in low throughput plants. The reasons for this may be the following:

1 – repetitive movements are performed for longer periods in full throughput slaughterhouses (the number of hours worked in the butchery phase is roughly double);

2 – the number of butchered animals was 6/7 times greater;

3 – operation times can be managed better in low throughput slaughterhouses (technical actions of longer duration);

4 - low throughput slaughterhouse workers often work in pairs accustomed to working with each other and specialising in a specific work phase. In full throughput slaughterhouses personnel tend to be rotated among the various workstations.

A piece of equipment that has considerably reduced risk is the mechanical dehider. Other solutions such as the electric “side pushing” machine or the mechanical arm for conveying sides of meat from storage units to trucks offer benefits for the handling of loads.

LIKELY DAMAGE

Data taken from the health reports supplied by enterprises are not uniform with regard to the evaluative aspects of CTD pathologies. This is due to a number of factors, such as the lack of attention paid by competent physicians to this problem compared, for example, with that of biological risk or noise. Moreover, the methodological study of situations that may cause musculo-skeletal disorders has been a recent development since the coming into effect of Legislative Decree 626/94. The results of health monitoring in full throughput slaughterhouses analysed here have however been significant: out of 64 workers examined in 1999, 11 complained of arthralgic disorders, and 8 of these suffered from bursitis, synovitis or tendinitis of the upper limbs.

Pig slaughterhouses

Two full throughput slaughterhouses and one low throughput slaughterhouse in the province of Modena were studied.

Personnel were employees or cooperative members. Workers to whom work was contracted out were not examined.

The ergonomics tables and subsequent profile datasheets give details of the results of the ergonomic analysis. These showed, for a number of working tasks, conditions of cumulative overload for the upper limbs, chiefly in the cutting phase, but also in some butchery positions, in both full throughput plants and low throughput plants where the cycle is not so parcelled out.

Damage: the presence of health monitoring in a number of slaughterhouses for some years, field investigations conducted by SPSAL Services and the reference regional centre and information supplied by enterprises and workers have led to the certification in the province of cases of occupational disease caused by cumulative overload of the upper limbs (already reported in the introduction), which in some cases have been recognised by INAIL.

q MANUAL HANDLING OF LOADS (MHL) AND ERGONOMICS OF BACKBONE POSTURE.

Legislative Decree 626/94 requires employers to undertake an evaluation of MHL risks, considering not only the weight involved but also the type of position assumed to perform handling operations, the frequency with which loads are handled, etc. The provisions of Legislative Decree 626 are based on the common nature of chronic, degenerative diseases of the osteo-articular system, common not only in the population at large but also in the workplace.

Most of these diseases are indeed found in specific working conditions, which play a precise causal or concausal role. In the meat industry in particular it was possible to single out some phases of the production cycle in which postural risks were present, with or without the manual handling of loads.

Cattle slaughterhouses

Where butchery lines are not endowed with aids, such as height-adjustable platforms, operators are forced to work adopting incorrect postures, such as bending, hyperextension, rotation and inclination of the spine, with or without the handling of loads.

When it is impossible to automate work phases, thus eliminating risk, it is necessary to act on the organisation of work and provide preventive solutions, worker training and information and health monitoring.

The survey conducted showed up risks deriving from the manual handling of loads especially in the deboning and cutting unit. Pieces handled, ranging from about 3 to 20 Kg each, are manually handled in the first phase, when part of the carcass is moved from the guideway to workbenches, and in the second phase, deboning and cutting.

In most of the workstations analysed, risk is not determined by the size of the load to be handled, since there are often suitable aids that reduce such a risk (mechanical handlers or arms, electric side pushing machine, hoisting tackles, guideways, etc.), rather workstations are such that it is impossible to perform work in a posturally correct manner.

As already mentioned, height-adjustable platforms are not always present. When the platform is stationary the operator is forced to adopt incorrect positions (excess bending and hyperextension of spine or leaning to one side to reach the part of the animal hanging up on the guideway).

The only way of keeping this risk under control is through postural education, with all workers given effective and timely training on the right physical ways of performing jobs.

Refer to descriptive datasheets on positions at risk for a detailed analysis.

Pig slaughterhouses

Let us run through some conclusions emerging from this study:

- in modern industry any residual risks are to be assessed on the ground, and possible improvements proposed, with special reference to manual handling at the end of the chain (hanging of cut hams) and the manual pulling or pushing of trolleys, collectors, meat sides hanging up on overhead cables;

- in the low throughput slaughterhouse under review workers’ backbones were generally subject to greater risk than in the full throughput plant, due to the greater handling of loads in the workplace and from one place to another, and to the layout of work zones (height of platforms compared with transportation chain), requiring greater and more prolonged bending.

PHYSICAL ERGONOMICS.

Illustrative tables.

Risk of cumulative overload for upper limbs.

Posture of backbone.

Manual handling of loads

in full throughput and low throughput cattle slaughterhouses

TABLE: ERGONOMICS IN CATTLE SLAUGHTERHOUSES

in full throughput pig slaughterhouses

TABLE: ERGONOMICS FULL THROUGHPUT PIG SLAUGHTERHOUSE (S.I.)

in low throughput slaughterhouses

TABLE: ERGONOMICS LOW THROUGHPUT PIG SLAUGHTERHOUSE (S.A)

NOTES

We refer the reader to the description of issues “RISK OF CUMULATIVE OVERLOAD FOR UPPER LIMBS - CTD” AND “MANUAL HANDLING OF LOADS”, as already illustrated: the same assumptions, criteria and operating and evaluative methods have been applied for both the bovine and pig butchery sector.

· The aim is to supply examples for evaluating the main aspects of physical ergonomics for different working tasks, not an evaluation that can be applied a priori to every slaughterhouse. In each working environment indeed it is necessary to take into account specific aspects, changes occurring over time and personal characteristics (subjective perception of workers and information gathered by the competent physician).

· The evaluation is accordingly indicative, non-exhaustive and non-generalisable.

The tables outline the riskiness of each phase.

To make things simpler and clearer, it was assumed that each task is carried out by the same worker throughout the shift, bearing in mind the actual breaks and pauses in the working day in both the full throughput and the low throughput slaughterhouse.

In practice, there is a rotation of workers doing different jobs, and this fact should be borne in mind when making appraisals of specific contexts : if rotation between different but equally risky tasks does not yield advantages, alternating with less repetitive tasks may have beneficial effects.

A full working day was of course assessed, covering butchery and cutting operations performed by different operators. This type of estimate of the physiopathology of cumulative overload is indeed more relevant than weighted averages for different exacting days in terms of working hours and commitments.

The tasks of slaughterhouse employees benefiting (partly at least) from incentives relating to the task performed were studied. This did not include casual labour or piece-workers in the narrow sense of the term in the pig sector. As already mentioned, third parties are resorted to for cattle meat cutting operations.

· The risk of cumulative overload for the upper limbs was studied using the method proposed by CEMOC-EPM (OCRA index – see TABLE on following page) for right-handed workers on the single line or on the left side of the chain. The index gives an integrated estimate of the frequency of technical actions, exertion (considered here in accordance with the HAL ACGIH 2000 method: subjectivity of the worker using the Borg scale and/or view of an expert SPSAL examiner), postures, additional elements and pauses or breaks.

The ERGONOMICS TABLES give the risk groups as per the table on the following page.

· The postural risk for the backbone was assessed for workers of average stature, using a criterion based on current Swedish guidelines, deducing the state of a cycle from the entire shift. One should stress the limits of this simplification, since, for instance, alternating an hour of continuous bending with an hour without bending is more onerous than 20 seconds of bending in every 40-second cycle. For a very tall worker the risk of a bent posture is usually greater. Finally, we should point out that for risk evaluation on the ground it is important to bear in mind draft European standards (draft prEN 1005-4:1998 E), for which the bending of the backbone of less than 20° is considered quite irrelevant (“green” area).

· Risk deriving from the manual handling of loads has been roughly estimated based on the criteria of the NIOSH working group, revised by EPM (in specific contexts it is however important to calculate Hoisting Indexes).

“OCRA” TABLE

OCRA Index and indicative evaluation groups for the risk of cumulative overload for the upper limb.

GROUP	Values OCRA		LEVEL OF RISK		Consequences		Classification criteria for the OCRA index and consequent preventive approach (1)
CLASSIFICATION IN RISK PROFILE (ERGONOMICS TABLES)
GREEN	<1	Risk absent		No consequence		RISK ABSENT OR NEGLIGIBLE
YELLOW/GREEN	1,1-2	Negligible risk The WMSDs forecast can be overlapped with that of the reference group		No consequence
YELLOW/RED	2,1-3,9	Slight risk Likely to be a slight excess (up to about 3 times) of WMSDs		- Recommended health monitoring - Suggest search for solutions to improve exposure conditions (especially for higher values)		SLIGHT RISK
RED	=>4	Risk present The higher the index the higher the risk. In addition to training and health monitoring, actions should be undertaken to improve workstations and/or work organisation.		Index values provide criteria for assigning priorities to actions. - Actions to re-devise tasks and workstations according to priorities. - Health monitoring and worker training/information.		RISK PRESENT

(1) Colombini D., Occhipinti E., Grieco A. “La valutazione e la gestione del rischio da movimenti e sforzi ripetuti degli arti superiori” (Assessment and management of risk deriving from repetitive movement and exertion of upper limbs) Franco Angeli, 2000. Page 177. OCRA: Occupational repetitive actions.

(2) WMSDs: work-related musculo-skeletal diseases.

Physical ergonomics tables

LEGEND

q OVERLOAD OF UPPER LIMBS

GREEN	risk absent or negligible
YELLOW	slight risk
RED	medium or significant risk
WHITE	risk not assessed

Boxes give body parts where risk is greatest (in descending order) on the basis of the postural analysis:

S	SHOULDER
G	ELBOW
P	WRIST
M	HAND

Also reported are possible additional postural risks for shoulders (DX or SN) and other elements of possible risk:

vibr.	focalised vibrations
pinch	fingertip hold
actions/min.	actions /minute of high frequency

(expressed where OCRA has not been calculated, this index already includes such calculations)

mic.p.

micropause > 10 seconds in short cycle, an element that helps reduce risk

q postural risk for backbone

estimated in part using the method suggested by Swedish regulatory guidelines:

GREEN	risk absent or negligible: backbone bent intermittently for a total duration of less than half the shift (bending for less than half of the duration of each short cycle)
YELLOW	possible risk: backbone bent(*) intermittently for a total duration of at least half a shift
WHITE	risk not assessed

(*) on the basis of draft European standards (draft prEN 1005-4:1998 E), bending in excess of 20° was taken into account.

q Risk deriving from manual handling of loads

approximate estimation based on criteria drawn up by NIOSH working group, revised by EPM (in specific contexts it is however important to calculate Hoisting Indexes).

GREEN	risk absent or negligible
YELLOW	risk present (1), to be quantified
WHITE	risk not assessed

(1) Tables show the main elements of risk encountered:

P	WEIGHT
FV	VERTICAL FACTOR height of hands from ground at beginning or end of hoisting
DV	VERTICAL DISLOCATION of weight
DO	HORIZONTAL DISTANCE between weight and body
DA	ANGULAR DISLOCATION (twisting of backbone)
Pr	quality of hold/grip not optimal
Frequency	high frequency of manual handling
Push/Pull	same manual handling

ACTIVITY: Cattle butchery and primal cutting – Elements for ergonomics analysis (see LEGEND)

Overload of upper limbs

Posture of backbone

MHL

WORK PHASES

OCRA DX

OCRA SX

Additional risk for shoulder

notes

Cerv. column Bent T > 50% cycle

Lumbar column Bent t > 50% cycle

Man. handling loads

IND

ART

IND

ART

IND

ART

IND

ART

IND

ART

1

Reception of cattle

2

Unloading

3

Lairage and walk to stunning box

4

Stunning

DX

DX

4.1

Fixing of hind leg to chain

DV

5

Jugulation and bleeding

6

Removal hind legs

P

S P

7

Dehiding with removal of milk gland or testicles

S M

S M

DX

8

Removal of forelegs and head

S P M

M

DX

P – Pr DA

8.1

Removal of forelegs only

P

P

8.2

Cutting of head and removal of tongue

P

S M

SN

9

Complete Dehiding (mechanical)

S P

DX

9.1

Complete Dehiding (manual)

SP M

S M

DX SN

DV

10

Evisceration of abdomen

SP M G

SM

DX SN

11

Opening of sternum

Vibr.

12

Thoracic evisceration

Pr

13

Splitting into sides

Vibr.

14

Finishing

P

S P M

P M

DX SN

14.1

Removal marrow

P

P

P M

P M

14.2

Cutting of cranium

15

Chilling

DV

16.1

Cutting and deboning anatomical cuts

S G P

S G P

DX SN

P – Pr DO

16.2

Cutting and deboning industrial cuts

S G P

S G P

DX SN

DA Pr - P

17

Cold storage

DV

18

Packing

19

Shipment of goods

TABLE: ERGONOMICS FULL THROUGHPUT PIG SLAUGHTERHOUSE ACTIVITY: full throughput pig butchery and primal cutting – Elements for ergonomic analysis. (see LEGEND)
	Overload of upper limbs				Posture of backbone		MHL
TABLE S.I. page 1 WORK PHASES	ocra DX	ocra SN	additional risk for shoulder	notes	head bent for t > 50% cycle	bent back for t > 50% cycle	manual handling loads
1. RECEPTION OF PIGS
2. UNLOADING
3. LAIRAGE AND SHOWERING
4. STUNNING or CARBONARCOSIS
5.1. JUGULATION (variable rate and posture)
5.2. INITIAL HOOKING
6. BLEEDING
7. SCALDING
8. DEPILATION
9. REMOVAL CLAWS
10. SCALDING
11. FINISHING
11.2 SECONDARY HOOKING (to scales)
12. EVISCERATION
12.0. REMOVAL OF BOWELS	SM	M	DX	Vibr
12.1. EVERSION OF TONGUE	SGPM		DX-SN
12.2.1. EVISCERATION OF ABDOMEN
12.2.1.1. START EVISC. AND REMOVAL OF ANCHETTA BONE	SMP		DX
12.2.1.2. EMPTYING OF OFFAL	SMG		DX				P
12.2.2. GUT DRESSING
12.3.1. THORACIC EVISCERATION (offal)							P-DA
12.3.2. OFFAL DRESSING
13. SPLITTING INTO SIDES.		GS	SN	Vibr
14. REMOVAL OF HEAD							P-DA-Pr
15. FINISHING
16.0. HEALTH MARKING
16.1. CLASSIFICATION OF SIDES

	Overload of upper limbs				Posture of backbone		MHL
TABLE S.I. page 2 WORK PHASES	ocra DX	ocra SN	additional risk for shoulder	notes	head bent for t > 50% cycle	bent back for t > 50% cycle	manual handling loads
17. PRIMAL CUTTING OF MEAT
17.1 REMOVAL OF PORK LARD	SGMP	GSP	DX
17.2 CUTTING OF BACKBONE USING SAW	GM	SGM	SN	Vibr.
17.3 REMOVAL OF LEG	SPM	G	DX
17.4 REMOVAL OF COLLAR	SM		DX
17.5 CUTTING OF LOINS	GPM						P-DA-Pr
17.6 REMOVAL OF “PANNARA” SHREDS AND SHOULDER	M						P
17.7 REMOVAL OF BELLY AND GULLET	SPM	G	DX
17.8 REMOVAL OF TRIMMINGS	GSPM	MG	DX
17.9 CLEANING AND REMOVAL OF LARD	GSM)	GM	DX				P (1 hand)
17.10 REMOVAL OF SECOND LARD AND COLLECTION OF GULLET		GMS	SN
17.11 HANGING OF LARD	GSM	GM	DX
17.12 CUTTING OF HAMS
17.12.1 CUTTING HOOVES/TROTTERS USING SHEARER		GPM	no	Vibr.
17.12.2. BRANDING AND CLEANING OF ANCHETTA BONE	PGM	GSP	SN
17.12.3. CUTTING OF ANCHETTA BONE	M	GPM	no
17.12.4. REMOVAL OF ANCHETTA BONE	SPM		DX
17.12.5. INSERTION OF HOOKS	MGSP	M	DX
17.12.6. HOOKING OF HAMS TO CHAIN	GSM	GSM	SN DX
17.12.7. TRIMMING OF HAM
17.12.7.1. SELECTION AND HANDLING OF HAMS
17.12.7.2. CLEANING OF ANCHETTA BONE AND AITCHBONE	PM		SN
17.12.7. 3. CUTTING OF PESCE
17.12.7.4. REMOVAL OF MEAT SHREDS	PM		SN
17.12.7.5. TRIMMING OF HINDQUARTERS	PM	GM	no
17.12.7.6. REVISION
17.12.7.7.1. CLEANING OF HAM TRIMMINGS AND SHREDS	M	GM	no
17.12.7.7.2. SECONDARY CLEANING OF HAM SHREDS		SGM	SN	pinch sn
17.12.7.8. HANG UP HAMS							P-FV-DV-DO-DA

	Overload of upper limbs				Posture of backbone		MHL
TABLE S.I. page 3 WORK PHASES	ocra DX	ocra SN	additional risk for shoulder	notes	head bent for t > 50% cycle	bent back for t > 50% cycle	manual handling loads
17.12.7.9. HANDLING OF SCALES
17.13. PROCESSING OF COLLAR
17.13.1. HANGING OF COLLAR	GMS	GM	DX				P-DV-DA
17.13.2. UNLOADING OF COLLAR TO BE PROCESSED	GM	GM	no
17.13.3. REMOVAL OF BARDELLE AND BRANDING OF COLLAR	PGM	PM	no
17.13.4. DEBONING OF NECK	GPM	GPM	no
17.13.5. COMPLETE REMOVAL OF BONES
17.13.6. TRIMMING OF COLLAR	GM	GPM	no
17.13.7. SORTING OF SHREDS
17.13.8. SORTING OF PROCESSED COLLAR							P-DO-DA
17.14. CUTTING OF LOINS
17.14.1. CLEANING LOINS	SPGM	GM	DX				P
17.14.2. CUTTING OF LOINS WITH RIBBON CUTTER	GM	M	no				P-DO-DA
17.14.3. HANGING OF LOINS							P-DV-DA
17.15. CUTTING OF SHOULDERS
17.15.1 DEGREASING SHOULDERS AND PREPARATION OF TROTTER RIND	SM	M	DX
17.15.2 REMOVAL OF RIND AND HOOVES	SPGM		DX
17.15.3 BRANDING OF SHOULDER BLADE	SGM		DX
17.15.4. REMOVAL BLADE-BONE (POSSIBLY WITH BAZOOKA)	M	M	no
17.15.5 DEBONING OF FORELEGS (SIFTERS)	PM		no
17.15.6. HANGING OF SHOULDERS.
17.15.7. ARRANGEMENT OF TROTTERS.
17.16. HANGING OF UNDERBELLIES			no				P-FV-DA
17. 17. GULLETS
17.17.1. FLAYING MACHINE	GSM	M	DX				P
17.17.2. HANGING OF GULLETS AND LARD
17.17.3. SORTING OF TRIMMINGS AND SHREDS

TABLE ERGONOMICS LOW THROUGHPUT PIG SLAUGHTERHOUSE

ACTIVITY: low throughput butchery and primal cutting of pigs – Elements for ergonomic analysis (see LEGEND)

TABLE S.A. page 1 WORK PHASES NB: a number of phases were not evaluated here (empty boxes) since they were largely the same as those already evaluated in full throughput slaughterhouses (previous table)	Overload of upper limbs				Posture of backbone		MHL
	ocra DX	ocra SN	additional risk for shoulder	notes	head bent for t > 50% cycle	back bent for t > 50% cycle	manual handling of loads
1. RECEPTION OF PIGS
2. UNLOADING
3. LAIRAGE AND SHOWERING
4. STUNNING
5.1. JUGULATION (variable rate and posture)
5.2. INITIAL HOOKING
6. BLEEDING
7. SCALDING
9. REMOVAL CLAWS
11. Manual FINISHING: here with removal of heads (15)	no. actions!		DX
11.2 SECONDARY HOOKING (to small scales).	44 actions/min.	18 actions/min		mic.p.
12.1. EVERSION OF TONGUE.	18 actions/min	81 actions/min.
12. EVISCERATION
12.2.1.1. START EVISC. AND REMOVAL OF ANCHETTA BONE (using knife)	SM	M	DX				P (hand sn) FV - DV (offal) FO - DA exertion “peaks”
12.0. REMOVAL OF BOWELS (by hand)
12.2.1. EVISCERATION OF ABDOMEN (9-12 Kg)
12.3.1. THORACIC EVISCERATION (offal: 4-5 Kg)
12.2.1.2. EMPTYING OF OFFAL
12.2.2. OFFAL
12.3.2. PROCESSING OF OFFAL
13. SPLITTING INTO SIDES, including heads,.	20 actions/min.	12 actions/min		mic.p.
14. REMOVAL OF HEAD HALVES (half a head: 3 Kg)	SGM		DX				FV-DV-DO-DA
15. FINISHING (here performed with removal of heads)
16.0. HEALTH MARKING
16.1. CLASSIFICATION OF MEAT SIDES

TABLE S.A. page 2 WORK PHASES	Overload of upper limbs				Posture of backbone		MHL
	ocra DX	ocra SN	additional risk for shoulder	notes	head bent for t > 50% cycle	back bent for t > 50% cycle	manual handling of loads
17. PRIMAL CUTTING OF MEAT
17.1 REMOVAL OF PORK LARD (with side hanging up)	72 actions/min.	27 actions/min.
17.2 CUTTING OF BACKBONE USING SAW	SM	DX		vibr mic.p.			P (1 or 2 hands) DO effort of shoulder sn
17.3 REMOVAL OF HAM (16-17 Kg)
17.4 REMOVAL OF COLLAR (3.5 Kg)
17.5 SECTIONING LOINS	50 actions/min	28 actions/min		mic.p			P (1 or 2 hands)-DO
17.6 REMOVAL OF “PANNARA” SHREDS AND SHOULDER
17.7 REMOVAL OF BELLY AND GULLET
17.8 REMOVAL OF TRIMMINGS	34 actions/min	61 actions/min
17.9 CLEANING AND REMOVAL OF LARD SHREDS
17.11 HANGING OF LARD
17.10 REMOVAL OF SECONDARY LARD SHREDS AND GATHERING OF GULLET
17.12 CUTTING HAMS
17.12.1 CUTTING OF TROTTERS (using knife)	SGM	M	DX				P-FV-DV-DA-DO
17.12.2. BRANDING AND CLEANING OF ANCHETTA BONE
17.12.3. CUTTING OF ANCHETTA BONE (using pneumatic shearer)
17.12.4. REMOVAL OF ANCHETTA BONE
17.12.6. HANGING OF HAMS (15-16 Kg)
17.12.7. TRIMMING OF HAM
17.12.7.1. SELECTION AND HANDLING OF HAMS
17.12.7.2. CLEANING OF ANCHETTA BONE AND AITCHBONE	SMP	M	DX
17.12.7. 3. CUTTING “PESCE”
17.12.7.4. REMOVAL OF MEAT SHREDS
17.12.7.5. TRIMMING OF HINDQUARTERS
17.12.7.6. REVISION
17.12.7.7.1. CLEANING OF HAM TRIMMINGS AND SHREDS
17.12.7.7.2. SECONDARY CLEANING OF HAM SHREDS
17.12.7.8. HANGING OF HAMS
17.12.7.9. HANDLING OF SCALES

TABLE S.A. page 3 WORK PHASES	Overload of upper limbs				Posture of backbone		MHL
	ocra DX	ocra SN	additional risk for shoulder	notes	head bent for t > 50% cycle	back bent for t > 50% cycle	manual handling of loads
17.13. DRESSING OF COLLAR
17.13.1. HANGING OF COLLAR
17.13.2. UNLOADING OF COLLAR TO BE DRESSED
17.13.3. REMOVAL OF BARDELLE AND BRANDING OF COLLAR
17.13.4. DEBONING OF NECK
17.13.5. COMPLETE DEBONING
17.13.6. TRIMMING OF COLLAR
17.13.7. ARRANGEMENT OF TRIMMINGS
17.13.8. ARRANGEMENT OF DRESSED COLLAR
17.14. CUTTING OF LOINS
17.14.1. CLEANING OF LOINS
17.14.2. CUTTING OF LOINS USING RIBBON CUTTER
17.14.3. HANGING OF LOINS
17.15. CUTTING OF SHOULDERS
17.15.1 DEGREASING OF SHOULDERS AND PREPARATION OF TROTTER	57 actions/min.	40 actions/min.					P-FV-DV-DO-DA
17.15.6. HANGING OF SHOULDERS.
17.15.2 REMOVAL OF RIND (vertical) AND HOOVES							P-FV-DV
17.15.3 BRANDING OF SHOULDER BLADE							P - DO
17.15.4. REMOVAL OF BLADE-BONE
17.15.5 DEBONING OF FORELEGS (SIEVES)
17.15.7. ARRANGEMENT OF TROTTER RIND
17.16. HANGING OF BELLIES
17. 17. GULLETS
17.17.1. FLAYING MACHINE
17.17.2. HANGING OF GULLETS AND LARD
17.17.3. ARRANGEMENT OF TRIMMINGS AND SHREDS
17.18. MANUAL HANDLING OF PIECES TO BE DRESSED							P-FV-DV-DO-DA freq.-PUSH PULL

ERGONOMICS:

PREVENTIVE MEASURES

In work phase datasheets mention has been made of preventive measures having positive ergonomic effects and of good practice datasheets disseminated by ISPESL. Below are fundamental criteria for a more complete and generalisable approach.

q REDUCTION OF THE RISK OF CUMULATIVE OVERLOAD FOR THE UPPER LIMBS

Aims.

The aim is to reduce the risk of cumulative overload for the upper limbs, as confirmed by variations to evaluation indexes and by the drop in the incidence of work-related pathologies (cumulative trauma diseases or disorders), with incidence tending to move closer to that of the population at large.

Criteria.

The following indications are given for this purpose:

1. FLOW DIAGRAM OF PRIORITIES FOR REDESIGNING OR REORGANISING ACTIONS, of use in reducing cumulative overload (by Colombini D. et al., op. cit. “Evaluation and management of risk deriving from repetitive movements and exertion of upper limbs”).

2. A SUMMARY of an interesting document by virtue of its cultural and practical approach: “Ergonomic program management guidelines for meatpacking plants”, OSHA 1991.

3. A CHART we have added to the above, drafted after having consulted BUTCHERY and CUTTING workers and enterprises.

FLOW DIAGRAM OF PRIORITIES FOR REDESIGNING OR REORGANISING ACTIONS

(by D. Colombini et al. “Evaluation and management of risk deriving from repetitive movements and exertion of upper limbs” Franco Angeli, 2000)

[flow chart p110]

CYCLICAL STUDY OF RISK FACTORS
1. IDENTIFICATION OF ACTIONS REQUIRING USE OF STRENGTH	REDUCE THE USE OF STRENGTH - by introducing equipment - by improving existing equipment - by improving work posture
2. IDENTIFICATION OF ACTIONS REQUIRING EXTREME POSTURES	RESTRUCTURE WORKPLACE IN ORDER TO KEEP POSTURE AND MOVEMENTS BELOW 50% OF THE MAXIMUM ARTICULAR RANGE
3. IDENTIFICATION OF HIGH FREQUENCIES OF TECHNICAL ACTIONS	REDUCE, BUILT IN WITH THE CYCLE, THE NUMBER OF TECHNICAL ACTIONS - avoiding futile actions - distributing actions more evenly between the two limbs - reducing the repetition of identical high frequency actions - reducing subordinate actions - increasing the no. of workers
4. IDENTIFICATION OF ADDITIONAL RISK FACTORS	REDUCE THE HARMFUL EFFECT OF ADDITIONAL FACTORS - using more adequate work equipment
5. IDENTIFICATION OF INADEQUATE FUNCTIONAL RECOVERY PERIODS	BRING BREAKS AND/OR ALTERNATIVE WORK INTO LINE WITH REPETITIVE WORK PERIODS - by increasing recovery times - by distributing recovery times more evenly

2. SUMMARY…

…from “ERGONOMIC PROGRAM MANAGEMENT GUIDELINES FOR MEATPACKING PLANTS”

U.S. Department of Labor

Occupational Safety and Health Administration

1990 - OSHA 3121 reprinted 1991 - OSHA 3123

Notes freely translated from the text and summarised by SPSAL north Az. USL MO – R.G., not revised by the Authors – editor’s notes in italics

The Osha document, starting from the table of contents, is of special interest due to its origin and aims. It has been drafted in light of the (centuries long) experience of the meat industry in order to tackle and solve physical ergonomics problems in the sector. Integration of the contents of this document with the legislative situation in Europe (Legislative Decree 626/94) makes it possible to reveal significant and substantial similarities between the two approaches.

GUIDELINES FOR THE MANAGEMENT OF AN ERGONOMIC PROGRAMME IN THE MEAT INDUSTRY

...from the index:

INTRODUCTION

I. COMMITMENT REGARDING THE MANAGEMENT AND INVOLVEMENT OF WORKERS

A. COMMITMENT ON THE PART OF TOP MANAGEMENT.

B. WRITTEN PROGRAMME.

C. INVOLVEMENT OF WORKERS

D. REVIEW OF PROGRAMME AND PERIODICAL CONTROLS

II. PROGRAMME ELEMENTS

A. ANALYSIS OF WORKPLACE

B. PREVENTION AND CONTROL OF RISKS

1 PLANT ENGINEERING CONTROLS

2 WORK METHOD CONTROLS

3 PERSONAL PROTECTIVE EQUIPMENT

4 ORGANISATIONAL CONTROLS

C. MEDICAL MONITORING

D. TRAINING

1 GENERAL TRAINING OF WORKERS

2 SPECIFIC TRAINING OF WORKERS BY JOB

3 TRAINING FOR SUPERVISORS

4 TRAINING FOR MANAGERS

5 TRAINING FOR DESIGNERS AND MAINTENANCE WORKERS

6 TRAINING OF MEDICAL STAFF

III. DETAILED GUIDE AND EXAMPLES.

A. RECOMMENDED PROGRAMME FOR ERGONOMIC ANALYSIS OF WORKPLACE.

1 SOURCES OF INFORMATION

2 SCREENING GRIDS

3 ERGONOMIC ANALYSIS OF RISKS BY JOB

4 PERIODICAL ERGONOMIC REPORTS

B. PREVENTION AND CONTROL OF RISKS: EXAMPLES OF PLANT ENGINEERING CONTROLS FOR THE MEAT INDUSTRY.

1 DESIGN OF WORKPLACE

2 PLANNING OF WORK METHODS.

3 TOOLS AND HANDLES

C. MEDICAL MANAGEMENT PROGRAMME FOR PREVENTION AND TREATMENT OF CTD (CUMULATIVE OVERLOAD DISORDERS) IN MEAT PROCESSING PLANTS

…brief notes taken from text…

I. COMMITMENT REGARDING THE MANAGEMENT AND INVOLVEMENT OF WORKERS

A. COMMITMENT ON THE PART OF TOP MANAGEMENT.

Everybody should be aware of a serious commitment to the problem on the part of company management. The programme should be tackled by a team of ergonomic experts, steered by “top management”.

The programme should be characterised by the inclusion of prevention in daily activities, uniting health and safety protection with productivity.

Resources needed for the ergonomics programme should be allocated. Each manager, supervisor and worker must know what is expected of him with reference to the ergonomics programme.

B. WRITTEN PROGRAMME.

Extended to the entire working environment, with the definition and communication of aims to all staff.

C. INVOLVEMENT OF WORKERS.

Receive suggestions from workers involved, who can freely express opinions on measures adopted (feedback).

Take care of procedures for the timely reporting of disorders (CTD) so as to be able to act promptly at medical and technical levels.

The Health and safety committee (Translator’s note: in Europe, and in light of LD 626/94 the Prevention and Protection Service, with the participation of WSR (workers’ safety representative) and trade union representatives for respective powers) must receive information on areas where ergonomic problems exist, analyse this information and recommend corrective measures.

A team (or supervisors) must be trained to recognise and analyse jobs in which ergonomic problems are present and to come up with solutions.

D. REVIEW OF PROGRAMME AND PERIODICAL CONTROLS.

Top management meetings (at least every six months) are recommended for assessing the aims of the ergonomics programme, based on the following input:

- analysis of accident or disease index trends

- staff reports

- workplace comparisons before/after action

- review of appraisals

- recording and updating of improvement measures adopted

The results of these appraisals should be written down, shared by managers and communicated to personnel.

New aims emerging from these evaluations should be shared by workers. The shortcomings pointed up should be rectified.

Management should review the ergonomics programme every three months to check that aims are achieved and to discuss changes.

II. PROGRAMME ELEMENTS

A. ANALYSIS OF WORKPLACE

Analysis and processing of epidemiological data on injuries and CTD diseases (collected by competent physician)

Ergonomic analysis of job tasks (for example proposed method: epm cemoc)

Comparisons of risk indexes before and after intervention (for example OCRA before and after redesign).

Identification of low risk activities for workers possessing limited skills.

The evaluation should be updated when changes occur, and should be carried out again at least every year, to point up new or neglected risks and improvements made in the redesigning and performance of activities.

To encourage necessary worker involvement, planned meetings should be supplemented by “suggestion boxes” or questionnaires (for health monitoring anamnestic questionnaires on risks and disorders could be renewed).

B. PREVENTION AND CONTROL OF RISKS.

1. PLANT ENGINEERING CONTROLS

Where possible, redesigning aimed at “adapting work to man” instead of “forcing man to adapt to work” is always the most effective measure: changes to the workplace, methods and instruments designed to eliminate excessive movements, over-exertion, incorrect postures (extreme, incorrect or static), reduce repetitiveness, reduce the use of some types of hold (grip, pinch) and compression.

Measures include the adaptability of the workplace on the basis of individual anthropometric traits (rigid design of the workplace for a “standard worker” is incorrect), and sufficient space to perform actions, especially when cutting instruments are used.

2. WORK METHOD CONTROLS

Definition of procedures understood and applied by managers and workers:

a - Training of workers on appropriate techniques:

- cutting methods to improve posture and reduce strain on limbs

- care over knives, sharpening (editor’s note: workers and unit heads have suggested to us that an apprentice sharpener should use only flint lock, avoiding futile and overloading repetition, while for beginners domestic-type line sharpeners are recommended)

- correct hoisting methods

- correct use and maintenance of electrical or pneumatic equipment

- correct use of ergonomic stations and equipment

b - Period of adaptation for newly hired or returning workers.

- Adequate time frames, pauses and an instructor and expert supervisor are required.

c – Monitoring

- Regularly check to ensure that suggested methods are applicable and applied; otherwise, ask why not and study possible solutions.

d – Adaptation and changes.

- Speed of lines

- Allocation of workers

- Type, size, weight or temperature of pieces worked.

3. PERSONAL PROTECTIVE EQUIPMENT

When choosing PPE for meat processing work bear in mind the following factors:

- usability: avoid the use of more than one pair of gloves. Gloves that are too thick can reduce circulation and sensitivity. The glove must enable the worker to have a good grip of the knife and protect against injuries

- protection against extreme cold in order to protect joints

- (splints-braces, etc. do not constitute PPE: see medical section)

- other necessary PPE (for example reinforced aprons) must not increase anti-ergonomic aspects.

4. ORGANISATIONAL CONTROLS.

Designed to reduce the duration, frequency or severity of exposure to ergonomic stress, for instance:

- reduce the individual number of repetitive actions, limiting overtime and/or reducing the line speed

- introduce breaks

- raise the number of workers in critical positions, for instance involved in hoisting

- use worker rotation with caution, as a preventive measure and not (only – editor’s note) “if necessary” when disorders occur. Careful appraisal is needed to ensure that rotation does not always put a strain on the same muscle-tendon structures

- allocate “reserve” workers to fill in for absentees on the line

- job enlargement (same observations as those for rotation hold good)

Programmes for maintenance of equipment to reduce ergonomic stress:

- Programme for evaluation and routine maintenance of electrical equipment, saws, etc.

Possible measuring of vibration.

- Availability of replacement equipment and periodical and specific intervention and in event of trouble.

- Scheduling of sharpening operations.

Programming of cleaning to avoid slippery conditions.

C. MEDICAL MONITORING

(omission: this part proposes active health monitoring (periodical and general), and passive monitoring at the motivated request of workers informed about risks and damage, as well as local therapeutic measures. In our context preventive and regular monitoring is provided for or foreseeable, in addition to extraordinary inspections based on motivated requests. The therapy is carried out elsewhere)

D. TRAINING

1 GENERAL TRAINING

2 SPECIFIC TRAINING BY JOB

Training is of fundamental importance in an ergonomic programme. Only workers that are informed can be actively involved.

The training of workers must be planned with the use of qualified staff. Using suitable language it is necessary to present an overview of possible risks and disorders, causes and symptoms, preventive and therapeutic measures. It is necessary to assess the efficacy of the training programme in terms of learning and behavioural change.

An annual review-update would be desirable.

Newly hired workers should be given practical training on different lines, covering the use and treatment of knives and equipment, hoisting techniques and use of protective equipment.

Training should then continue in the workplace.

3 TRAINING FOR SUPERVISORS

In addition to general training, workers must be trained to recognise risks and in turn to train newly hired workers.

4 TRAINING FOR MANAGERS

On responsibilities and related ergonomic issues.

5 TRAINING FOR DESIGNERS AND MAINTENANCE WORKERS

On design and the ergonomic adaptation of workplaces.

6 TRAINING OF MEDICAL STAFF

On participation in risk evaluation and health monitoring.

III. DETAILED GUIDE AND EXAMPLES.

A. RECOMMENDED PROGRAMME FOR ERGONOMIC ANALYSIS OF WORKPLACE.

1. SOURCES OF INFORMATION

Prevalence and incidence of CTD.

2. SCREENING GRIDS

Ergonomic analysis of workplaces (for example Epm Cemoc method)

Analysis also covers risks for the back and multiple risks.

3. ERGONOMIC ANALYSIS OF RISKS BY JOB

4. PERIODICAL ERGONOMIC REPORTS

In-depth studies, revisions over time, analysis of trends.

B. PREVENTION AND CONTROL OF RISKS: EXAMPLES OF PLANT ENGINEERING CONTROLS FOR THE MEAT INDUSTRY.

1. DESIGN OF WORKPLACE

some examples to reduce extreme postures:

- work tables/areas with adjustable heights

- rotating cutting tables to reduce excessive exertion:

- adjustable equipment

- appropriate placement of “waste” (tape, baskets, etc.) to avoid the throwing of products or waste materials

- mechanical or electrical aids for operations requiring greatest exertion

- suspension of heavy equipment to reduce repetitiveness:

- branching of lines, lower line speeds to slow down some operations

2. PLANNING OF WORK METHODS.

Identify a scale of risks and define “low or high risk” jobs with the collaboration of the health officer (use of OCRA index, in our view very exhaustive, or HAL ACGIH, involvement of competent physician);

Examples to reduce incorrect postures:

- train workers to work using both hands

- follow “NIOSH” criteria for the manual handling of loads

To reduce exertion:

- automatism (e.g. in deboning)

- mechanical aids in deboning and hoisting

- electrical equipment

- articulated arms and counterweights to help with use of equipment

- ensure that meat is not frozen

To reduce repetitiveness:

- raise the number of workers performing a specific job

- job enlargement: combine in sequence a number of brief cycles to obtain a longer cycle (the concept of engineering “island”: only after appraisal can one see if the situation has improved)

- automation

- where possible, allow the self-management of work rates

- adequate breaks

4. TOOLS AND HANDLES

Examples of criteria for choosing of equipment:

- choose specific equipment or knife for each task

- design or choose tools that do not require extreme or uncomfortable postures

- choose grips that have surfaces grooves or edges/corners

- choose tools that can be used with both right and left hand or supply suitable tools for right- and left-handed workers

- triggers must be pulled by two or more fingers without exertion

- handles and grips must exert an even pressure on the muscular part of the palm surface, avoiding localised pressure

- choose lightweight tools and counterbalance those that weigh more than 1 or 2 pounds

- choose electrical or pneumatic instruments that produce little vibration. The application at one’s own initiative of “anti-vibration” devices to grips is not recommended.

Editor’s note: in the United States knives with the blade inclined to the line of the grip are common. These reduce the ulnar deviation of the hand during some cutting operations. The handles of other common tools also used in our country are endowed with a soft covering (sorbothane) to reduce pressure on the palm. Different opinions exist as to the appropriateness of such solutions, for which reason we invite workers to experiment this directly. The same holds true for electric knives, which on the basis of our experience may reduce wrist exertion but overload the shoulder.

C. MEDICAL MANAGEMENT PROGRAMME FOR PREVENTION AND TREATMENT OF CTD (CUMULATIVE OVERLOAD DISORDERS) IN MEAT PROCESSING PLANTS

(omission; epm cemoc and others propose preliminary operative forms and criteria)

3. FURTHER CONSIDERATIONS BASED ON OUR EXPERIENCE WITH WORKERS AND ENTERPRISES

A common prerequisite for preventive measures is the correct evaluation of risks.
Preventive measure	Motives	Constraints and requirements
INFORMATION EDUCATION TRAINING of workers	There are other priority prerequisites: a well-trained cutting, deboning and sharpening worker performs fewer actions with less exertion. The speed of the chain remaining equal, this translates into a reduction of the risk of cumulative overload. Training must be accompanied by information on risks and damage and include learning and behaviour tests.	It is necessary to have instructors, time dedicated to the topic, initial training outside the chain (an instructor and time to learn well are needed)
PARTICIPATION	The cultural approach adopted by OSHA guidelines and European Directives focus on the responsible involvement of all levels in the management of ergonomic problems. Rotation criteria for more or less differentiated tasks, behaviour, choice of tools for personal use, such as knives, cannot disregard such an approach. It is well known that “work satisfaction” is a determining factor for mental and physical wellbeing. The dogmatic enforcement of rigid “ergonomic” models could have counterproductive effects also in psychosomatic terms (muscular tension, which could aggravate overload).	Time and space for brief but regular ad hoc meetings. Opportunities to communicate and consult with WSRs and heads
ERGONOMICS: DESIGN OR CORRECTIVE MEASURES	Innovative measures often respond to economic, hygienic and ergonomic needs: automation of the handling of loads, automation, etc. Machine work rates can however have a considerable effect on cumulative overload: less heavy fatigue, more speed.	Organisational coherence between productivity and health protection.
ORGANISATIONAL COHERENCE	Training, rational rotation, reduction of exertion and the elimination of futile actions must go to reduce the risk of overload, not to speed up work rates, otherwise the preventive impact is lost. If may be necessary to add workers in the most critical positions.	To maintain and develop limited profit margins in the meat industry one should concentrate not on maximising work speed but on other ways of increasing productivity and enhancing the product: e.g. automation, quality of meat, cuts and processing; sectoral production and vertical integration, secondary processing, up to the retailing phase…
BREAKS	According to reviews and studies conducted by Epm-Cemoc the ideal objective in terms of musculo-tendinous rest time is to have breaks from repetitive work performed over several hours (a break of 1/5 or 1/6 of the time worked for every overloaded hour)	Study and negotiate brief but frequent and rational breaks from work
HEALTH MONITORING by the competent physician	We believe this to be an essential additional measure: - in addition to estimating risk indexes, it is fundamental to systematically gather data on the global epidemiological status of workers to assess and monitor over time these work-related in specific areas – early diagnosis is a secondary form of prevention - prevention can also be customised through a judgement on suitability, with additional precautionary measures, replacements and restrictions where necessary, and unsuitability in a few cases.	The competent physician must be involved and play a part in evaluating risk management. He must be kept up-to-date on the issue and devote additional time beyond that necessary for medical examinations

q REDUCTION OF THE RISK OF BACKBONE OVERLOAD ASSOCIATED WITH INCORRECT POSTURES OR MANUAL HANDLING OF LOADS

Cattle slaughterhouses

PREVENTIVE SOLUTIONS (Correct postures)

Bending of trunk with or without the handling of weights	- Do not keep legs straight and back bent forwards - Bring weight close to body and flex knees - Keep one foot in front of the other to improve balance - Do not lift weight in jerky fashion - Preferable for two workers to lift large weights - Avoid carrying weight with one arm, split into two loads if possible and hold with both hands
Hyperextension of spine	- Avoid arching the back backwards and creating an elevation below the feet so as to work with arms below the height of shoulders
Rotation of trunk	- Place feet in the direction of movement so as to turn the whole body and not only the trunk

EXAMPLE OF A PRACTICAL SOLUTION WITH REFERENCE TO MUSCULO-SKELETAL DISORDERS

SOLUTION TITLE	Loading of sides of meat onto truck using mechanical arm
TASK	Transport meat side onto truck for commercial distribution
PROBLEM	Manual handling of load; over-exertion of backbone and upper limbs
SOLUTION	Handling of meat side using telescopic mechanical arm capable of hanging the piece up directly inside the truck
COSTS/BENEFITS	Elimination of the risk of manual hoisting

Pig slaughterhouses

Less space is devoted to this topic compared with repetitiveness because it has already been dealt with in the previous paragraph on cattle slaughterhouses (where the problem is partially overlapping and more relevant because of the larger weights and sizes of sides and cuts) and for the following reasons:

1. – Industrial-scale plants have done much over time to reduce these risks, experimenting and validating improvements. Some good practice solutions are disseminated in Ispesl datasheets.

2. - Guidelines on the enforcement of Legislative Decree 626/94 by the Committee of Regions and autonomous Provinces with the collaboration of ISPESL and ISS contain many recommendations in relation to the manual handling of loads. A lot of material is currently available on evaluations and preventive measures (for example, the Environment and Work monograph with software for calculating hoisting indexes).

We recall here the need to assess and act on critical points of residual risk in full throughput lines, from mechanical handling to the end of the chain.

In low throughput plants some improvements may be based on industrial-scale experiences (for example the suspension of heavy equipment). If this is not possible, it will be necessary to act on organisational aspects (sufficient worker numbers, rotation, etc.) and on training.

Ergonomics: legislation

Legislative Decree 626/1994, implementing Directives of the European Union, deals with ergonomics and working conditions (principles of ergonomics, manual handling of loads, video terminals, Personal Protective Equipment, equipment and machines, workplaces, etc.).

Of special importance for the topics dealt with here are:

· article 3, sub-section 1, letter f:

“General measures for health protection and safety of workers are:

(omission) observance of ergonomic principles (1) when designing workplaces, choosing equipment and defining working and production methods, also with a view to attenuating monotonous and repetitive work”.

· Title V on the manual handling of loads. Art. 48 reads: “The employer shall adopt necessary organisational measures or resort to appropriate means, in particular mechanical equipment, to prevent the need for workers’ manual handling of loads (...) If it is not possible to avoid manual handling, the employer shall adopt necessary organisational measures, resort to appropriate means or provide workers with adequate means so as to lessen risks involved in the manual handling of loads, as per attachment VI (…) If the manual handling of a load by a worker cannot be avoided, the employer shall organise working areas so that handling is as safe and healthy as possible… (omission).

(1) For the drawing up of ergonomic principles, the Guidelines for the enforcement of Legislative Decree 626/94 define ergonomics as “the application of scientific information regarding human beings in relation to the design of objects, systems and environments destined for personal use (Pheasant, 1991)”. The guidelines, after having stressed the increase in occupational diseases affecting the neuromuscular and skeletal system, generally caused by static or dynamic muscular overload, incorrect postures or localised pressure with reference to the way of designing and constructing work cycles, cite operative and evaluative references also reported by this publication (monograph November-December 1996, published in “Medicina del Lavoro”) and indicate the main Italian UNI, European EN and international ISO standards on the subject. Of particular importance for the topics dealt with here are:

- UNI 8459: Ergonomics of work systems. Basic terminology and general principles (ISO 6385-81).

- UNI 10120: Definition and methodologies for measuring essential anthropometric variables for ergonomic design. See also European standards EN 547-1,2,3; EN 614-1.

- UNI EN 26385: Ergonomic principles for the design of work systems (ISO 6385).

- ISO 10075 and 10075-2 : mental workload (extension 6385).

- ISO/CD 11226: ergonomics; evaluation of working posture.

- ISO/CD 11228: ergonomics, manual handling of loads; hoisting and transportation.

Presidential Decree 459/1996, implementing the “Machinery Directive”, refers to Attachment 1, where reference is made to the observance of ergonomics principles: “under normal conditions the discomfort, fatigue and mental tension (stress) of the operator must be minimised, bearing in mind the principles of ergonomics”.

While the desirability or need for more detailed laws on the principles of ergonomics is a matter of international conjecture, the above guidelines and Italian law lead one to conclude that good practice standards may be enforced to guarantee the observance of ergonomic principles as required by Legislative Decree 626/94 (good practice standards are European EN standards or harmonised UNI-EN standards for the machinery Directive; Italian UNI standards and international ISO standards should also be deemed as such according to the aforementioned Guidelines).

MICROCLIMATE

General aspects and survey in a bovine cycle

1. Introduction

The characteristics of the microclimate of working environments in the meat industry are such that it is not necessary to make the distinction between full throughput and low throughput slaughterhouses. The decision was taken to measure critical values for this type of risk in a full throughput slaughterhouse representing all the most significant variables that can have a bearing on workers’ health.

To measure thermohygrometric parameters a microchip-based control unit, ANADATA MICROCLIMA, made by the company LSI was used: this instrument is able to calculate, on the basis of acquired data, synthetic indexes for assessing environments, broken down into MODERATE, COLD or HOT: The following measurements were obtained:

· Dry bulb temperature [°C]

· Wet bulb temperature:

- forced ventilation [°C]

- natural ventilation [°C]

· Relative humidity [%]

· Partial pressure of vapour [KPa]

· Absolute air velocity [m/sec]

· Global heat temperature [°C]

· Mean radiant temperature [°C]

2. Description of environments and of workers’ activities.

Working conditions are characterised by a cold and humid microclimate whose effects must be evaluated on the basis of moderately to very intense working activity.

Conditions depend on the type of job being performed. An initial measure was taken in a work area where small pieces are cut. The setting was a large room, about 50 metres in length, endowed with microdiffusion air conditioning, which does not generate draughts and keeps air temperature at 10°C. The setting may thus be defined as MODERATELY COLD.

The type of work may be considered as medium-heavy, consisting of the handling of pieces of meat usually weighing over 10 kg and its cutting into smaller portions.

Clothing is medium-light.

Measures were then made along the dehiding line in the butchery room: this environment, endowed with a heating system only, communicated with outside (kill area), so temperatures are directly influenced by outside temperatures. In the winter temperatures are kept higher by heating. The main problem of these areas appears to be that of relative humidity, which is high due to the continuous use of water for cleaning purposes. In this case it is more difficult to make an evaluation since we are beyond the limits laid down for cold environments, and yet it is not quite correct to talk of a moderate environment. Working activity is variable and mostly moderate in intensity.

Clothing adopted is similar to that of environment 1.

3. Evaluation of the microclimatic environment

As already mentioned work environments can be broken down in thermohygrometric terms as follows:

· MODERATE

· HOT

· COLD

The work areas in question lie somewhere between COLD and MODERATE environments.

COLD environments are characterised by conditions that require the intervention of the thermoregulation system in order to limit the potential drop in temperature of different parts of the body. These may be defined as follows:

· environment with low operating temperatures (approximately 0÷10 °C for moderately cold environments, less than 0 C° for severely cold environments);

· moderate spatial and temporal variability of conditions;

· quite uniform physical activity and type of clothing worn.

Reliable and widely applicable evaluation criteria are not currently available. The literature suggests two criteria:

- HEAT INSULATION method for REQUIRED CLOTHING

The method is based on checking the acceptability of the heat resistance of clothing to maintain the body’s heat equilibrium. Two parameters are defined:

· a minimum I_min value of resistance of the clothing, such as to maintain the heat equilibrium of the body despite a moderate sensation of cold (associated with a vasoconstriction of the capillaries such as to bring skin temperature down to around 30°C);

· an optimal I_neu value to maintain heat equilibrium, so that skin temperature and perspiration record normal thermal neutrality values.

In practice, here is also an upper limit for heat insulation, caused by the fact that clothing should not impede the worker’s movements. Too big an increase in optimal clothing may also lead to excess sweating which, soaking clothes, poses the danger of considerably reducing heat resistance.

- method based on the WIND-CHILL INDEX (and CHILLING TEMPERATURE related to the WCI), making it possible to assess environments in terms of their capacity to produce local chilling with reference to specific body parts (hands, legs, head), having the highest external surface/volume ratios. This method is applicable in particularly severe, cold and ventilated environments. It represents the amount of thermal power per unit area lost by a cylinder of a size comparable with that of the body parts most subject to freezing, and is evaluated on the basis of following criterion:

- WCI 1000 kcal/h m2 TCH -12 (°C) Sensation of intense cold

- WCI 1200 kcal/h m2 TCH -21 (°C) Limit for quick freezing risk

- WCI 1400 kcal/h m2 TCH -30 (°C) Freezing after 20 minutes of exposure

- WCI 1600 kcal/h m2 TCH -40 (°C) Freezing after 15 minutes of exposure

- WCI 1800 kcal/h m2 TCH -49 (°C) Freezing after 10 minutes of exposure

- WCI 2000 kcal/h m2 TCH -58 (°C) Freezing after 8 minutes of exposure

- WCI 2200 kcal/h m2 TCH -67 (°C) Freezing after 4 minutes of exposure

- WCI 2400 kcal/h m2 TCH -76 (°C) Freezing after 1 minutes of exposure

MODERATE environments are those requiring a moderate degree of intervention of the thermoregulation system, thus it is easier to obtain the state of homothermy in the worker. They may be defined as follows:

· uniform environmental conditions that do not vary greatly over time;

· absence of local heat exchanges between worker and environment having significant effects on global thermal equilibrium;

· moderate physical activity, at basically similar level for different workers;

· basic uniformity of clothing worn.

These environments are assessed by referring to the level of thermal wellbeing or discomfort perceived by occupants. Thermal comfort is defined as “the mental condition in which satisfaction is expressed about the heat environment”, and from a technical stance is frequently identified with thermal neutrality, i.e. the state in which the worker does not express a preference for either a warmer or cooler environment than the current one.

Indexes most commonly used to assess thermal wellbeing in moderate environments are the PMV and PPD.

PMV (Predicted Mean Vote) is the value indicating the predicted mean vote of a sufficiently large group of persons on the basis of the following scale of heat sensation:

· PMV = +3 Hot

· PMV = +2 Warm

· PMV = +1 Slightly warm

· PMV = 0 Neutral

· PMV = -1 Slightly cool

· PMV = -2 Cool

· PMV = -3 Cold

This is the subject of ISO standard 7730: recommended value -0.5÷+0.5. Applicability limits come within the following ranges of environmental and personal parameters:

· metabolism: 0.8÷4 met;

· clothing: 0÷2 clo;

· air temperature: 10÷30 °C;

· radiant temperature: 10÷40 °C;

· air velocity: 0÷1 m/sec.

Another index, related to the PMV, is the PPD (Predicted Percentage Dissatisfied): it is usually defined as the percentage of those expressing a vote of -2 or -3 or +2 or +3. With PMV=0 PPD=5%.

This is the subject of ISO standard 7730: reference value: <10%.

In practice, in living and working environments the following aspects should be borne in mind in relation to thermal wellbeing:

· the existence of spatial and temporal gradients for parameters determining the thermal wellbeing of organisms;

· the existence of local heat exchanges;

· the presence of draughts assessed using the PD index (Percentage of individuals dissatisfied about the presence of draughts);

· inadequate change of air.

In light of the above definitions, it is clear that evaluations about moderately cold environments can be correctly applied only to measure 1 (cutting), while in work areas 2 and 3 the conditions do not appear to point to a cold environment. In the winter period, indeed, the cooling of air due to rigid outside temperatures is countered using a heating system. In these work areas, indexes referring to a moderate environment have been used to assess the state of discomfort, with suitable considerations made regarding the effects of single, critical thermohygrometric parameters.

4. Characteristics of measuring points and values

Position 1: cutting of small pieces

Characteristics:

· moderately cold environment, about 50x50 metres in size

· room temperature controlled by microdiffusion air conditioning system

· no draughts

· heavy work consisting of the movement of large pieces of meat and their cutting up into smaller pieces

· light-medium clothing, consisting of:

- rubber boots and gloves (1 long glove)

- trousers

- shirt (some in T-shirt) or overalls

- rubber aprons with metallic mesh

- headwear

For the calculation of microclimatic indexes the following values were taken into account:

- Metabolism: 3.0 Met

- Clothing: 0.8 Clo

Positions 2 and 3: butchery line

Characteristics:

· moderate environment, communicating with outside (kill area), thus in the winter the temperature rises as the area is further from the exit

· air conditioning system, heating only

· very high relative humidity resulting from the use of water

· variable work

· clothing as in previous environment

For the calculation of microclimatic indexes the following values were taken into account:

- Metabolism: 2.0÷3.0 Met

- Clothing: 0.8 Clo

5. Evaluation of results

As already mentioned, the application of indexes relating to moderately cold environments may only be effected for the work area located in the cutting unit, where measured temperatures lie at the upper limit of these environments. Since the environmental parameters given in table 1 justify the application of indexes for moderate environments, the PMV and relative PPD were calculated for all three positions, using a single level of clothing and, for butchery positions, several activity values. As can be seen in table 3, the results of PMV calculations fall within an acceptable range: only for particularly intense activities in the butchery line is it possible to obtain the value of a moderately warm environment.

A detailed analysis of single parameters does however highlight some aspects capable of producing states of serious discomfort. We refer in particular to the dry bulb temperature and relative humidity: in the cutting unit the temperature is kept at about 10°C, in any case below wellbeing levels (a range of 16-20°C), while in butchery positions temperatures can be kept higher in the winter thanks to a heating system. In these units the summer situation should however be reviewed, when the lack of insulation with the outside may lead to very high temperatures. Relative humidity proved to be outside wellbeing limits, acceptable values being from 40 to 60%. On this point it is interesting to introduce K. Scharlau’s study, predicting a curve showing the optimal ratio between dry bulb temperature and relative humidity. Outside these values conditions of discomfort may be felt. The curve, given in fig.1 and table 4, gives the optimal hot-humid limit, above which humans go into a state of oppression and discomfort. If in a given place air temperature exceeds the value suggested for that relative humidity, the difference between the two temperatures gives the degree of discomfort owing to hot-humid conditions.

Table 1 – Measured thermohygrometric parameters

Position	Dry bulb temp. [°C]	Wet bulb temp. vf [°C]	Relative humidity [%]	Partial p. water vap. [KPa	Air velocity [m/sec]	T. globe thermometer [°C]	Average radiant temp. [°C]
1	9.5	8.2	84.7	1.04	0.03	11.7	12.5
	9.6	7.8	78.9	0.98	0.03	11.2	11.7
	9.8	7.7	75.6	0.95	0.04	10.6	10.9
	9.9	8.3	81.5	1.03	0.03	10.5	10.7
	10.0	8.2	79.3	1.01	0.01	10.6	10.7
2	16.2	15.5	93.3	1.75	0.03	17.0	17.2
	16.0	15.2	92.2	1.71	0.04	16.9	17.2
	15.8	15.5	97.1	1.78	0.03	16.9	17.2
	16.4	15.9	95.2	1.81	0.03	16.8	16.9
	16.3	15.9	96.1	1.82	0.02	16.8	16.9
3	17.2	16.6	94.3	1.88	0.02	17.4	17.4
	17.3	16.9	96.2	1.93	0.04	17.6	17.7

Table 2 – External meteorological data (measured at Liceo Classico, Mantua)

Time	Temperature [°C]	Relative humidity [%]	Air pressure [hPa]	Wind velocity [m/sec]	Solar radiation [mW/sq.cm]
7:00	9.4	68.4	998.5	0.7	2.1
8:00	9.5	62.2	998.5	0.7	7.6
9:00	10.0	61.2	998.5	0.4	15.1
10:00	10.6	59.0	998.8	0.6	21.6
11:00	11.3	56.4	998.9	2.1	19.5
12:00	11.4	55.3	998.6	2.8	23.2

Table 3 – Microclimatic indexes (calculated for the mean values of environmental parameters given in table 1)

Position	Activity [Met]	Clothing [Clo]	Required insulation [Clo]	Minimum insulation [Clo]	WCI	PMV	PPD
1	3.0	0.8	0.62	0.30	404	-0.39*	8.15
2	2.0	0.8	-	-	-	-0.24	6.15
	3.0	0.8	-	-	-	0.69	14.89
3	2.0	0.8	-	-	-	-0.04	5.03
	3.0	0.8				0.88	21.46

* for simulations the dry bulb had a Temperature of 10°C

Table 4 – Scharlau curve

Relative humidity [%]	Scharlau Temperature [°C]
100	16.5
95	17.31
90	18.16
85	19.08
80	20.06
75	21.11
70	22.23
65	23.45
60	24.79
55	26.25
50	27.88
45	29.70
40	31.76
35	34.14
30	36.94
25	40.33
20	44.59

Fig. 1 – Scharlau curve

Relative humidity

Air temperature

Considerations pertaining to pig cycle

Elements for evaluating risk and preventive measures.

In addition to the extensive evaluation of the cattle slaughterhouse and to the notes given in the risk profile datasheets, where there is also mention of external climate problems in different seasons, below are some clarifications with reference to pig butchery and preliminary cutting.

In the butchery phase there is high humidity, often with values close to saturation, up to the side splitting and head removal phases. Water vapour comes from biological liquids, preparation baths and water serving to cool splitting saws.

Prevention centres on the possible closure or segregation of the main sources of steam (baths) or on the removal of steam combined with a suitable change of air.

A similar situation occurs in the cleaning phase, which should if possible be concentrated in times when the cycle is non-operative.

The sources of radiant heat or convection heat from warm air are however generally to be found some distance from operators.

For primal cutting and related works (cold storage and warehouse loading) greater importance was attached, depending on the setting, to air temperature (cold) and air velocity.

National legislation (Legislative Decree 286/1994 and subsequent amendments) establishes for meat cutting (code S) a room temperature of less than 12°C. For the meat cutting, deboning, packing or packaging phases the internal temperature must be equal to or below 7°C, with the exception of the hot cutting of the sides of recently butchered animals and with lower limits for livers.

For subsequent meat processing (code L) lower room temperatures are fixed, and there are greater problems centring on contact with cold surfaces, which we do not consider here, not having a bearing on this risk profile in B (butchery) and C (cutting) phases.

In seeking organisational solutions to obtain hygienic conditions in the meat industry and the wellbeing of meat cutters, experimentation is ongoing for the pre-cooling of sides of meat, such as to enable processing at room temperatures of 15-16°C (several municipal health bye-laws establish for full throughput workstations minimum winter temperatures of 16°C, excepting technical needs).

Refrigerators and cold storage units have temperatures of between 0° and 4°C, with a possible range dropping to -2°C. A number of workers frequently go in and out of these environments.

Workers operating in cold microclimates must avoid direct exposure to draughts. The automatic interruption of air velocity coming from the fans of the refrigerating unit when the door is opened and the worker comes in pushing the load is a useful measure for keeping this risk in check.

Other measures include the use of PPE to protect against the cold and complete changes of clothing, including underwear, soaked by sweat during the hot season, before going to work in a cold environment.

NOISE AND VIBRATIONS

Cattle slaughterhouses

With reference to risks deriving from physical agents, evaluations were carried out on both noise and vibrations produced by the instruments used in slaughterhouses. Health reports supplied by competent physicians with reference to monitoring carried out from 1993 to 2000 on approximately 800 workers in the sector were also examined.

NOISE

It should first be mentioned that work in the slaughterhouses surveyed is performed in extensive work areas to favour the mechanical handling of animals. Moreover, these areas communicate directly with the outside, and there is no physical separation between different line positions. These structural elements may undoubtedly have adversely influenced the results of measurements on noise. Some positions where noisy equipment is not used are indeed very close to others where, for example, saws are used to split carcasses into sides of meat. Noise from the outside (such as moving trucks) is felt in positions closest to where animals enter. Again, floor and wall surfaces are not covered with sound absorption materials for hygienic reasons. Last but not least, the sound caused by pulleys when they slide along and hit each other is recorded.

Despite these negative environmental factors, no work area posted levels of exposure >90 dBA.

As might be expected, the most critical values were recorded in the following phases:

1) stunning, with gun

2) mechanical dehiding

3) side splitting

Risk is higher in full throughput slaughterhouses, since in low throughput slaughterhouses butchery activity is performed only in the morning, while in the afternoon secondary activity is carried out (cleaning and maintenance).

1) The work area of the stunner, who uses a gun, proved to be the noisiest, due in part to its closeness to the animal entrance to the “stunning box” (or kill area) and to the area communicating directly with outside. The gun is used about once a minute, and the gunshot noise also influences the work area of the worker responsible for fixing the animal’s hindleg to the chain of the butchery line. This worker stands opposite the stunner, and waits for the shot animal to roll from the “stunning box” to the underlying zone so that it can be hung onto the chain. The iron gate that closes the “stunning box” produces an impulsive noise that adds to the gunshot noise. In these two positions values of between 85 and 90 dB A were recorded in the full throughput slaughterhouse.

2) The zone where mechanical dehiding is performed (in full throughput slaughterhouse) also includes work areas for the removal of forelegs and the head. The dehiding machine is a technical innovation that has undoubted advantages for these workers. The only con is the production of considerable noise, which also affects neighbouring activities. Another source of noise are the mobile platforms on which dehiders work; the Lep (d) measured for positions in this zone was 85 dBA.

3) The third noisiest work area was that of the cattle meat side cutter. The equipment used (saw) was the same for both full throughput and low throughput slaughterhouses, and produced a noise level of 85 dBA. Being an end-of-line position, it did not make a significant impact on other work areas.

The remaining work areas all posted levels of exposure of between 80 and 85 dBA, with the exception of the manual dehiding area (low throughput slaughterhouse), where workers were exposed to <80 dBA.

It is believed that these noise values are chiefly the result of the impact of pulleys that transfer animals and of the reverberation of the work environment. Actions to reduce noise (e.g. installation of “baffles” or sound absorption panels) must take into account the hygienic needs of this type of productive activity by using impervious and sanitisable materials.

Evaluation of damage

Despite the lack of especially worrying “peaks”, the slaughterhouse work environment is a fairly noisy place, which affects nearly all workers. The result of health monitoring on about 800 workers in the sector that underwent audiometric examinations between 1993 and 2000 showed 120 cases of hypacusia, almost all of which in group I or II (according to Merluzzi), i.e. with increases in the auditory threshold at the frequencies of 3000 and 4000 Hz.

This percentage is very high, although it should be stressed that this figure is absolutely “raw”, in that it takes no account of any previous occupational exposure in other noisy productive sectors.

The health monitoring of workers in nearly all slaughterhouses (except 1) examined began in 1996, 5 years after the coming into force of Legislative Decree 277/91.

VIBRATIONS

With regard to risks deriving from the use of vibrating instruments, the survey was limited to one type of instrument, the saw (for splitting of carcasses into sides of meat, breastbone saw and circular saw used in the cutting unit). The stunner gun produces a recoil that is not measurable as an “acceleration factor” typical of vibrating instruments.

Power-driven saws used in the slaughterhouses under review are fixed to a suspended hoist using a steel cable. This optimises handling despite their significant weight and size (the side splitting saw weighs a gross 82-85 Kg and is 130-145 cm in length depending on the model).

It is necessary however to be very accurate when using such equipment, especially bearing in mind their inherent dangerousness. The vibrations declared by saw manufacturers are below 2.5 m/s2. This value is below the “level of action” for exposure to hand-arm vibrations fixed by the Draft EU Directive on physical agents 94/C230/03.

The “level of action” is the value of exposure at which specific measures must be adopted to protect exposed workers. Such measures include worker training on the specific risk, specific actions to reduce the risk, the health monitoring of exposed workers. The “threshold level” (1 m/s2) is the value that should be aimed for to reduce or eliminate the risk, i.e. the value below which permanent and/or repetitive exposure does not have negative consequences for the exposed worker’s health.

Full throughput slaughterhouse workers often have to work on mobile platforms, which considerably facilitate those tasks requiring extreme stretching and bending of the backbone. A modest source of vibration transferred to the whole body is that originating from these platforms, but the ergonomic advantages of this piece of equipment more than outweigh its shortcomings.

Evaluation of damage

The effects of power-driven saws on the hand-arm system were assessed, together with risks deriving from repetitive movements, in the ergonomics chapter.

Pig slaughterhouses

NOISE

Evaluation of risk.

An examination of evaluation reports pursuant to Legislative Decree 277/1991 in 3 slaughterhouses (2 full throughput and 1 low throughput) confirmed the presence of high levels of intensity in a number of areas, first and foremost the area where livestock move or are kept and in neighbouring areas, where this type of animal makes more noise than cattle.

Other sources of noise were chilling and ventilation plants, chains, rollers and the pneumatic transportation of offal.

For full-time workers in the full throughput plant working in the livestock and/or kill, jugulation and initial hooking areas, the personal exposure level (LeP/d) of 90 dBA may be exceeded: values of between 91.7 and 94 dBA were estimated.

The table below gives examples of some levels of noise intensity (Leq in dBA) of some work areas in a number of enterprises.

Evaluation of damage

The introductory part gives data on certification pertaining to occupational hypacusia.

Preventive measures

Personal Protective Equipment, especially in or near the area where livestock are kept.

Redesign or adjustment and maintenance of transportation chains, looking to reduce noise level.

VIBRATIONS

With regard to risks pertaining to the use of vibrating instruments, we refer you, for side splitting saws, to the general considerations given in the cattle butchery risk sheets.

Other vibrating instruments that should be taken into account, especially in light of Community legislation about to be introduced, are circular saws and electric knives.

PERSONAL PROTECTIVE EQUIPMENT (PPE)

The term Personal Protective Equipment (PPE) is taken to mean any piece of equipment to be used by workers to protect against one or more dangers posed to their health and safety (for example: gloves to protect against cuts, shoes with nonslip sole, etc.).

PPE must be used when there is a risk that cannot be eliminated, or cannot be reduced sufficiently by means of collective prevention and protection measures, or by work reorganisation measures.

The employer is obliged to identify and choose adequate PPE; to do that he must:

EVALUATE RISKS - risk evaluation is a fundamental instrument providing all the information needed to choose suitable PPE vis-à-vis the assessed risk and actual conditions of use.

EVALUATE THE FEATURES OF PPE - associate protection levels and classes of PPE available on the market with assessed risk levels, also bearing in mind the environmental conditions present and the subjective traits of single workers.

INFORM/TRAIN workers regarding:

· the reasons for their use

· situations and time frames for use

· methods of use

· operating instructions (preservation, cleaning, etc.).

It is necessary to provide training and information for all types of PPE, training is compulsory only for category III equipment and hearing-related devices.

PPE Requirements

To protect the health of users, Legislative Decree 475/92 provides regulations obliging manufacturers to sell on the market only PPE that conforms to essential health and safety regulations.

In accordance with Legislative Decree 626/94, the employer is obliged to acquire PPE that conforms to the provisions of decree 475/92, which identifies instruments at the disposal of users to guarantee the acquisition of PPE that conforms to legal requirements:

· CE declaration of conformity

· CE marking

· Briefing note.

PPE is broken down into three categories, with reference to the growing complexity of designs and growing dangerousness of the risks against which it affords protection.

1^st Category (risks of slight damage) example: gloves protecting against diluted detergents, gardening gloves

2^nd Category (risks of medium damage) example: gloves for mechanical risks, safety shoes, ear protection, eye protection, metal mesh gloves.

3^rd Category (risks of serious or fatal damage) example: fall protection devices, protection of respiratory tracts, steel mesh or metal plated aprons or waistcoats.

Certification procedures are required for all these devices.

For the first category the DECLARATION OF CONFORMITY issued by the manufacturer is sufficient.

For the second category a technical test is required, with relative CERTIFICATION issued by a NOTIFIED ORGANISATION.

For the third category certification is the same as that for the second category. The manufacturer is obliged to adopt, at his discretion, one of the two product control systems:

· control of finished product (art.9 of Legislative Decree 475/92)

· control of quality system (art. 10 of Legislative Decree 475/92).

CE marking

CE marking must by law be affixed to each piece of PPE to certify that the equipment conforms to essential health and safety requirements in pursuance of Legislative Decree 475/92.

Briefing note

The briefing note is mandatory, and must accompany every PPE sold on the market.

The note must be drafted accurately and in comprehensible form by the manufacturer, in the language of the member state in which the equipment is to be used.

The employer shall use the briefing note to acquire all elements needed to make an informed choice.

The user must be able to find a relationship between PPE protection classes and the different types and levels of risk present in the specific working environment.

It shall contain essential information for the employer to fulfil his obligations regarding the correct use and management of PPE (maintenance, cleaning, storing, expiry dates, servicing, etc.), which must be followed to the letter.

The briefing note shall contain useful and essential elements to ensure that correct information and training is given to workers obliged to use PPE.

PPE must:

· be adequate to prevent risks without bringing about a larger risk (e.g. reduction of the field of view, impossibility of discerning messages or warning signs);

· be suitable for the conditions in place in the workplace (microclimate, etc.);

· take into account workers’ ergonomic or health needs (equipment must be comfortable and lightweight, not cause allergies, etc.);

· be adaptable to the user according to his needs (different sizes, adjustment system).

If more than one piece of PPE is used simultaneously, they must be compatible and remain effective in relation to the risk involved.

Classification of protection devices

· PROTECTION OF HEARING

· PROTECTION OF RESPIRATORY TRACTS

· PROTECTION OF EYES AND FACE

· PROTECTION OF HEAD

· PROTECTION OF BODY

· PROTECTION OF UPPER LIMBS

· PROTECTION OF LOWER LIMBS

Protection of hearing

Risks: exposure to noise

Device types

· ear plugs

· earmuffs

· hearing protectors.

Choice

These devices serve to diminish the amount of sound energy transmitted to the ears through the air, and must be used if it is impossible to prevent harmful exposure in any other manner.

The law requires employers to provide ear protection to all workers exposed to LEP >85 dBA, while workers are obliged to wear this type of protection when exposure is in excess of 90 dBA of LEP or, for workers exposed to lower LEP levels, at the specific recommendation of the Competent Physician.

The employer must evaluate risks in order to acquire information on levels of personal exposure to noise (LEP dBA) and must identify user situations, in particular the need to understand messages, warning signs or alarms.

It is necessary to assess the auditive threshold of the worker having to use the device. In the event of an auditive deficit, the Competent Physician shall provide precise recommendations as to an appropriate choice of device for the worker.

The employer shall use the BRIEFING NOTE to acquire data on the noise abatement capacity of the ear protection or on its capacity to lower noise intensity.

For daily levels of personal exposure of 85 dBA, it may be sufficient to provide hearing PPE that can reduce noise levels by about 10-15 dBA, with an exposure level of 70-80 dBA considered acceptable. If indeed exposure were higher this protection would be insufficient, if it were lower the worker would be over-protected, causing discomfort (sense of isolation from colleagues and from environment) and possibly refusal to use the protective device.

In a subsequent phase workers or their representatives are to be consulted to identify the right type of protection that workers will have to wear, bearing in mind factors such as comfort, lightness, robustness, ease of cleaning, maintenance, absence of side effects.

It is important for the worker to choose the ear protection from those available that best meets his needs. It is however necessary to consider some variables connected with the characteristics of the work to be performed and of the persons that must use the device.

Ear plugs are recommended if a lot of sweating is involved or if work is performed in a warm/hot environment, if eyewear is used, if the job entails frequent movements. Earmuffs are recommended if it is necessary to repeatedly put on and take off the protective device, or if the external ear canal is inflamed.

Protection of respiratory tracts

Risks: exposure to biological agents conveyed by organic materials.

Device types

Filter respirators: - filtering facepieces

- semi-face masks with interchangeable filters

It should be stressed that simple hygienic masks whose job is to safeguard the product do not provide protection of any sort in the event of exposure to potentially pathogenic biological agents. On this point, Legislative Decree 626/94 imposes the use of PPE that conforms to requirements laid down in Legislative Decree 475/92.

Risk evaluation must identify the type of agent, the infecting load, in order to define the operations and environments that require the use of devices to protect the respiratory tracts.

Filter respirators purify the air before it is inhaled. They consist of a face mask that can be filtering or act as a support for different filters depending on the type and concentration of the pollutant.

Devices affording protection against biological agents should be chosen from among filter respirators for dust particles.

Technical standards EN 149 and EN 143 break down filter respirators for particles into three classes according to filtering efficiency (capacity of withholding suspended particles).

FILTERS FILTERING FACEPIECES

· class P1 FFP1 low efficiency filters

· class P2 FFP2 medium efficiency filters

· class P3 FFP3 high efficiency filters

Medium and high efficiency filters differ according to the capacity of withholding solid particles only or both solid and liquid particles.

If they are effective against water-based solid and liquid aerosols, the PPE is marked S.

If they are effective against organic-based solid and liquid aerosols they are marked SL.

The filtering gains in efficiency by increasing the quantity of filtering material, producing a consequent rise in respiratory resistance. Once the risk and the suitable device have been identified it is important not to be over-protected. The increase in safety coefficients to obtain greater efficiency entails larger and heavier devices, with greater respiratory difficulty, which may lead to discomfort and non-use of the PPE.

Filter respirators suffer from a loss in adherence of the inside of the face mask, caused by adherence defects along the side of the face mask owing to the profile of the edge and to the quality and elasticity of the materials used. The quality of the face mask may also drop below standards because of the traits of the worker’s face, the tension of the border, the worker’s movements, the presence of moustache, beard and whiskers.

PPE must be adaptable to different face sizes (with different sizes available and adjustment systems). Devices must be made from soft, non-allergenic and lightweight materials and be endowed with a respirator exhaling valve that enables air to be released directly without going through the filter again.

Prior to use the user must receive training on the use of the respirator. Training must show the correct way of wearing the PPE and of carrying out adherence tests.

Instructions given for the cleaning, maintenance, replacement and duration of filter respirators must be followed to the letter.

Protection of eyes and face

Risks: exposure of eyes and face to squirts, splashes, drops and liquids containing potentially pathogenic biological materials.

Device types: face mask

Choice

In view of the need to protect both eyes and the face, the protective device must be of the mask type.

The choice of eye and face protection is particularly important in view of the delicate nature of the visual apparatus and the direct and indirect risks to which it is exposed in the workplace.

It is particularly important to assess effects caused by the use of PPE, such as the possible diminution of the field of view and of comfort, or eye fatigue. This may be a partial impediment to the worker’s safety.

Masks must:

· be adaptable to the shape of the user’s head and ensure stability

· be combinable with other headgear if necessary,

· be compatible with the use of corrective eyewear and with the use of other PPE.

The mask screen must be optically neutral, and must not cause alterations to images, the cause of eye fatigue, burning and migraines.

Technical standard EN 166 lays down three different optical classes (1-2-3-) indicating the degree of optical neutrality of the eyepiece.

Optical class 1 indicates the highest quality. Optical class 3 eyepieces are not suitable for prolonged use.

The eye and face protection device must be marked on the eyepiece and on the frame, with a horizontal sequence of letters and numbers, showing the protective capacity and properties of the device. For masks, marking must be present on both the screen and support.

The order and meaning of the alphanumerical code present on the marking

POSITION I scale number (only for protection against light radiation)

POSITION II identification code of manufacturer (letters or numbers)

POSITION III optical class ( 1-2-3-)

POSITION IV the letter appearing in this position identifies the degree of mechanical resistance to the impact of solid materials; it may be S-F-B-A- in increasing order.

POSITION V a number identifies protection against:

3 Liquids (drops and splashes)

4 Coarse particles

5 Gases

POSITION VI VII

K Protection (for surface damage) against fine particles (unscratchable lens)

N Demisting

An example of marking on the screen of a mask protecting against splashes and squirts could be as follows:

Position I absence of number, since protection against light radiation not necessary

Position II code of manufacturer, e.g. KJH

Position III optical class 1, this being the best, is recommended for prolonged use of the device

Position IV letter S indicates degree of mechanical resistance, in this case high resistance to impact not necessary

Position V number 3 must be indicated, giving specific protection against squirts or splashes of potentially pathogenic biological materials

Position VI letter k: unscratchable treatment (optional)

Position VII letter N: demisting treatment (optional).

Protection of head

Risks: situations where there is the danger of being hit by objects or materials or of hitting one’s head against stationary parts.

Device types: protective headgear

Choice

They must withstand impact and perforation, be lightweight, adaptable to head shape (adjustable edges), equipped with sweat band, afford an adequate field of view in relation to the task being performed, integrate with other PPE (e.g. earmuffs, face masks) and be made from compatible and non-irritant materials. The headgear must be adjustable so that it adheres perfectly to the head and be kept fastened at all times.

Protection of body

Risks: - use of hand-held knives

- exposure to biological agents (bacteria, virus, etc.)

- exposure to low temperatures

Device types:

· protective aprons for use of hand-held knives

· protective clothing for low temperatures

· clothing to protect against biological agents

Choice

· protective aprons for the use of hand-held knives

After having verified the presence of effective collective protective devices and assessed consequent residual risks, suitable personal protective equipment is selected for eliminating or further reducing risks.

To make correct choices it is necessary to know: the type of activity and work phases, the ways in which activities are performed and equipment used, the parts of the body that may suffer knife wounds.

This information makes it possible to identify knife types, movements performed with knives during cutting operations, the position of the piece being worked on, the force exerted with the knife and the parts of the body to be protected.

The following clothing is worn to protect against wounds caused by cuts and slashes from hand-held knives:

- simple apron (covering the front of the worker’s body, from the chest to the legs);

- protective trousers (worn below the waist, endowed with two separate leggings);

- protective smock (worn on the bust and covering the chest, down to the waist and up to the shoulders).

These items of clothing are made with a metal mesh or metal plates.

The part of the body to be protected is determined by the type of activity and movements performed. The profile of knives used serves to establish the degree of protection required of the clothing.

These clothes are suitable for work in which the danger of penetration is low, such as work involving a broad-bladed knife, i.e. a knife which at a distance of 20 mm from the tip has a width in excess of 12 mm.

For works where the danger of penetration is high, e.g. when a narrow-bladed is used (at a distance of 20 mm from the tip the knife has a width of 6-12.5 mm), clothes affording greater protection must be used.

It is indispensable to ascertain the degree of protection afforded by the apron from the briefing note, and to know exactly what type of knife is used.

For correct protection the garment must be the right size for the worker. Size measurements should take into account the worker’s stature, chest and waist circumference. This information is supplied by the manufacturer and given in the briefing note.

Weight must also be taken into consideration for the comfort of the garment. For garments having the same degree of protection, purchase preferences should be given to those items proving to be lighter.

· Protective clothing for low temperatures

Professional clothing to combat the cold must be flexible and soft and allow unrestricted movement and excellent protection against low temperatures.

**· Clothing protecting against biological agents

As regards body protection against biological agents, attachment IV of the M.D. of 29 September 2000 (health measures to protect against transmissible spongiform encephalopathies) establishes that protective clothing be worn while performing hazardous operations.

The manufacturer of such devices must be able to prove through documentation that clothing has undergone the tests and methods set forth by ASTM technical standards).

The employer will thus have to ask the manufacturer for technical documentation certifying that the device conforms to these standards.

Protection of upper limbs

Risks: - use of hand-held knives

- exposure to low temperature

- exposure to biological agents.

Device types:

· glove, glove with short cuff, glove with long cuff and metal mesh arm protection.

· gloves and arm protection made from cutproof fibres.

· protective gloves to protect against low temperatures.

· protective gloves to protect against biological agents.

Choice

The choice of glove type depends on the tasks to be performed.

For all operations requiring strength, steel mesh gloves are preferable, ensuring greater protection against the thrust of the blade.

For subtler cutting and trimming operations safety gloves made from fibre are preferable, allowing more unrestricted movement. This type of glove is however not very resistant to perforating wounds.

It is advisable to wear a cotton glove below the protective glove to avoid skin irritation and favour heat insulation. From a hygienic point of view it is necessary to wear a polyethylene glove between these two gloves.

When large pieces of meat are being handled, such as sides of meat, fresh and seasoned hams and whenever there is the danger of wounds to the wrist, forearm and arm, it is necessary to use the protective cuff armband.

Protective armbands may be made of plastic, steel mesh or fibres that can withstand cuts but that do not protect against perforating wounds.

It is important to ensure that with the use of these protective devices other parts do not remain unprotected, especially where the armband is fastened.

It is also necessary to ensure resistance and allow the worker unrestricted movements.

The use of a right-hand glove is necessary to avoid wounds caused by the hand slipping along the blade of the knife. In this case it is sufficient to use the safety glove made of cut-resistant fibre.

To ensure the utmost comfort it is necessary to select the size of glove according to the size of the user’s hands, allowing the fingers sufficient freedom of movement.

It is important to choose the right size not only for comfort but also for safety: small gloves may damage hands, small arm protection may limit movements, and gloves that are too long are also a source of danger.

To prevent gloves from slipping systems may be adopted to hold up the glove.

Gloves and arm protection against cuts and perforating wounds must be marked with the pictogram below, which must be affixed to the product or packaging.

[pictogram]

Protection is not guaranteed by such devices engine-powered knives or cutting equipment are used.

Metal protective devices conduct electricity, thus one must avoid contact with taut parts.

Devices must be checked visually both before and after use to ensure their integrity, with particular reference to flaws, damage or the absence of rings, without making any modifications.

Special attention must be paid to plastic arm protection. This material, coming into contact with oil and grease or high temperatures may no longer meet recommended performance requirements.

The briefing note on gloves and arm protection against cuts and perforating wounds indicates the degree of protection supplied depending on the profile of the knife (i.e. width of the blade at a distance of 20 mm from the tip). It is essential to check this level of protection and know exactly the type of knife used.

Safety gloves made from fibre, affording protection against cuts, are marked with the pictogram as per below.

[pictogram]

The numbers given below the figure relate to the following glove resistance properties:

· First number indicated: RESISTANCE TO ABRASIONS

· Second number indicated RESISTANCE TO CUTS CAUSED BY BLADE

· Third number indicated RESISTANCE TO SLASHES

· Fourth number indicated RESISTANCE TO PERFORATION

There are 4 levels of resistance for each requirement, with the exception of resistance to blade cuts, which has 5 levels.

The higher the glove resistance the greater the protection.

It is necessary to observe the recommendations given in the briefing note, with special reference to:

· choice of size

· how to put on and adjust the glove

· how to fix arm protection

· how to perform correctly: cleaning, sterilisation, control and maintenance, without making modifications to the PPE.

To protect hands against exposure to biological agents, gloves must bear the pictogram as per below.

[pictogram] MICRO-ORGANISMS

The aforementioned M.D. of 29 September 2000 establishes that such devices be classified in the third category and possess the requirements laid down in technical standard EN 370. The manufacturer must accordingly provide adequate documentation and certification to the user.

Protection of lower limbs

Risks: - heavy objects falling on feet

- slipping

- exposure to low temperatures.

Device types:

· safety/protective/work footwear.

· model: low-heeled shoes, boots

· shoes endowed with quick removal device

· shoes and boots providing heat insulation to combat cold.

Choice

Footwear must have nonslip soles to afford a good grip on floors, even when these are covered with liquids and slippery materials.

It must be endowed with reinforced toe cap that can withstand the weight of falling objects (e.g. pieces of meat, pulleys), crushes (e.g. caused by trolleys) if pieces are handled manually and the penetration of knives unexpectedly dropped.

Footwear must also be thermally and hygienically sound, i.e. guarantee protection against cold and humidity and help the skin to breathe. It must also be soft, flexible and lightweight.

EN technical standards distinguish between:

· Safety footwear (S):

endowed with toe cap to protect toes against knocks and tested to withstand a physical impact of 200 joules (e.g. mass of approximately 20 Kg falling from a height of one metre).

· Protective footwear (P):

endowed with toe cap to protect toes against knocks and tested to withstand a physical impact of 100 joule (e.g. mass of approximately 10 Kg falling from a height of one metre).

· Work footwear (O):

not endowed with toe cap to protect toes against knocks.

When choosing footwear it is essential to directly involve the worker, who must be able to choose from a range of shoes (the same as if it were non-professional footwear for daily use). This allows the worker to have a higher degree of comfort and wearability, since it is also important to meet the worker’s subjective needs.

PHASE DOCUMENT

Preamble

Cattle and pig butchery may be performed in recognised industrial-scale plants having a capacity of hundreds of butchered animals/day or in non-industrial plants having a limited capacity. Low throughput slaughterhouses, mainly family-run, can butcher up to 1,000 equivalent bovine units (UGB) a year and in any case not over 20 UGB a week. One UGB corresponds to an adult bovine, or two calves, or five pigs, etc.

Many of these plants, especially low throughput plants for which legislation (Legislative Decree 286/94 and subsequent amendments) establishes that produced meat must be sold directly to consumers or resellers, are connected with activities involving direct sales to consumers (grocery and butcher’s stores).

In large-sized full throughput plants workers are often specialists performing one task or a group of tasks, while in other plants workers perform all or nearly all jobs. In low throughput plants, workers are involved not only in butchery operations but also other tasks, for example sales, which in terms of hours worked may prevail over purely butchery activities.

Work phases are carried out in sequence and in sub-phases, basically following a well-established butchery technique, which produces a given type of “semi-processed” product.

In view of the above, variants in the full throughput cycle compared with the low throughput approach do not usually appear to be highly significant, but rather dependent on the organisational choices or needs of the single firm, possibly due to logistical constraints or space availability.

The description of the two production cycles will thus be based on the full throughput slaughterhouse, in which basic operations are most parcelled (basically due to production needs).

This will make it possible to provide a detailed description of all phases and jobs in order to identify all specific job-related risks.

Full throughput butchery is a complete cycle, from livestock to the production of various sizes and cuts of meat, from meat sides to vacuum-packed meat destined for retailing.

In addition to the butchery line there may be other work phases producing finished, ready-to-sell products, such as the production of homogenised food.

The handling of by-products in the plant is limited to tripery, while the handling of thoracic offal, heads, hides and legs is extremely limited as far as the bovine cycle is concerned. These parts are usually sent to other enterprises for further processing.

The production cycle revolves around the butchery line or chain, whose general technological set-up goes to establish the time frames and production capacity of the slaughterhouse.

CATTLE BUTCHERY CYCLE

LAIRAGE

The phase examined includes:

1. reception of cattle

2. unloading

3. lairage and pathway to stunning box.

1 - Description

This phase, partly carried out by slaughterhouse staff, partly by veterinary officers and partly by external haulage workers prior to the butchery phase, is rather complex. Traits largely depend on the organisation of available space and on the logistics of single plants.

Animals arrive at the slaughterhouse onboard trucks that are especially equipped and authorised for this purpose. These vehicles are managed by external haulage contractors that usually have specific work contracts with the slaughterhouse or contracts with the animal seller. Very rarely are transport workers also slaughterhouse employees. This can only happen in small-scale butchery enterprises that acquire, directly from farmers, limited amounts of animals to be butchered. This fact is significant for the purpose of applying preventive measures in accordance with art. 7 of Legislative Decree 626/94.

The arrival of animals at the slaughterhouse is usually planned well in advance.

This aspect may change in periods when elements of “turmoil” occur, for example during the outbreak of BSE.

In these circumstances unexpected and thus irregular working situations may occur such as to introduce occupational risks (in addition to specific health risks) that are usually absent or suitably covered, such as the overcrowding of cattle pens (lairage), the unusual abundance of trucks and animals, extraordinary operations, etc.

The first operation to be performed is the weighing of the truck. As soon as it is loaded it is examined by the veterinary officer, who examines health documentation kept with the animals to single out any irregularities or suspect animals. In these cases the animals involved are isolated and placed under observation, awaiting testing. If animals are clearly sick the veterinarian may decide, in this early phase, to butcher the animal in isolation. These butchery operations are performed in ad hoc structures generally present in large-sized full throughput slaughterhouses.

The next operation is to unload the animals in temporary pens, known as lairage areas. In the full throughput plant examined there are two types of such areas: one pen organised with pathways leading directly to the stunning box; a second pen destined for the stay of animals. This second structure is used for cows who are given time to recover from the stress of transportation before being butchered. The pen leading directly to the kill area is used for beef bullocks. Both structures are endowed with protected pathways leading to the kill zone.

Animals should be grouped in the pens taking groups of origin into account. In other words, animals must be led to the stunning box with other individuals of the same group to reduce the likelihood of restlessness or agitation, conditions that may generate serious management and containment problems.

Animals are unloaded from the back of the trucks using equipped ramps. These ramps are fitted with concrete side guards and a protected external walkway.

This limits the danger of animals escaping, and at the same time, if the truck is positioned correctly, it also allows the operator finding himself on the animal ramp to escape.

Photo 1/B: unloading of animals.

Truck unloading operations are carried out by the hauliers. For safety reasons, operators must not usually climb onto the truck where animals are kept, but this possibility cannot be ruled out. For cows in particular it is almost inevitable that the operator will have to climb onto the truck among the animals, since cows are usually tied to the truck itself. This operation does not usually entail problems, but risks obviously cannot be ruled out.

The situation is different for bullocks: these are not tied, and the operator does not need to come into direct contact. In this case it is absolutely forbidden for the operator to climb onto the truck as the risks are great.

Animals must be helped to get off the truck, with care taken not to cause agitation.

In the pens animals are handled by the slaughterhouse groom and directed inside the enclosures. Cattle are split up and grouped together via a series of gates managed by the grooms. Operators do not come into direct contact with animals, since they are in separate corridors. These corridors are formed using reinforced cement or tubular metal vertical structures. Tubular structures are also present above concrete pathways. Only suitably trained grooms and veterinary officers can work in the pens.

Animals, kept in single file in these lanes, are inspected by the veterinary officer during an ante mortem examination.

They are then arranged in “homogeneous” groups in single file along the pathway leading to the stunning box.

Photo 2/B: pathway to the stunning box.

2 – Equipment, machinery and plants

External manoeuvring areas

In the yard weighing operations are performed and trucks are manoeuvred for unloading and subsequent washing and sanification operations. These areas are significant because their size and organisation are essential safety factors for persons in the area and for the specific operations performed there.

Transportation trucks

These vehicles should possess the characteristics to facilitate sanification after each transportation operation, and must be equipped with raised platforms, ramps and walkways for the unloading of animals.

These devices should preferably by mechanised (hydraulic operation), so that workers are spared dangerous manual actions, the manual handling of loads, etc. Technical devices for the handling and positioning of ramps should conform to necessary safety requirements.

It must also be possible to separate animals inside the truck and sort them in groups. The even distribution of the load is also indispensable for guaranteeing the stability of the truck on the road.

Unloading ramps

In full throughput slaughterhouses unloading ramps are fixed concrete structures, while in small plants they may be mobile equipment that is positioned for each unloading operation. In all cases however the haulage worker must be able to pass along a pathway other than that walked on by animals but parallel to it, so as to be able to help with the moving of cattle from a position protected against accidental contact.

Lairage

The lairage area provides temporary shelter, where animals are kept for some time prior to being butchered or simply being directed to the stunning box, and in which the ante mortem examination is carried out by the veterinary officer. Depending on the length of stay, these pens must be able to guarantee the possibility of giving animals food and drink. They must also be able to guarantee the effective containment and separation of animals into groups.

Pens must conform to hygienic requirements typical of workplaces where hygiene risks are high. They must thus be well lit and be easy to clean and disinfect. The specific traits of slaughterhouse pens vary in relation to the internal pathways where workers responsible for controls (grooms and veterinarians) must be able to walk and approach animals, but separated from animals by barriers. These places should also be endowed with systems and equipment to assist with the handling of injured or fallen cattle. This problem is particularly important, since animals move in single file in cramped areas, where it is extremely difficult to work with normal handling devices.

Another need for the pen zone, which in some contexts has already been satisfied, is that of the showering of cattle before the butchery phase in order to improve the cleanliness of the whole process.

Pathway to stunning box

This is a protected walkway, formed by concrete or tubular metal structures, in which animals go from the pen in single file towards the stunning box. In this case too it is always necessary to have this pathway flanked by a walkway for the assisting operator, who steers animals along the path from a protected position.

3 – Risk factors

Persons being knocked over in manoeuvring areas

This risk is very much dependent on the size and organisation of manoeuvring areas, and on procedures to be established for the performance of various operations. The more these factors are inadequate or poorly defined, the greater the risk, especially for workers in the yard, performing weighing operations, etc., of being knocked down by manoeuvring trucks and lift trucks, or sundry vehicles not related to the butchery line.

It should also be noted that many potentially dangerous manoeuvres are performed by workers not employed by the slaughterhouse (hauliers). This sometimes means that such workers are not aware of established procedures, routines, etc.

Accidental contact (traumas) with animals

A risk common to practically the whole phase described is that of traumas resulting from accidental contact with animals that need to be moved (getting off trucks, moving to lairage, single file channelling, ante mortem examination, etc.). This risk is particularly high when unexpected events occur, for example when it is necessary to separate a suspect animal from the group walking in single file or still on the truck, after the inspection, or when accidents occur, such as animals falling along the pathway or escaping from retaining structures. A typical situation in which this risk is particularly high is that of the unloading of trucks, when human intervention is needed, for instance to untie cows or open division gates inside the truck. In all these cases workers have to enter enclosures, in direct contact with animals that are clearly agitated, move in confined spaces and perform improvised operations. Then they have to use “extemporaneous” equipment to remove animals that have fallen or are injured, such as lift trucks and ropes or chains to lift the animal out of the enclosure. In all these cases the specific risk factor is compounded by the type of retaining structures, sometimes metal tubes, located in the immediate vicinity of animals, which may be crushed or trapped. The most dangerous animal parts are obviously the head, horns and hindlegs. But the whole animal that is moving or falling can cause very serious damage to the worker.

Other traumas may be caused by the particularly severe physical exertion required of these workers when unloading and handling animals, especially when it is necessary to improvise when animals fall, escape, etc.

Biological risk

This risk is associated with workers in this phase coming into contact with animal secretions and excretions, especially when there are sick animals.

Risk deriving from hostile microclimate

Operations are performed outside (unloading) or in the pens, where there is the risk of draughts and sudden temperature changes close to entrances. The work of grooms also involves entering and exiting pens close to the pathway to the stunning box.

Humidity is high in the pen enclosure.

4 – Likely damage

Likely damage on the basis of risks present and epidemiological data is quantified, or rather estimated, by production unit and not by single phase.

5 – Actions

With reference to risks present in outside manoeuvring areas, namely the danger of being run over by vehicles, clearly the risk depends on the plant and the type of activity. A small-sized slaughterhouse for instance operates only on some days of the week, and a single vehicle is usually sufficient to supply the butchery line for a butchery session. In full throughput slaughterhouses there is an abundance of scheduled vehicle traffic.

Essential prevention thus involves close coordination between the plant’s prevention system and the haulage firm to establish clear and unambiguous manoeuvring procedures, clearly identify areas set aside for various operations, to informally make those workers entering the slaughterhouse area with their vehicles aware of their responsibilities. The manoeuvring area must be endowed with appropriate signalling so that in addition to meeting essential safety requirements any persons entering the slaughterhouse for the first time can move about correctly.

In these cases a “yard manager” must be appointed to coordinate all yard activities, so as to avoid interference or dangerous situations. Every truck driver entering the plant should also be given a written memo giving the layout of the plant and indicating the paths to follow and the areas in which operations are to be performed.

With reference to the risk of traumas deriving from accidental contact with animals, it should first be said that this risk is run by employees of the slaughterhouse, haulage workers and veterinary officers (“contractors”). The areas in which these risks arise are, at least in theory, quite separate: haulage workers work in the unloading phase in the yard, grooms manage the lairage area on the inside, as do veterinary officers. In practice the distinctions are not so clear-cut, especially in smaller slaughterhouses.

With regard to unloading operations one should in theory prevent (forbid) workers from climbing inside the truck where animals are kept. This ban must be observed to the letter for beef bulls. With regard to dairy cows coming from permanent stalling, which have to be tied up to the vehicle, it appears inevitable that the operator has to climb onto the truck and be in direct contact with the animals. With regard to the opening of division gates inside the truck, a system must be devised to permit opening from the ground.

Once the vehicle and animal ramps are in position, the doors are opened and the animals get off. In this phase no worker must be on the cattle ramp, and any available side spaces (useful as escape routes for workers) must be isolated. Assistance to animals must be provided from outside, being careful to avoid unnecessarily violent or rough handling, which may further agitate animals. The barriers separating animals from workers assisting them in this phase are often tube structures. This may lead to the crushing of limbs. Solid barriers would be preferable, with a walkway for workers enabling them to perform actions from above.

Lairage operations, performed exclusively by the grooms, entail getting animals to move in single file and their sorting in homogeneous groups through the opening and closing of gates. These operations involve some risk of crushes, and must be performed by expert staff. An organisational measure to be adopted is that of forbidding non-experts (including haulage workers) from entering this area. Another element requiring special attention is the system used to close box gates. Systems used should ensure the safety of such closures to prevent them from being opened accidentally by animals or persons, or from being left open by mistake.

A critical element for which solutions must be found is the already mentioned need to act when animals fall or are injured inside the boxes or when in single file on the walkways.

This problem is more evident in full throughput plants where the spaces of boxes or walkways are flanked and, beyond the space for workers, there is no area for the handling of equipment or machinery. In small slaughterhouses this problem is less evident, since there is usually only one walkway, and it is easier to bring machines closer. The central problem does not appear to be solved however.

Thus such zones should be equipped with special hoisting equipment making it possible to safely remove an injured or fallen animal. It must be possible to isolate the animal from the one coming after in order to perform harnessing operations in relative safety. If such stationary equipment is lacking, it is necessary to ensure that machinery (lift trucks or the like) can work from outside the walkway to remove animals. The possibility of moving machines close to walkways or boxes is in any case a recommended structural measure.

With regard to hostile microclimates, it is suggested that work positions with draughts, where workers operate in the presence of continuous temperature changes (inside/outside) be eliminated. The lairage area should be endowed with a general ventilation system, with openings located in an appropriate manner. With regard to animal unloading areas, the installation of roofing is suggested, so that workers are sheltered from inclement weather.

6 – Outsourcing

As already mentioned, the phase consisting of the reception, weighing and unloading of animals is carried out by haulage firms which, irrespective of the type of supply contract, must be considered as slaughterhouse contractors, for the adoption of coordination measures pursuant to art. 7 of Legislative Decree 626. In this case such measures must be particularly significant. Some operational elements of this coordination are specified in the previous chapter.

While it might appear to be paradoxical, the work of veterinary officers in this and all other phases may be compared to that of contractors for the adoption of preventive measures and their coordination. At the present time it appears that neither the customers (slaughterhouses) nor the “contracting” parties (ASLs) have recognised this point.

BUTCHERY

Part I

The phase in question includes:

4. stunning of cattle;

5. jugulation and bleeding.

1 – Description

The animal moves towards the stunning box along an enclosed pathway. It is “steered” by a worker located outside the walkway. The stunning box is a cage with four full side walls, the upper part is open to enable stunning, although it is endowed with protection to limit the danger of accidental contact with the animal.

The front zone of the stunning box is shaped so as to minimise the shift in the position of animals according to their size.

The back wall and one side wall of the stunning box can be opened with a pneumatic vertical sliding mechanism. The back part is closed after the live animal has entered, while the side part is opened after the animal has been stunned.

The stunning box is always positioned so that the cattle pathway and the floor of the stunning box are raised compared with the inclined floor towards which the mobile side wall opens. On the opposite side is the worker responsible for stunning, placed in a raised position compared with the floor of the stunning box. This enables him to perform stunning from a suitable position, with the best possible vision of the shooting field and of the zone to hit.

The worker holds a captive bolt gun loaded with blank caps.

The shot causes the instantaneous release (and subsequent return) of a metal bolt that enters 6-7 cm inside the animal’s cranium, causing stunning. This technique makes it possible to work on the animal relatively easily and to cause subsequent death by bleeding (Legislative Decree 333 of 1.09.98).

Photo 3/B: Captive bolt gun.

Once shot, the bovine animal falls down in the stunning box. The operator presses a button to open the side wall. The animal falls by virtue of gravity into a zone where another operator hooks a hindleg to the hoisting tackle. The animal is hooked up using certified chain bindings having a capacity ranging from 1,200 to 2,500 Kg. The animal is hoisted up (in the industrial cycle) using a guided hook, while the hoisting tackle usually has a non-guided hoisting device.

The hooking zone is circumscribed by vertical guards, suitably spaced out (30 cm circa), to allow the worker to escape and prevent the animal’s escape.

While the animal is hung and lifted up, the ground operator moves the next animal into the stunning box.

Photo 4/B: vertical protective elements

In the meantime the stunning worker moves to the side of the shooting position and, using a knife, makes a preliminary incision of the hide in the front part of the neck. Cutting causes the first abundant release of blood. After bleeding each animal, the operator cleans himself using the shower. The cutting of the hide effected by the stunning operator (a workload that appears excessive in the full throughput cycle) means there is a clear-cut separation of knives used for the subsequent jugulation operation.

The cutting of the hide is indeed considered a “dirty” operation, being effected on the outer part of the animal, whereas jugulation is considered a “clean” operation.

After having performed the incision and cleaned himself, the stunning operator returns to the stunning zone, where he reloads the gun and proceeds with the next shot. This operator must be qualified by virtue of a training course in accordance with the provisions of Legislative Decree 333/98.

The next operation is performed immediately downstream. The hung animal is moved above a trough covered with grating, where an operator standing on a mobile raised platform cuts the jugular canal to cause rapid and complete bleeding. This operation may be performed with the use of a normal knife with which blood vessels are severed or with the use of a hollow knife that is driven into the animal’s blood vessel, with the operator cutting upwards.

The latter knife is connected to a flexible hose that directly conveys the blood to a tank.

Photo 5/B: jugulation

An anticoagulant is placed directly into the hollow knife.

Blood is usually allowed to drop into the trough (cutting with normal knife) for bullocks, while the hollow knife technique is used for cows. This mixed system makes it possible to collect blood separately depending on the type of animal and use to be made of the blood.

The hollow knife is left inserted for about 20 seconds. Complete bleeding happens in about a minute, during which time the animal is moved above a blood collection trough. In this position too there is an abundant release of blood, and the operator washes himself after every animal using the shower.

After bleeding the hung animal is moved to the next workstation.

Photo 6/B: bleeding

2 – Equipment, machinery and plants

In this phase the following machines and equipment are used:

Stunning box or killing cage, consisting of four plain side walls. The back wall and one side wall are openable using a pneumatic vertical sliding system operated by the worker. The upper part of the stunning box is endowed with protective tubing to limit the possibility of accidental contact with the animal. The only unprotected part, for a length of about 60 cm, is the front part (the most dangerous part), where the operator shoots from. The front part of the stunning box is tapered so as to limit the freedom of movement of the head of smaller sized animals.

The back door is opened to allow the animal to enter and then immediately closed. After stunning, the side door is opened and the animal falls by virtue of gravity from the stunning box into the area where the animal is hung onto the hoisting tackle.

Captive bolt gun: for one shot, loaded each time (for each animal) by the operator, with blank cap (only release charge, no projectile). This gun is completely metallic and endowed with two safety catches: one on the trigger and one in the zone where the bolt is released (the hammer is freed when the gun rests against the animal’s head. The gun is returned to a gun holder with the bottom open.

Electric hoisting tackle: this is operated by the ground operator responsible for hanging up the stunned animal. This equipment in the industrial cycle is structured so as to effect the guided hoisting of the load, i.e. the hook is inserted in a slanting runner that restricts the degree of freedom and thus oscillation. This detail is extremely important, since in this phase the animal is not dead, only stunned, and there may be violent spasms, with movements of the limbs and head. This may cause dangerous oscillations and put considerable strain on hoisting devices.

The animal is hung onto the hoisting tackle with the chain bindings applied by the ground operator, using the so-called “strangulation” system. These chain bindings must have a capacity such as to withstand strains over and above the maximum weight of animals. In the full throughput cycle bindings are used that have a certified capacity of 2,500 Kg, a safety factor of about 2.5.

First overhead guideway section

The first stretch of overhead guideway, or rail, takes the animal to the workstation where the hindlegs are removed, and the animal is hung by the two hind hocks using pulleys fitted with hooks and inserted in the main guideway of the butchery chain.

On the first section of the overhead line the animal is hung up using a single chain fastened to a hind leg.

Knives – Hollow knife with flexible hose

With regard to the use of the hollow knife for jugulation, it should be stressed that this operation requires a degree of dexterity and a certain amount of experience, since the knife must be driven into the blood vessel in an axial manner, cutting upwards in a single action as the animal tenses and at the same time moves along the transportation line.

Mobile work platform – the platform on which the worker responsible for jugulation stands, it is height adjustable so that the operation can be performed under the best ergonomic conditions and be adapted to the size of animals butchered.

3 – Risk factors

Accidental contact with animals: this risk is present during the entire phase described, and appears in a number of ways. Even before entering the stunning box, for instance, the animal may refuse to enter, and the ground operator may have to come into contact with the animal in an attempt to encourage it to move. The risk is mainly to the upper limbs. Inside the stunning box the risk for the worker responsible for stunning is high, since he must come into contact with the animal’s head. The animal may be agitated and move its head in an unforeseeable way. It should also be borne in mind that in this phase the operator moving close to the animal’s head is holding a gun, which may go off accidentally and cause injuries to the operator, or hit the animal in an incorrect position, causing not only suffering but also further uncontrolled movements.

This risk factor is heightened in the inclined area, when the stunned animal exits the stunning box. Here the animal often tenses violently, as the chain bindings are fixed to a hindleg, which is thus a particularly hazardous operation. The animal may attempt to stand up and try to escape, with the danger of knocking over the ground operator. Accidental contact with animals is also possible during the hide cutting and jugulation operations, again with reference to uncontrolled movements caused by spasms deriving from stunning. It should be noted that these operations require workers to come into close contact with the head and forelegs of the hung animal.

Risk of falling load

During this phase the risk of a falling load, i.e. the animal hung onto the transportation line, is particularly high, since the animal is hanging from a single point, and for most of the journey it is still not dead. The animal’s convulsions, producing uncontrolled movements, may thus cause the load to become unhooked from the hanging and transportation systems is the pulley is released from runner, etc. This risk is present throughout the butchery chain, and is attributable to unforeseeable and accidental causes (breaking of hocks or pulleys, etc.).

Risk of cut wounds: connected with the use of knives in the hide cutting and jugulation phases. This risk depends on the uncontrolled movements of hung-up animals, as already mentioned.

Risk of gun-related traumas: this risk is tied up with possible shots let off accidentally by the operator, recoil, etc., harming the operator himself.

Risk deriving from anti-ergonomic factors

The use of the gun entails a biomechanical overload of the upper limbs and in particular an additional risk for the shoulder. The calculated OCRA index is in the red zone for the right arm and in the green zone for the left arm.

With the animal being suspended from the guideway, workers in low throughput slaughterhouses face the risk of incorrect postures (yellow zone). When performing tasks this worker always works with both arms raised above his shoulders. With one hand he takes hold of the control unit attached to the ceiling operating the guideway of the butchery line, and with the other takes hold of the animal’s foreleg and accompanies it to the jugulation zone.

Handling in the full throughput slaughterhouse appears to be easier (green zone), since the chain used for suspension is within easy reach.

Noise-related risk: connected with the use of the gun (about 64 shots an hour). The three workers involved in this phase are most exposed.

Biological risk: biological risk is present throughout the slaughterhouse. In the phases described here the significant element is the copious blood to which workers are exposed during the hide cutting and jugulation phases.

Risks deriving from hostile microclimate: this risk too is present throughout the butchery chain. In this zone, the hot-humid conditions are compounded by draughts, since the work setting is not completely confined to an inside environment.

Psychological risk – stress – work rates. This phase involves particularly high work rates, especially for the stunning worker. The killing of animals may also cause negative psychological reactions. It is felt that this aspect should be studied in greater depth.

4 – Likely damage

Likely damage on the basis of risks present and epidemiological data is quantified, or rather estimated, by production unit and not by single phase.

5 – Actions

The work phase examined, referring to a “mature” full throughput cycle, i.e. operating for about 20 years with the same basic technology, already benefits from a number of measures designed to reduce risks. These measures have been adopted on the basis of experience and generally appear to be quite effective.

· The stunning box: its shape, with a tapered front section, minimises the freedom of movement of the head of small-sized cattle and thus reduces the likelihood of errors being committed by the stunning operator and the possibility of traumas owing to uncontrolled movements of the animal.

· Upper protection of the stunning box: in this case too protection limits the possibility of coming into contact with the trapped animal. The most dangerous zone however (front section), where stunning is performed, is unprotected.

· Zones where hung-up cattle move in front of operators (cutting of hide and jugulation) are endowed with metal structures designed to protect workers against any uncontrolled movements of the animal.

· These workers always wear protective headgear.

· The inclined floor, in front of the stunning box, where the animal is hung up using the chain bindings, is relatively protected against the danger of an incorrectly stunned animal climbing back up and charging. This protection consists of vertical metal bars circumscribing the zone, through which the worker can escape but which cannot be crossed by the animal.

· The hoisting tackle and guided hook make it possible to reduce oscillations of the animal and any uncontrolled movements of the limbs and head, and thus reduce the danger of workers being struck. This solution is not present in low throughput slaughterhouses.

· The first stretch of the overhead transportation guideway is endowed with devices that prevent pulleys from coming out of their runners on the rail. These devices should be used for all guideways. In this case protection is added to a part of the transportation line subject to particular stress and where the risk of losing the pulley is very high.

· Redundant-capacity chain bindings have been adopted due to the strain exerted on the hoisting system not just from the weight of animals but from movements caused by post-stunning convulsions.

· The mobile raised platform in the jugulation zone has recently been introduced to optimise the position of the operator in relation to the size of the animal.

· To perform jugulation and hide cutting at the front of the neck, operations that require the operator to move close to the animal’s forelegs, a special approach technique is used to be able to perform operations outside the likely trajectory of kicks.

6 – Outsourcing

The phase described and most of the butchery line (up to dehiding) has recently been outsourced. The firm in question is a butchery cooperative. The number of cooperative workers corresponds to half the number of workers in the butchery chain. The contractor appears to act correctly in relation to those risks typical of operations in this phase, and all workers regularly use prescribed PPE.

BUTCHERY

Part II

With phase 3 the butchery cycle proper begins. This phase in the industrial cycle includes all operations performed on the outside of the butchered animal before opening up the carcass to remove offal.

The phase examined includes:

6. removal of hindleg tips

7. dehiding and removal of milk gland

8. removal of foreleg tips and head

9. completion of dehiding

1 - Description

REMOVAL OF HINDLEGS: The animal reaches the first operator from the bleeding zone, the right hindleg hanging from a chain. The operator stands on a work platform that is height adjustable. The first operation is the dehiding of the free hindleg up to the haunch, using a hand-held knife.

Then, using a hand-held, power-assisted hydraulic slicing machine, he cuts off the (free) left hindleg.

Photo 7/B: power-assisted hydraulic slicing machine

The second operator, standing on a raised, stationary platform, removes the udder, or genital organs (penis and testicles) and puts them in ad hoc receptacles. He then inserts in the hock of the dehided limb the hook-pulley and inserts the pulley in the transportation guideway. The hooks with movable pulleys arrive via rails situated close to these first workstations from the washing positions located outside the butchery room.

Photo 8/B: insertion of the hook with pulley.

The transportation system, which in this phase entails the passage from the slaughter guideway to the butchery guideway, drives the animal along, acting on the hock hooked up by the second operator, at the same time “freeing” the remaining leg from the hoisting chain fitted after stunning. In this way the operator in position 3 receives the animal hanging up by a hock (left) with the right hindleg free.

In the same way as operator 1, operator 3 dehides the limb up to the haunch and removes the leg with the use of a second hydraulic slicer. He then inserts the hook, endowed with pulley, into the hock and inserts the pulley into the main guideway of the butchery line. This operator stands on a stationary work platform.

At the same time the slaughter guideway system returns the hoisting hook and chain to which the butchered animal was hung in the stunning zone.

During this phase, through the operations described above, the animal is thus moved from one transportation system to the other. The guideway to which the animal is hung by both hocks is the main one of the butchery line. The animal will now only be unhooked in the cutting phase. Indeed even after the carcass is split into two sides, these will remain hung up onto the transportation line via the hooks inserted in this phase.

DEHIDING OF UPPER PARTS: This phase is carried out by 6 operators in stations 4, 5, 6, 7, 8, 9, and is preparatory to the actual dehiding phase, which will be subsequently carried out using specific machinery. The operators stand on two raised work platforms in groups of three. In greater detail, operators 4, 5, 6 dehide the front part; operators 7, 8, 9 are practically opposite the other group and dehide the back part up to about 20 cm above the anus zone. The anus is then sealed up using an elastic binding, or plastic bag (for cows), using a specific piece of equipment, a sort of pneumatic gripping device. This is a meat processing hygienic measure which, together with the closure of the oesophagus, prevents meat contamination caused by intestine materials during the various work phases. Operators work as the transportation chain advances, each operator begins work on an animal at one end of the platform and moves along the platform together with the animal. In the meantime the colleague before him works on the previous animal. Each operator has completed operations when he arrives at the end of the platform. At that point he passes behind his colleagues and moves to the start of the platform, and resumes work on another animal, and so on. Each worker thus performs all of this phase’s operations on one animal at a time. The time available for each operator is the “usual” 56 seconds. Operations are performed using hand-held knives. Variables for these operations are the type of animal. For some operations are simpler and quicker, for others more time is required depending on the difficulty of dehiding. Skill, precision and speed of execution are required.

COMPLETION OF MANUAL DEHIDING: Workers performing operations 10 and 11 are positioned on a mobile work platform, whose height can vary from 0.4 m to 1 m from the ground, depending on the length of animals. These due two operators perform, respectively: dehiding of lower back part, resuming the work performed in stations 4, 5, 6, the cutting of forelegs using a hand-held knife and dehiding of forelegs (like all manual dehiding operations, this is preliminary to subsequent mechanical dehiding). Opposite these workers is operator 12, he too standing on a mobile platform (height ranging from 0.1 m to 0.6 m from the ground), removing horns and dehiding the head. Horns are detached using a hydraulic slicing machine, different in size but very similar to those used for the cutting of legs.

COMPLETE DEHIDING OF ANIMAL: The hung-up animal is moved along the transportation rail to the dehiding machine. Here it stops until the operation is completed. In previous phases the animal has already undergone those actions needed to prepare for this operation, which is very important for the quality of the product and productivity of the line. In other words, dehiding must be rapid and must not damage the carcass, e.g. tearing muscular bundles, breaking backbone, etc.

Two workers work with the dehiding machine, one on each side, standing on mobile platforms, which move vertically following the movement of the working part and radially (moving away from the carcass in the final dehiding phase).

The hide of the animal is torn from the carcass using an oil-pressure/hydraulic system formed by a rotating cylinder around which the hide is wrapped.

Photo 9/B: insertion of the hook with pulley.

The cylinder tears off the hide, which is gripped by two chain bindings joined to the cylinder itself. Dehiding is performed downwards, i.e. from the hind quarters of the animal towards the head. The two workers first insert the two strips of hide already detached, in the ham zone, in the two chain bindings. They then operate the machine: the cylinder begins to rotate and wrap around itself first the chain bindings and then the hide, which in the meantime is set in motion and begins to be removed from the carcass. The cylinder continues to rotate, and at the same time the machine begins its descending movement together with the two operators who, using knives, follow the operation and facilitate hide removal. When the working part of the machine moves close to the animal’s head, the point where the maximum traction is exerted, the arms supporting the platforms on which the operators are standing move away from the machine, effecting an arc of circle on a horizontal plane.

After the hide has been torn off, the cylinder reverses its motion and drops the hide on a conveyor belt located immediately below the machine. The hide is released from the chains using two auxiliary chains, which loosen the two main chain bindings by which the two strips of hide are held. The moving conveyor belt below immediately transports the hide out of the butchery line to a specific hide processing area.

The hide indeed must never go past the carcass along the line. From here on the line is considered as “clean”. In the above operations two other pieces of equipment are used.

The first, two pneumatic gripping devices, blocks the hindlegs of the animal during dehiding and relieves the transportation rail. The equipment is dedicated to this purpose, and is placed opposite the dehiding machine on the other side of the animal. In this way the transportation system is not subject to traction during dehiding.

Mechanical stress exerted on the guideway by mechanical dehiding is indeed capable of producing damage and being a risk to worker safety.

The second piece of equipment is an electrostimulation device operating at 130 V, consisting of 4 needles that are stuck into the animal’s back. This operation tightens muscular mass when the hide is torn off, so that the operation can be carried out at high speed without tearing muscles and leaving the “valuable” mass of the animal intact.

This phase completes the sequence of “outside” works. In subsequent phases the carcass will start to be “opened up” for the removal of offal and subsequent cutting.

2 – Equipment, machinery and plants

During this phase the following equipment is used:

Overhead transport systems (guideways)

The first guideway with hoisting tackle is located in the kill zone. In this first transportation system each hooking point must be able to bear the weight of a bovine animal (with relative tolerance), bearing in mind the stress caused by animal convulsions until bleeding is complete. In this system the hoisting hooks are never removed from the runners. The elements that are continually moved are the chain bindings described in phase 2.

The second guideway (the main one) consists of a rail onto which pulleys with hooks are fastened. The “in phase” feed system entails a rate of 56 seconds per animal. The capacity of this guideway is 1,000 Kg/m. Its “step” is 2.46 m. This means that each animal has a guideway capacity of 2,460 Kg, about twice the weight of the heaviest animal that is usually butchered.

Hooks endowed with pulleys are fastened onto the main guideway using a mechanical system that raises the pulleys, which are then applied by operators at a height below shoulder level.

There is a third overhead transport system through which cleaned hooks (and pulleys) are conveyed to the zone of use from the cleaning zone.

Work platforms

All operations in this phase are performed on raised platforms, stainless steel structures correctly protected on three sides with normal guards. The operational side, that looking onto the passing animals, is endowed with low barriers (0.4–0.6 m), or has no type of guard at all. Some of these platforms are mobile, i.e. adjustable in height by operators, to adapt the workstation to the height of the animal, or because the phase requires that various actions are performed at different heights. The average height of the platform floor naturally varies for operations regarding the hind quarters of the animal (high), 2.5–3 m from the ground, and operations regarding the front section (low), at heights varying from 0.1 to 1 m from the ground. In greater detail:

- operator 1 is on an adjustable platform, working on the upper part of the animal, with a barrier on the operational side 0.4 m in height;

- operators 2 and 3 work on a stationary platform, in the upper zone, with barrier on the operational side 0.4 m in height;

- operators 4, 5 and 6 work on a stationary platform, in the upper zone, totally devoid of protection on the operational side;

- operators 7, 8 and 9 work on a stationary platform, in the upper zone, and have a barrier on the operational side 0.4 m in height;

- operators 10 and 11 work on a mobile platform, at a height ranging from 0.4 to 1 m from the ground (working on the lower zone of the animal), and have a barrier 0.4 m in height;

- operator 12 works on a mobile platform set at a height varying from 0.1 to 0.6 m from the ground;

- operators 13 and 14 work on platforms at the dehiding machine, which are adequately guarded against the danger of falls and move throughout the machine process (from 0 to 3 m in height circa).

Photo 10/B: mobile platform.

Hand-held knives: used in all operations in this phase. Each operator is given various types of knife and a sharpener. This equipment is carried on a belt, and knives are normally placed in hot water sterilisers located near workstations.

Hand-held hydraulic slicers

This equipment is used to remove the hindlegs and horns. These portable machines are powered by a fluid under pressure. The fluid produces the energy needed to power the “knife”. Machines are operated using a pneumatic system. Manual commands directly operate the pneumatic valves piloting the hydraulic control unit that generates power flows. This eliminates the presence of electrical equipment in these machines.

This equipment is endowed with dual control power-on systems, requiring that both operator hands are needed (and are thus in a safe zone) to operate the machine. These machines are suspended via a cable and endowed with a support, close to the workstation, to lessen the weight borne by the operator.

Hooks with pulleys: this metallic equipment is continually used and subjected to considerable mechanical stress. They must be checked frequently and replaced at the end of their operating life.

Hydraulic dehiding machine

This machine is of fundamental importance in the full throughput butchery chain. It completely dehides the animal very quickly, leaving the underlying carcass and its valued parts intact.

The hydraulic machine consists of two vertical bars/frames along which the working part and the side platforms on which the operators stand run/slide.

The working part is a rotating cylinder endowed with two metal chains. The machine tears the hide off the animal through the traction exerted by the rotating cylinder, which wraps the hide around it, starting from above (back part) and moving downwards (towards neck zone). The machine thus acts by combining two movements: the rotation of the cylinder and translational motion deriving from the cylinder itself. The two operators working with the machine fasten the two strips of hide to the chain bindings on the upper part of the animal, then they simultaneously operate their control units to begin the work cycle. The strips of hide are pulled by the chains (“strangulation”) onto the cylinder, which rotates and begins to move downwards. In the meantime the two operators follow the dehiding process with knives. When close to the animal’s neck, the point where the maximum traction is exerted, the two platforms move away from the animal’s body, effecting an arc of circle on a horizontal plane (“elephant’s ears”). Once dehiding is complete, the cylinder reverses its motion and drops the hide onto a conveyor belt located immediately below the machine. The original strips of hide are released using two auxiliary chains, which loosen the two main chain bindings.

Conveyor belt for transporting hide

This is a very normal continuous conveyor belt, located below the dehiding machine. It receives the animal’s hide and transports it to another area where the hide is first processed. In the full throughput cycle the immediate removal of the hide from the butchery zone is considered a fundamental element of meat processing hygiene. In smaller slaughterhouses this condition may not always be guaranteed.

Clamps to block and support carcass

Opposite the dehiding machine, on the opposite side of the butchered animal, the full throughput cycle uses a device to block the hindlegs, consisting of two pneumatic clamps that block and support the legs and the entire carcass, relieving traction stress from the suspension and transportation system, formed by the hocks, hooks with pulleys and guideway. The device is operated by a dehiding worker once the animal is ready for dehiding. It is located at a height of about 3 m from the ground, in a neutral position, i.e. out of the reach of workers. The system is not part of the dehiding machine. It appears that it is not adopted in limited capacity or smaller slaughterhouses, where the speed of dehiding (and operations in general) is not of great importance.

Carcass electrostimulation device

This is an electrical device, not part of the dehiding machine, consisting of four plugs placed on the top part of the animal’s back as soon as the hide has been torn from that zone (i.e. in the initial phase). Four needles emerge from the four plugs. These needles are inserted in the muscular mass and a voltage of 130 V cc is administered. This electrical charge tightens the muscles in the carcass, making dehiding easier, avoiding damage to animal muscles and consequent economic damage, due to the traction exerted on the hide by the dehiding machine. The action performed by the equipment is included in the dehider work cycle and is automatic.

Pneumatic gripper

This is a small hand-held piece of power-assisted equipment used to fasten an elastic band or small plastic bag to seal up the rectum. This is to prevent possible meat contamination in subsequent work phases caused by intestine materials. Similar to this operation is the sealing of the oesophagus in a subsequent phase.

Suspended showers for washing

Each workstation has its own suspended shower with flexible hose to enable workers to wash frequently and to clean work zones, structures and the worked parts of animals. These devices are not present in smaller slaughterhouses.

Knife sterilisers

Each workstation has a steriliser for knives, working with hot water at a temperature of 80°. Sterilisers are located in such a way as to be easy to use for operators in the same work zone.

3 – Risk factors

In this phase of the work cycle practically all risks typical of the butchery phase are present. This chapter looks at risks that are specific for operations carried out. Risks that we may view as being ubiquitous are dealt with in the general chapter.

Ubiquitous risks are taken to mean: exposure to noise; hostile microclimate, biological risk, risks deriving from the use of general installations (electricity, compressed air, fluids under pressure, hot water, etc.) .

Specific risks in this phase are as follows:

Risk of falling from height

This risk is present during all work performed on raised platforms, practically all the stations examined in this phase. The risk is clearly higher for those stations positioned higher up, where workers operate on the hind quarters of the animal, and for stations where protection is totally lacking on the operational side. For a precise identification of types refer to chapter 3.2.2, a summary of which is given below:

- operator 1 is on an adjustable platform, working on the upper part of the animal, with a barrier on the operational side 0.4 m in height;

- operators 2 and 3 work on a stationary platform, in the upper zone, with barrier on the operational side 0.4 m in height;

- operators 4, 5 and 6 work on a stationary platform, in the upper zone, totally devoid of protection on the operational side. The situation in this case is further complicated by the fact that the three operators rotate on the platform and advance on the operational side, following the passing animal. This makes it difficult to adopt personal fall prevention systems;

- operators 7, 8 and 9 work on a stationary platform, in the upper zone, and have a barrier on the operational side 0.4 m in height;

- operators 10 and 11 work on a mobile platform, at a height ranging from 0.4 to 1 m from the ground (working on the lower zone of the animal), and have a barrier 0.4 m in height;

- operator 12 works on a mobile platform set at a height varying from 0.1 to 0.6 m from the ground;

- operators 13 and 14 work on platforms at the dehiding machine, which are adequately guarded against the danger of falls and move throughout the machine process (from 0 to 3 m in height circa).

To have as exhaustive a picture as possible of the risk situation, we should say that it is quite evident that for most stations examined it is not possible to install normal guards with foot guards (height m 1, intermediate barrier at 0.5 m and foot guard at min. 0.15 m). Realistically, it would be necessary to re-determine all the altimetric values of main infrastructures and equipment. Secondly (compounding the situation) it was seen that under operational conditions, with the presence of animals hung up on guideways, the operator working at a height in no way perceives the risk of falling, since there is no sensation or awareness of being thrust towards a void. In this sense the animal acts as a contrasting element and semi-stationary reference, or at least this is the sensation perceived by the worker.

In practice, if the worker loses balance or his movement lacks coordination, there is a very real risk of falling. Stations endowed with barriers at a height of 0.4 m are slightly more protected, but they clearly do not provide standard safety, but merely lessen the risk. Less exposed are operators workers on platforms whose level does not exceed one metre from the ground. Not because the risk of falling is less, rather because of the less serious consequences of falling. In any case, even though it is important to consider preventive measures in terms of differing working heights, it is deemed indispensable for all raised stations to be protected against the danger of falls (see chapter on “Actions”).

Risk of cut wounds

This risk is related to the generalised use of hand-held knives in all stations. Only obvious observations can be made, relating to the fact that operations to be performed require dexterity, precision, physical exertion and a certain speed of execution, and that each operator performs his operations in close contact with colleagues, who are busy performing their own tasks. Accordingly the degree of attention to other workers may not be high. The risk of cut wounds is thus concerned with wounds caused by the operator himself or by neighbouring colleagues.

Mechanical risk of sundry traumas

This risk affects the upper half of workers’ bodies, limbs in particular, deriving from possible accidental contact with equipment. Dangerous elements are those relating to overhead transport systems.

Operations and stations most exposed are those in which the animal is transferred from the first to the second guideway, where hooks with pulley are to be inserted in the hocks and fastened to guideway rails, works on the upper part (hind quarters) of the animal, where the operator’s hands are close to the rail containing pulleys and hooks used to hand up the animal. All of these elements are dangerous and can cause injuries, even accidental bumps (with hooks) and knock-downs between moving parts (pulleys and rail).

It should not be forgotten that all manual dehiding operations require not only precision and speed of execution but also a fair amount of physical exertion, which must be commensurate with actual needs, different for each animal. This means that any uncoordinated or unforeseeable movement must be considered not as an exceptional event, but as a “physiological” aspect of the job.

Mechanical risk of cuts caused by slicing machines

This risk is usually insignificant, since this equipment is endowed with a manual dual control. A residual risk may be present in cases in which two workers are present in one workstation at the same time (e.g. during training), when the exposed person is the one not using the machinery.

Risk of animal hung to the hoisting and transportation system falling

This risk may be due to the breakage of a hock, the accidental unfastening of a hook, breakage of a hook or the hook–pulley system, a pulley coming off the runner, or structural yielding of the guideway. Bear in mind that the system universally adopted for hanging animals onto the butchery line and generally for meat in the sector entails the use of open hooks devoid of safety devices.

This risk is present in raised stations, where traumas to the upper limbs may be serious, and for persons that may be walking under the line at that moment. Clearly these persons are exposed to the most serious risk.

To adequately formulate the assessment of such a risk, we might say that where the suspension of the animal also entails hoisting and more severe stress, owing to ante mortem convulsions (prior to complete bleeding), the hoisting and transportation system entails the use of chains with nooses (so-called “strangulation” method). After the bleeding phase there are no more irregular strains from the animal’s body that can cause hooks to become unfastened.

Breakage of the hock is however a “real” problem, since it may happen at any time, without any violent causes, but simply due to the animal’s structure, pathologies, etc. It is quite a rare event, but it cannot be ruled out and is difficult to predict.

The breakage of hooks is also unlikely, whereas breakage of the hook–pulley system is more likely. The two elements are joined by two steel plates, are subjected to stress, leading to “fatigue”. In the long run this may cause yielding and breaks.

Pulleys coming off the runner is another possible event. It is more likely to happen where there are changes to guideway levels, curves and exchanges.

The yielding of structural parts of the guideway is usually a remote event, with the exception of the mechanical dehiding operation. Mechanical dehiding is indeed the most critical operation with regard to the danger of the carcass falling down. During this operation the traction exerted by the machine on the animal is extremely high and capable of exerting critical stress on the animal suspension system. This stress is transmitted to the animal’s hocks, hooks, pulleys and guideways, and is capable of breaking one or more of these elements. This may in turn cause the carcass or mechanical suspension elements to fall. The greater the speed of execution of the operation, the greater such stress appears to be.

The extent of the risk depends on many elements. There are of course the structural and maintenance conditions of the suspension system. Secondly, there are machinery operating modes, working speed, the presence of electrostimulators and, fundamentally, the auxiliary system adopted to block and hang up the animal. Finally, the possibility that the area where the carcass might fall is accessible to persons.

The possibility of damage to persons is however limited when the ground area is inaccessible, while machine operators appear not to be in the line of trajectory of the fall. This is the theory, in practice it is likely that only one of the two points of support (hocks) of the carcass will be torn, so before the animal falls to the floor the carcass will become seriously unbalanced and will oscillate in the direction of one of the two machine operators.

Risk of getting trapped–entangled

This risk is specific to the upper limbs of the two dehiding machine operators when the machine’s working part is set in motion. The two operators insert the strips of hide in the chain bindings keep holds of the hide until, by virtue of the traction exerted by the machine, the chain bindings clasp (“strangle”) the hide. This is a delicate phase in which a simple but precise manual technique needs to be adopted to avoid very serious damage. The machine is operated via a dual command, that needs to be effected simultaneously by both operators standing on the platforms.

Each of the two operators also has an emergency button within easy reach.

From what was observed, a non-marginal degree of risk is present when setting the chains in motion despite the safety devices in place, since the action of the cylinder when the machine cycle gets under way continues without interruption until dehiding is completed. There is a precise moment when the operators have to let go of the hide clasped by the chains being wrapped around the cylinder. If for any reason the worker does not let go or a hand remains caught in a chain, the worker is clearly prone to very serious damage. The pressing of the emergency button will cause the machine to stop, but does not appear likely to avoid injuries.

In addition to this specific risk one should also consider the possibility of dehiding operators accidentally coming into contact with the working (rotating cylinder) from which they are not physically isolated.

Risk of violent issuing of carcass parts

The risk of being struck by parts of hide or meat is present during mechanical dehiding, especially for the two machine operators. The risk is considerably less for other persons, since the ground area close to the machine is not usually accessible.

This risk increases as the operation proceeds, and is highest close to the animal’s head, when the exertion generated by traction is highest.

Mechanical risk (dehiding machine and transportation of hides)

In the area below the dehiding machine, where the hide transportation system is installed, there is a general mechanical risk deriving from the possibility of an accidental contact with moving parts, either of the machines or the hide transportation system, in addition to a high risk of being hit/knocked down by suspended loads.

Anti-ergonomic risk

The removal of the ends of hindlegs using grippers causes a biomechanical overload of the upper limbs, especially the right wrist. The calculated OCRA index places the right arm in the red zone and the left arm in the yellow zone.

The same operation in a low throughput slaughterhouse is less risky (yellow zone for right arm and green zone for left arm).

There is always a postural risk, since the operator adopts an incorrect posture (bending of spine) during dehiding of the leg.

The removal of the milk gland is a very demanding operation due to the effort required of the shoulders and hands. The calculated OCRA index posted a red zone score for both the right and left arm.

There is another postural risk (bending of spine – yellow zone) because despite the presence of height-adjustable platforms the operator is forced to bend to reach the front part of the animal.

Removal of the head and tongue in full throughput slaughterhouses brings with it a significant risk of biomechanical overload for the upper limbs. The calculated OCRA index is in the yellow zone for the right arm and in the red zone for the left arm, with the intense exertion of the left shoulder and hand.

In low throughput slaughterhouses the head is removed at the same time as the forelegs. The entire operation is generally less risky, being in the yellow zone for both the right and left arms. There is however a risk deriving from the manual handling of loads, as well as a postural risk (yellow zone), since the operator lifts with a hand the animal’s head, weighing around 20 Kg, after it has been severed, and transports it to the removal zone. Subsequently, with a twist of the back, the operator drops the head in a special receptacle.

Dehiding in full throughput slaughterhouses using the dehiding machine saves workers in terms of the overload of upper limbs. The OCRA index recorded only a moderate exertion of the right shoulder and wrist (yellow zone).

In low throughput slaughterhouses dehiding is still performed manually, and consequently, the calculated OCRA index rises to the red zone for the right arm (maximum exertion for shoulder, wrist and hand) and to the yellow zone for the left arm. A postural risk is also present, since operators, reaching for parts of the animal to dehide, adopt incorrect postures, such as bending, leaning over and hyperextension of the spine.

4 – Actions

Risk of falling from heights there is no protection against this risk, which is significant during the dehiding of upper part of the animal, when the height of the work platform is more than one metre above the floor.

In newly constructed plants the risk may be eliminated by designing workstations endowed with normal railings and foot guards. This means that the passage of the bovine animal in front of each operator must occur at a suitable height in relation to the zone in which operations are to be performed. In other words, single workstations must be located at different heights depending on the dehiding zone. This must be between the height of the operator’s shoulders and the height of the railing/guard.

Clearly this means a greater parcelling of single stations. This appears relatively easy to accomplish when one worker is working on a single platform, so the most suitable height for the platform can be obtained every time. It is more difficult however when more than one worker is on a single platform working at the same time on extensive areas of the animal (such as stations 4 to 9, etc.).

In all cases in which it is not possible to install normal railings, we suggest installing a retention system to which operators should be fastened using a safety harness. This system should consist of an overhead rail above the work platforms (one for each platform), onto which the steel cable retainers (pre-tensioned) are hooked, to be connected to the harnesses worn by workers. The rail should have a ring structure in those collective stations where each operator follows the same animal from the beginning to the end of the platform and then returns to the head of the group, passing behind his colleagues. This system has a minimum impact on existing structures and does not entail a shake-up in the current organisation of work. Alternatively, if one wishes to keep mutually fastened hooking points, there is the problem of parcelling operations performed on each animal by each worker. This does not appear to be particularly easy to solve, and it may be a cause of friction within the group, something that should be avoided. The proposed system, in addition to increasing the use of PPE, involves an element of rigidity, consisting of the mutual position of the groups of three operators. This is already a normal practice however, and is unlikely to exacerbate the situation. The harnessing should not of course be heavy, so as not to overload operators even more, as they are already wearing a considerable amount of PPE (the safety devices already mentioned, waterproof apron, boots, etc.), and carrying knives and a knife sharpener fastened to their belts.

With regard to the risk of cut wounds, workers are endowed with the usual PPE, consisting of a steel mesh glove for the hand not holding the knife, forearm protection and steel mesh smock, even though not all these guards are worn completely. With regard to possible wounds caused by neighbouring colleagues, no special measures appear to have been adopted. The only suggested measure is that of a greater distance between one animal and the next, and of course the extension of the work platform. This aspect of the problem should be born in mind when thinking about the sizing of full throughput plants. Production lines are designed for given production rates, and over time are overloaded. This leads to an inevitable shrinking of operating spaces and overload of guideways.

To prevent traumas caused by contact with moving parts of guideways, traditional open and accessible guideways should gradually be replaced by closed systems in which moving parts are inaccessible. This would also prevent pulleys from coming out of the runner.

Pending these changes, it is suggested that at least the sections of guideways placed in the immediate vicinity of workplaces be protected and rendered inaccessible through the use of barriers. Such measures have already been implemented in the industrial line (in line with directives). Moreover, critical guideway sections, where there are level changes, crossroads, bends, etc., have been afforded protection against the unhooking of pulleys.

With regard to the mechanical hoisting system for the raising of the hook-pulley system (already inserted in hocks) the following is proposed.

It may be possible to eliminate the manual handling of hook-pulley systems by adopting a system for the mechanised positioning of hooks and pulleys so that the hook can be inserted in the animal’s hock. In existing systems it is believed that the phase in which the load is tightened should be deliberately set in motion by the operator using a system of consensus, possibly two-handed. This new system would eliminate the risk of crushing-trapping when the load is tightened.

There remains the risk of accidental contact with the actual hooks when the upper parts of the animal are being worked on. Contacts may be due to simple uncoordinated manoeuvres or movements, remembering, as mentioned previously, that such events are common given the type of work performed.

There are several possible solutions:

- firstly, protect the zone in which hooks slide, where this risk is present;

- adopt modified hooks endowed with a system of protection, possibly in combination with a system to prevent unhooking;

- adopt an extra hock retention system similar to that deployed in the mechanical dehiding phase. In addition to protecting hooks and eliminating risks for workers, this could obviate another risk: carcasses falling to the ground.

With regard to mechanical risks deriving from slicing machines, it is believed that machine safety devices, consisting of a dual pneumatic button requiring the use of both hands at the same time, are adequate. With regard to the presence at the station of a second worker, the adoption of a suitable working procedure appears to be sufficient.

Prevention of the risk of the animal falling from the overhead transport system is a serious issue and not easy to eradicate, even though it is confined to exceptional and accidental events. With regard to the protection of ground staff, people should be prohibited from moving in zones where loads are suspended. It is also necessary to install protection in zones exposed to such a risk, since bans placed on transit in the zone below the butchery chain are not always observed, sometimes due to real work needs. Moreover, the area in which an animal becoming detached from the overhead system can cause damage, and which should be out of bounds for transit, is quite extensive.

A second aspect is concerned with the system by which the animal is hung up. It should first be said that throughout the sector the open hook system is adopted, in which hooks are not endowed with safety devices. This fact creates problems that are not easy to solve. This is an issue that should be looked at by standards authorities. On the one hand the adoption of a system of “closed” hooks appears a great challenge, and may bring about additional risks. On the other, the risk in question is not so much the possible unhooking of hooks owing to the lack of closure devices as the possible breakage of the animal’s hind hocks onto which the hooks are attached. A technical solution is at hand (for the time being only adopted in the mechanical dehiding phase), by which the carcass is hung up using not only the hooks fastened to the hocks but also pneumatic grippers that get a hold of the whole hindleg of the animal. This system should be extended to the whole butchery chain until the carcass is split into two. At that point of the process the carcass has already undergone intense mechanical stress (which should guarantee its resistance) and a part of its weight has already diminished (removal of offal).

With regard to the risk of pulleys coming out of runners, it is necessary to adopt closed guideways that eliminate the problem at source. For the time being, existing structures should be modified by adopting mechanical protection to combat these risks, consisting of steel blades placed along the sides of the rail, at a suitable distance, to physically prevent the pulley from coming out of the runner.

The problem of “hook-pulley” system damage can be solved by the adequate sizing of these systems, with regular checks on their state and scheduled substitution at the end of their operating life.

As regards the structural safety of the transportation guideway, sizing is again an important aspect, and the integrity of the system and all its components should be regularly checked.

An observation should be made on this question, with special reference to structural installations: the capacity of the continuous handling system and of all its components must be calculated and designed with generous margins of safety, since when the line is installed a given work rate is usually determined. This rate is likely to rise over time, due to new work techniques or new equipment. In these cases the guideway is not replaced, and there is thus the risk of overload.

The risk of dehiding workers getting trapped–entangled in the machine’s working parts (rotating cylinder and chains) does not appear to be suitably countered. At the preset time the two machine operators need to give their approval at the same time, pressing an appropriate button, when the cycle begins. It is proposed that this system be integrated with a second level of approval to be provided by both workers after the phase in which the hide is made taut using the two chain bindings. In other words, once the two chain bindings in which the workers manually insert the strips of hide are tightened, the movement of the cylinder should be stopped and be allowed to continue only after receiving a second positive instruction (dual and simultaneous command) for the cycle to begin.

At this point there remains the risk of coming into contact with the working part during dehiding. A solution may be to install cylinder protection, acting as a spacer, which may be positioned automatically after the chains are made taut following the second command giving consent to the start of the cycle.

This protection would constitute not a total isolation of the dangerous part but rather a physical barrier separating the part from workers, acting as separator and spacer, which would be effective in preventing accidental contacts due to uncoordinated movements, etc.

The risk of issuing parts of hide or carcass hitting dehiding workers appears to be under control thanks to the design of the machine. The two work platforms move away from the dangerous area in the finale dehiding phase, when the risk is greatest.

The risk of accidental contact with moving machine parts, present in the “low” zone opposite the dehiding machine, where the hide is unloaded onto the conveyor belt, is not considered by the machine manufacturer (despite CE marking). In full throughput plants the zone is fenced off quite effectively. It is proposed that the zone be circumscribed by insurmountable barriers endowed with safety interlock.

Equip the butchery line with height-adjustable mobile platforms in order to avoid incorrect postures, such as bending of the spine.

Place the head collector receptacle in low throughput slaughterhouses closer to the area where animal heads are removed and adopt correct postures, turning the whole body and not only the trunk, so as to avoid twisting of the spine.

Equip the butchery line with height-adjustable platforms where the mechanical dehiding machine is not present. This measure prevents workers from taking up incorrect postures and allows them to work keeping the piece in the “safety zone”, i.e. below the level of the shoulders and above the hips.

BUTCHERY

Part III

This phase marks the final stage of the butchery line, with removal of the head, opening of the carcass, evisceration, splitting of the carcass into two sides, finishing, post mortem examination, removal of marrow, washing, weighing and economic appraisal of meat, health marking, transport to chilling tunnel.

This phase is carried out by 14 slaughterhouse workers and is followed by one or two veterinary officers, one of whom works in the butchery chain, and carries out control, cutting operations, etc. on various organs.

The phase examined includes:

10. evisceration of the abdomen

11. opening of breastbone

12. thoracic evisceration

13. splitting of carcass into sides post-mortem examination

14. finishing.

1 - Description

· At the end of the dehiding phase the animal remains suspended to the transportation chain via the two hooks fastened to the hind hocks. It then advances along the line to station 15. Here an operator situated on a mobile platform opens up the breastbone using a reciprocating electric saw. The machine is portable, and is kept in position via an aided suspended system to limit the incidence of the weight of the machine on the worker’s arms.

· Opposite this station is station 16, where an operator endowed with pneumatic grippers fastens an elastic band to the base of the oesophagus after having emptied it in an upwards direction (towards the stomach). This operation, combined with the sealing of the anus, at the beginning of works, minimises the risk of meat contamination on the part of intestine materials. This could occur only if abdominal offal is accidentally broken during the removal phase.

· Operator 17 remove the head of the animal using a hand-held knife. The head falls onto a work table, on which the next operator (station 18) cleans the head and removes the tongue, again using a hand-held knife. He then hangs the tongue and head, side by side, onto the offal transportation line. This is a ring-shaped transportation line next to the butchery line, on which the various organs removed from the animal are placed, so they appear all together, next to the relative sides of meat, for the post mortem examination effected by the veterinary officer. Subsequently organs are distributed to the various areas destined for specific processing.

· In station 19 an operator on an adjustable platform removes abdominal offal (intestine, stomach, pancreas, bladder, genital organs) using a hand-held knife. The abdomen is kept open using a pneumatic retractor applied by the operator before performing the operation. The retractor is endowed with a circuit powered by hot water at a temperature of 82°C and a system of nozzles by which the equipment is washed and sterilised after each animal. This equipment makes it easier to remove abdominal offal, reducing the likelihood of organs being struck and opened up. To avoid such a possibility, which would contaminate the meat, a manual technique is employed, with the knife “overturned”, i.e. with the blade pointing outwards. This is adopted especially by less expert operators.

The use of the retractor was detected only in the full throughput cycle, and is not present in smaller slaughterhouses.

Once removed, abdominal offal slides via a conveyor into a bowl, hanging onto the offal transportation line, which will transport this offal for unloading in the tripery room, after having been examined at the veterinary officer station together with other parts of the same animal. The system conveying offal to the transportation bowls is adjusted automatically according to the height of the work platform, which in turn is regulated by the operator according to the animal’s height. This helps prevent the falling of offal and minimises the risk of breakage. At the end of the operation the retractor is removed and applied to the next animal.

Photo 11/B: removal of abdominal offal.

· In station 20 an operator working on an adjustable platform removes a part of the thoracic organs (heart, lungs, liver, oesophagus, trachea/windpipe, etc.), detaches the diaphragm and pleura, cleans and removes all offal, leaving it attached to the carcass through the part of the oesophagus still in place after the intestinal pack. This operation is performed using hand-held knives after having applied a pneumatic retractor similar to the one used in the previous phase.

· In station 21, again on an adjustable platform, the operator removes all remaining thoracic organs and hangs them on the hooks of the offal transportation line. The offal line is arranged so that at this point all offal is sorted in order and side by side: head, tongue, abdominal offal, thoracic organs of the same animal. The series of organs moves in phase with the butchery line so as to reach the station of the veterinary officer at the same time as the relative sides of meat. The evisceration technique requires that the set of thoracic organs remains “a set” and not scattered organs.

· Station 22 is located opposite the previous station on an adjustable platform. Here an operator uses a hand-held knife to remove the tail, then, using a pneumatic rotary cutter, performs preliminary finishing operations, consisting of the removal of fat from that region.

· Station 23 is where the carcass is split into two sides with a longitudinal cut, with the cutting of the animal’s backbone into two parts.

This operation is carried out by an operator standing on a self-propelled mobile platform (moving up and down via a pedal command operated by the worker and from side to side automatically, in step with the overhead guideway transporting the carcasses.

The operator uses an electric band saw weighing about 100 Kg, attached to a suspension aid. Like all other operations under review, this operation requires particular skill and speed of execution. At the end of the operation the worker cleans both equipment and the sides of meat. At the end of the operation the platform returns to the start position, moving back by about 1.2 m. A second machine is located close to this station. It is a reserve machine to be used in case the first machine breaks down, so as to avoid interruptions to the work cycle. It should be noted that the carcass can be split into two sides manually, especially in some low throughput plants, with the use of an axe.

Photo 12/B: splitting of carcass into two sides.

· The next station is that of the veterinary officer. After cutting, the sides of meat are submitted for inspection, and at the same time the offal transportation line presents abdominal offal, thoracic organs, the head and tongue of the animal. The veterinary officer must carry out, in the time allowed by the “pace” of the line (56 seconds per animal), all the sight controls and sample controls on the various organs with the use of hand-held knives.

If problems are detected, organs are removed from transportation lines and placed in ad hoc receptacles to be sent for destruction. At the end of finishing operations, suspect sides of meat are conveyed to a separate line and placed in the unit for suspect animals, pending further analysis. Normally, after the veterinary examination, organs carry on along their transportation lines and are mechanically conveyed to specific areas for further processing (dressing of heads, offal, tripery).

· Stations 24 and 25 are located on a stationary platform, where the sides of meat undergo final finishing with the use of hand-held knives.

· Station 26 is a ground station, where final finishing of the lower part of the meat sides is performed, in particular the neck and gullet zones. Operations are performed using hand-held knives.

· Station 27, again on the ground, entails the removal of the spinal cord via suction. A worker, using a sort of vacuum cleaner, extracts bone marrow from the whole medullary canal. This marrow is conveyed to a closed tank before being sent for destruction.

Photo 13/B: extraction of marrow.

· After this operation the sides of meat go to an automated shower-type cleaning station, where no operators are involved.

· Station 28 is the final station of the butchery chain, where sides of meat are automatically weighed and assessed for their economic worth. This evaluation is effected by a highly expert member of the butchery line. Evaluation of the animal is very important, as it determines its market value, and price for the producer. Cattle are indeed bought and sold at “dead weight”, and the unit price depends on the properties of the single animal. Each side of meat is thus identified with a label giving its relative classification.

2 – Equipment, machinery and plants

Continuous overhead transport system (guideway) for butchered animals: this is the main guideway around which the entire butchery cycle revolves. After dehiding the animal carcass remains hanging up by its hocks on the hooks (endowed with pulleys), which slide along an overhead rail, pulled by chains operated by an electric geared motor. Transportation guideways observed in this phase of the industrial cycle are in practice of two types: that of the main butchery line, which goes to the end of the finishing phase and carries on to the suspect animals storage unit; the second, which “receives” loads arriving at the finishing phase and transports them out of the butchery line to the automatic weighing unit and then to the chilling tunnel. In a normal cycle there are no interruptions to the transportation system, and the transfer point from one system to another is protected against the possibility of pulleys accidentally coming off the rails. The second guideway is also moved by a chain operated by an electric geared motor located above the guideway operating at 380 V c.a.

Work platforms: these are stainless steel platforms on which workers stand and on which the various operations described are performed. They are located at various heights, and the majority are mobile, in that the operator can adjust the height of the work floor according to the height of the zone in which work is performed. In this part of the line the maximum height of the platforms does not exceed 1.5 m, while minimum heights are 0.6-0.7 m from the ground. Platforms are adequately protected on three sides, being endowed with normal railings and foot guard, but are unprotected on the operational side. A variant of the general type is the platform used in station 23, where the carcass is split in two. In this case the platform equipment moves up and down via a pedal command operated by the operator on the platform, and is also endowed with a system for the automatic sideways movement of the platform so that vertical cutting operations can be performed while the animal continues to move along the transportation line. The distance covered by the equipment is about 1.2 m.

Hand-held knives: used for most jobs in the phase. Each operator is given four types of knife and a sharpener. This equipment is carried in the worker’s belt, and knives are normally placed in hot water sterilisers located close to workstations after use on the animal.

Hooks with pulley: this metallic equipment is used in continuation and subjected to considerable mechanical stress. They must be checked frequently and replaced at the end of their operating life.

Frame saw: This portable machine is used to cut the breastbone, and is powered by 48 V three-phase AC electric current via the transformer located above the guideway. The tools used on this machine are built specially for this use, and have a rounded end to reduce the likelihood of internal organs being broken when the sternum bone is sawn. As a result, this characteristic leads to a significant improvement in passive safety, reducing the risk of wound cuts due to accidental contact during the work phases in which the machine is not handled. The machine is hung up on a metal cable with suspension aid to reduce the weight borne by the operator, and is switched on via a single button on the handle.

Pneumatic gripper: This is a small hand-held piece of power-assisted equipment used to fasten an elastic band to seal up the oesophagus. This is to prevent possible meat contamination in subsequent work phases caused by intestine materials. Similar to this operation is the sealing of the rectum, described in phase 3.

Splitting saw: this special machine is used as a portable machine, although its weight (around 100 Kg) renders it unusable without a suspension aid system. It is basically a band saw with which the operator cuts the carcass longitudinally, proceeding downwards along the backbone. It is powered by an electric engine operating at 48 V three-phase AC, in turn powered by a transformer located above the guideway. During the cutting operation the operator uses a pedal command to gradually lower the platform he is standing on, so that he is always working from an erect position. In the meantime the platform moves along via an automatic system to keep the operator “in phase” with the advance of the carcass along the transportation guideway. The machine is endowed with dual command buttons, which have to be kept pressed down, and which the operator has to press at the same time to switch the machine on. It should be observed that the machine’s handles are not endowed with guards. This could trap the worker’s hands if the machine is removed from the system of suspension. This type of machine appears to be universally used in butchery operations. The same operation may be performed using automatic rotary cutters, or manually using an axe.

Pneumatic degreasing knife: This is a portable machine powered by compressed air, endowed with a rotary cutter, with which the operator removes excess fat close to where the tail is joined. The circular knife is kept rotating by the pneumatic system, while the operator manually pulls the knife.

Continuous transportation systems: In addition to the main guideways transporting animals along the butchery chain, in this phase another system of continuous transportation is used, the so-called offal line. As already mentioned, this line, structurally similar to the butchery guideway (moved by chain, in turn powered by electric geared motor), is installed to the left of the butchery line, has a ring structured, moves anticlockwise, and thus for a stretch moves in parallel and in phase with the butchery chain. The offal line consists of 24 stations, each of which is comprised of 3 hooks and a bowl. In the stretch moving parallel with the butchery chain the following are suspended on this line: head, tongue, abdominal offal (in bowl) and thoracic organs. These products moves along to the station of the veterinary officer, then the line begins the return journey, and when it reaches specific openings it “unloads” the various organs in areas destined for further processing (tripery, processing of heads, red offal). Before returning to parallel to the butchery chain the various elements are cleaned in the automatic cleaning station.

Marrow removal machine: This equipment has been introduced to fulfil obligations of legislative measures to tackle the outbreak of bovine spongiform encephalopathy (BSE). It consists of a vacuum pump, connected to a hose handled by a ground operator, and a closed receptacle in which the marrow extracted from the sides of meat is conveyed to a unit for subsequent destruction. The extracted air is discharged outside via its passage in a battery formed by three absolute filters.

3 – Risk factors

Risk of falls of suspended loads

This risk derives from the possibility of an animal carcass suspended to the main transportation chain falling to the ground due to the breakage of elements that keep it suspended. This risk has already been described in phase 3 (dehiding of bovine animal). In this phase the risk is similar, with the same structural and dynamic elements. There are no new negative factors, indeed some conditions make the risk less likely in this phase. Firstly, the suspended animal has already been dehided mechanically, an operation entailing intense mechanical stress for the carcass, such that it is believed highly unlikely that the carcass will undergo structural yielding such as to cause a fall. Secondly, various organs are gradually removed from the carcass, lightening the burden for the suspension system. Thirdly, no particular traction-related stress is envisaged in the phase examined. Elements of residual risk are the possibility of pulleys coming off the rail or of the structural yielding of the guideway or of single hook–pulley systems.

With reference to possible changes to butchery techniques arising out of the BSE outbreak, with the whole of the animal’s backbone having to be removed, we take this opportunity to state that experiments have shown that if the bovine animal is not cut on the centre line, but rather next to of the backbone, so as to keep the latter whole, the resulting hung up sides of meat tend to lose their shape, extend abnormally and even collapse in some parts. This leads to the conclusion that to keep the backbone whole butchery techniques would need to be completely overhauled.

Risk of falling from heights

This risk was also examined in the previous phase, and is very similar in this phase, since most workers are located on raised work platforms. In this phase most platform bases are less than one metre from the ground, with the exception of stations 19, 20 and 23, which can be raised to a height of 1.5-1.7 m. Different assessments must be made for low throughput cycles, where workstations and platforms are less specific. In the industrial cycle all stations examined in this phase are totally devoid of protection on the operational side. In operating conditions workers are in direct contact with the animal to be worked on, to which they reach out and use as an element of support. Actual risk should therefore be assessed in light of these elements. It is believed however the risk, albeit “mitigated” by the above conditions, cannot be neglected or underestimated, but should be tackled and prevented. An unusual risk of falling from a height may be faced by workers in the side splitting phase if the suspension system of the relative band saw were to break. This machine is heavy (100 Kg). The risk of falling derives from the possibility of being dragged down by the fall of the saw if the handles are a closed type. These may trap and keep hold of the worker’s hands.

Risk of cut wounds

This risk is relative to the general use of hand-held knives in all workstations. No special observations are to be made, except for the obvious remarks that operations to be performed require skill, precision, physical exertion and a certain speed of execution, and that each operator performs operations in close contact with colleagues, who are similarly intent on performing their own job. Thus the degree of attention to what other colleagues are doing cannot be high. The risk of cut wounds is thus concerned with wounds caused by the operator himself or by neighbouring colleagues.

Mechanical risk deriving from contacts with equipment and installations

This general risk is present throughout the butchery chain. Inevitably the floor of work areas is slippery; thus it is possible that workers can make accidental contact with sundry equipment following slips or falls. Possible specific risks include the presence of the offal transportation line, risk consisting of the hooks to which various organs are fastened. Hooks are placed at various heights, depending on the ergonomics of operations, but they dangerous when accidental contact is made with “empty” hooks. Other specific risks are mobile platforms for ground workers in the vicinity. In particular, the self-propelled platform on which side splitting workers stand appears to be a relevant risk, since it is situated close to the service walkway, where the presence of ground staff is frequent.

In this phase there does not appear to be a particularly significant risk of accidental contacts with parts of the overhead transport system (guideway - hooks-pulleys), since all operations are performed at lower heights.

Risks deriving from accidental contact with working parts

In this phase the following machines are used: frame saw to open up the breastbone, splitting saw and pneumatic rotary cutter used to remove fat from the perianal zone. Machines must possess CE marking.

The frame saw constitutes a risk deriving from the lack of a two-handed operating command (the saw is switched on using a single button that needs to be kept pressed on the main handle). This risk is mitigated by the fact that if this machine is held with a single hand, it is practically impossible to use to perform operations on the animal. There remains the risk of making accidental contact with the moving working part if the machine is operated with a single hand for operations other than that for which it is intended. On this point it should also be said that accidental contact with the working part at rest can cause damage not less than that caused by the moving part. With regard to the tool, it has already been said that the saws used in this phase have a rounded end (for production purposes) to improve safety. Residual risks are thus reduced.

The splitting saw (or rather saws, the one in service and the replacement machine) are endowed with adequate protection for the unused parts of the blade (inspection shutter and substitution of interlocked blades) and with two-handed, “pressed down” command systems. Saws are moreover kept in an operational position by a suspended aid system which ensures a sufficient longitudinal equilibrium. This reduces the risk of workers hitting themselves with the machine because of uncoordinated movements. It should also be noted that the operational configuration of these machines is such that incorrect positions in relation to the normal vertical working plane is only a remote possibility. Residual risk appears to be acceptable.

The rotary cutter used to remove fat from the zone where the tail is joined is a portable machine powered by compressed air. It is held in one hand and the single command button needs to be kept pressed down during operations. It is endowed with a start-up safety device, requiring the use of both hands to switch on the knife. Subsequently the machine is kept switched on through the use of one hand. If the button is released the machine stops working, and to switch it back on the two-handed procedure must be repeated. In this way the manufacturer has rightly sought to provide protection for the critical start phase, when an accidental manoeuvre is more likely. To switch the machine on the worker has to use both hands, and accidents appear unlikely. Once the knife is switched on one hand is free, but it should be said that for injuries to occur the free hand would have to be inside the crown of the knife. Residual risk thus appears to be acceptable.

Risks of falls owing to slips

This risk is present in all butchery phases, also in areas where livestock are handled, and in areas where post-butchery operations are performed (cold stores, deboning, cutting, packing, shipment, etc.). Clearly however these risks are higher in the butchery and tripery halls and areas where offal and heads are processed, as well as the preliminary hide processing area.

In the butchery hall the floor is constantly covered in water, deriving from frequent washing effected in all workstations, and is covered with grease, blood, scraps of meat, etc. This makes the floor very slippery, with a high risk of slips and falls and thus of relative traumas. The risk of falls caused by slips is also present on work platforms, although the metal grates on the platform base limits the extent of such risk.

4 – Actions

With regard to the risk of suspended animals falling to the ground, already dealt with in phase 3, it should be observed that although transit is forbidden in the zone in which carcasses may fall, this zone is not circumscribed or physically enclosed. This fact was not detected in any of the plants examined. The actions already suggested in points 3, 4 and 5 are thus proposed, namely:

- Isolation of the area where carcasses may fall, i.e. to physically prevent the butchery line from being crossed.

- Cattle suspension aids, adopting systems that ensure the animal’s hindleg is blocked and kept in position, in addition to the current system keeping the hocks in place.

- Adoption of safety guideways whose structural elements physically prevent the pulley from coming off the runner. With regard to existing structures it is possible to adopt temporary measures, e.g. the installation of metal structures that prevent this from happening.

- Accurate sizing and checking of system capacities (guideway and hook-pulley system).

- Accurate and timely maintenance (control, repair, substitution) of mechanical parts.

Risk of falling from heights

A radical approach must be adopted to the risk of falling from heights, referring to workers operating on raised platforms, although operating conditions mitigate such a risk in some cases.

In the event of new installations, the problem can be tackled via the adequate altimetric sizing of lines. The animal transportation guideway should be installed at a height sufficient to allow work platforms to complete the required “travel” (downwards too), to enable operators to perform single basic operations on the various parts of the animal, at an adequate height, i.e. in an erect position, from the hips to the shoulders. This solution includes the installation of railings at all stations. Collective raised stations should of course be reviewed, since one of the basic elements of the proposed solution is the possibility for each operator to adjust the height of his workstation at any time. And this solution would help avoid ergonomically negative positions.

For existing lines this solution appears difficult to implement, unless emergency restructuring or improvement actions are submitted pursuant to art. 48 of Presidential Decree 303/56, in which case the possibility of adopting the above solution should be assessed on a case by case basis.

An alternative to the installation of normal railing on workstations is the adoption of safety harnesses, endowed with pre-tensioned retention ropes for single operators. Bearing in mind the characteristics of workstations, one should observe that systems “limiting workers’ fall to 1.5 m” are not considered adequate, since as we have seen many stations are below one metre in height. It would therefore be necessary to adopt systems with cables having a fixed, predetermined length, so if workers fall from the platform they would avoid impact with the ground.

Risk of wound cuts

Operators are endowed with standard PPE, consisting of protection of a steel mesh glove for the hand not holding the knife, forearm protection and steel mesh smock, even though not all these guards are worn completely. With regard to possible wounds caused by neighbouring colleagues, no special measures appear to have been adopted. The only suggested measure is that of a greater distance between one animal and the next, and of course the extension of the work platform.

This aspect of the problem should be born in mind when thinking about the sizing of full throughput plants and when purchasing new equipment.

Mechanical risk deriving from contacts with equipment and installations

With regard to the risk of accidental contact with the empty hooks of the offal line it is proposed that each operator can manually remove hooks close to the workplace, insert them in the part that is to be hung up and then hang them on the transportation chain, which will be fitted with ad hoc fastenings that are not dangerous or normally inaccessible. An alternative may be that of physically circumscribing the offal line so as to avoid accidental contact with jutting elements (hooks) throughout the chain, with access or exchange points close to workstations where organs are to be hooked up to the line. This second solution introduces a certain rigidity of the system and requires adequate spaces, but is also rules out the possibility of contact with moving (albeit slowly) parts, i.e. with all moving elements of the transportation line.

With regard to work platforms and the risk of accidental contact with ground staff, the only solution is that of isolating the ground area with barriers.

Risks deriving from accidental contact with working parts

It is proposed that a two-handed dual command be adopted for operating the frame saw.

Risks of falls owing to slips

In one of the full throughput plants examined a new type of flooring is being tried out. This appears to be very promising and potentially able to significantly reduce the serious problem of floor slipperiness. This risk appears to be one of the most significant and ubiquitous of the whole sector. The experimental flooring is so far used in cold stores and freezing tunnels, where the operating temperature goes down as far as –50°. It has been observed that in these severe conditions the floor, covered with iced condensation, is not at all slippery. It is still necessary to verify compatibility with working environments, before which it is necessary to completely overhaul an entire hall, as preparation of the strata below the floor requires major intervention that cannot be carried out for simple portions. This solution appears to be limited by the cost, estimated at 130-140 €/sq.m (265.000 £/sq.m).

Other measures adopted to reduce this risk are footwear with nonslip soles, which are normally worn.

CHILLING, CUTTING, PACKING, SHIPMENT

The phase examined includes:

15. chilling

16. cutting of meat

17. cold storage

18. packing

19. handling and shipment of goods.

1 - Description

Phase 5 marks the end of the butchery cycle. Work is performed not in the butchery hall but in controlled temperature areas. Sides of meat are first chilled to bring bones to a temperature of 7° C. They can then be further processed, either being shipped off as they are or cut into quarters. Quarters can then either be shipped or cut further. Meat can then be shipped as fresh meat and kept at 0°C or frozen at –25°C and shipped as frozen meat.

In this phase about 45 persons are employed in the full throughput cycle.

In greater detail:

· Once assessed and labelled, sides of meat are transported via the mechanised guideway to the rapid chilling unit, where they are stored at a temperature of 0°C for about 2 hours. During this time they are not handled or processed in any way.

· When they leave the rapid chilling tunnel the sides of meat are handled by two operators who “load” the storage units. From this moment on the transportation guideway is no longer mechanised, and sides of meat are handled using a “side pushing” machine by a ground operator, who can handle 5-6 at a time.

· Storage units always operate at an unventilated 0°C, and require that meat be stored for a minimum of 24 hours to attain a bone (or “heart”) temperature of 7°C. During this time the meat is ink-stamped with a meat health marking, something that could not be done with the meat still warm. Each side of meat is given a label with its destination, which may be a customer or the deboning plant.

· From the storage units the sides of meat are taken out by three work teams, each formed by three persons, and transported to the 3 “quarter cutting” stations at which a like number of 3-member teams are working.

· At these units the meat is cut into quarters, or lesser anatomical cuts. In the former case, the forequarter of the animal is hung up directly via a hook to the same transportation guideway, using a device that raises the forequarter. In the latter case, when the anatomical cut is less than a quarter, the same device is used to position the piece on the guideway runner, but the piece is fastened onto the hook using nylon cord to keep it at a height that can be adjusted manually. After cutting, pieces are manually fastened onto guideways.

Photo 14/B: electric rotary cutter.

Photo 15/B: quarter cutting station.

· The three “quarter cutting” stations are in different rooms and serve different purposes. Work areas are at a controlled temperature of 12°. This value is a compromise between production needs, requiring temperatures close to those of meat preservation (0°-2°C) and the need to protect workers’ health. These workers spend the whole working shift in these rooms. The experience of this compromise may be said to be positive, since no real hygienic problems were encountered for meat worked in these conditions. The three stations serve, respectively, sundry clients (sundry pieces and cuts); industrial clients (large batches of quarters); “deboning” client (various cuts destined for internal deboning unit). Operators make cuts using portable electric rotary cutters of various sizes or portable, electrically powered frame saws, or an axe, for various veal cuts. When performing splitting operations using an axe, it should be said that these operations in the full throughput cycle are considered as “residual”, but in some low throughput cycle it is a routine operation for both standard and “special request” cuts, since this traditional method has a positive impact on the quality of resulting meat and bones. In particular, the overheating produced by the mechanical splitting saw is avoided. If the regulation providing for the elimination of the backbone is implemented, we predict that this particular aspect will no longer be taken into consideration.

· After the carcass is cut into quarters by the 3 teams of operators (each consisting of 3 persons), orders are transported to the shipment zone, ordered by specific batches. These operators perform the final finishing of cuts, weighing and identification.

· The meat prepared in the shipment unit is loaded onto trucks by 3 teams of porters (4 persons per team) who serve 6 loading stations. Trucks can transport meat in quarters or smaller cuts, sides (rarely) or vacuum-formed packs of deboned meat going directly to retailers, or deboned meat in “bulk” caissons destined for industrial processing. Finally, frozen meat that has been deboned and packed can be sent from the freezing cycle for direct retail sale.

· The cutting of quarters into anatomical retail cuts, a process known as deboning, is not examined specifically here, as this operation is performed in an ad hoc production unit by a contractor and has some extremely specific traits. It is a manual operation using knives, with extremely high work rates and requiring the utmost precision and expertise. Depending on the destination of meat, deboning can be performed with workers operating singly or in a chain. Single-operator boning is performed for meat destined for direct consumption or freezing, with the separation of the various anatomical cuts, their deboning and finishing. Deboning in a chain, also known as “hot” deboning, is performed for meat destined for further processing, for example the industrial production of hamburgers, in which the meat will be subjected to heat treatment of some sort. The deboning cycle also produces meat destined for subsequent industrial processing, which is shipped in “bulk” caissons, dry ice being placed between the various layers of meat.

Photo 16/B: truck loading zone.

2 – Equipment, machinery and plants

Side pushing machinery:

This dedicated machinery is used to handle sides of meat without workers having to physically push the pieces of meat. The machine is very similar in form to industrial machines used to clean floors. The original idea behind the construction of this machine came indeed from the fact that one of these floor-cleaning machines had in the past been improperly used by workers to lessen exertion deriving from the manual handling of sides of meat.

Electric rotary cutters:

These are portable 48 V AC machines with safety isolating transformer, or 220 V double wound isolating machines. They are of various sizes and weights. Larger ones are suspended, while others are held directly by the user.

They are used to perform various operations: cutting, degreasing, finishing, etc. They are endowed with protection for the unusable part of the tool, with a single on/off button that needs to be kept pressed down. The operator must use both hands to operate the machine. This equipment is endowed with a clutch, which comes into action when a given cutting exertion is exceeded, causing the rotation of the cutting disc to come to a halt.

Frame saws:

Used to perform various anatomical cuts, these portable machines are held with both hands, and are endowed with an on/off button that needs to be kept pressed down, with a 220 V input and double wound isolating. The tool is cantilevered on the machine body, and has a rounded end.

Axe

The axe is commonly used to satisfy “special requests” for veal cuts. It is generally held in both hands, with the worker on a raised platform.

Work platforms

In this phase a number of work platforms are used, differing in terms of structure and height of the base, since meat is suspended to the overhead conveyors at a single level, while operations need to be performed at different levels. There are stationary stations in which “scissor-like” height-adjustable platforms are installed, and movable stations, which can be positioned in different points of the work area. These are non-adjustable platforms endowed with ladder (3 or 4 rungs). These stations are now being replaced by adjustable platforms in fixed stations.

Photo 17/B: platform now being phased out.

Photo 18/B: mobile platform.

Quarter cutter

In the three stations where sides of meat are cut, equipment is used to raise (to the overhead guideway) the cut forequarters situated below. The forequarter is fastened at the height at which it is cut. The relative hook is then automatically taken up to the guideway using the electric hoisting tackle. If anatomical cuts are less than a quarter, a nylon cord is placed between the hook-pulley and meat cut. This cord is insert in the cut using a specially shaped knife, which makes a hole in the cut and inserts the cord when it is removed. This device makes it possible to keep various cuts at a suitable height for manual handling.

Hydraulic hoisting tackle

This equipment is situated close to loading gates where refrigerated trucks are standing by. It consists of an arm operated by a hydraulic system, and is used to transfer produce from guideways of the production unit to rails on the trucks, avoiding the manual handling of loads. This equipment is spreading to low throughput slaughterhouses too.

Electric pallet trucks

These are used in the shipment area to load packed products onto trucks.

3 – Risk factors

Hostile microclimate

Work in this phase is performed in controlled temperature environments, in particular in storage units at 0°C, where the following operations are performed: labelling of meat batches according to their destination, meat health marking and the removal of sides of meat for their transportation to quarter cutting stations. Cutting, weighing, final finishing and shipment operations are performed in rooms where the temperature is kept at about 12°C.

Wounds caused by hand and electric knife cuts

With regard to the use of hand-held knives, which are of course common in this phase, refer to previous observations. Worthy of note is the fact that work rates are not extreme in this phase (except for deboning), and workers are unlikely to wound their colleagues since stations are usually spaced out more than those in the butchery chain. It has been observed however that PPE is less used to protect against knife wounds.

There is a (theoretical) risk of self-wounds, since all electric knives are endowed with a single on/off button. However, all machines require that both hands be used simultaneously, and analysis of damage has not recorded a significant incidence of injuries resulting from this risk.

Risk of falling loads

This is the possibility of various meat cuts becoming unhooked from the suspension and transportation systems. While this risk was chiefly determined by structural elements (yielding of guideway, animal hocks, etc.) in previous phases (butchery), in this phase risk depends on the possibility of suspension pulleys coming off runners, since there are numerous hand-operated exchanges, with relative safety catches. The possibility of loads falling down thus depends almost entirely on errors when managing the guideway system. There have indeed been practically no cases of falls owing to the accidental unhooking of meat cuts from suspension hooks.

Risks of falls owing to slips

These risks are due to the floor being made slippery by produce waste, the dripping of meat during the chilling process, etc. The risk, which we recall is ubiquitous and extremely significant in all phases, is less relevant here than in the butchery sector, since there are fewer meat-based biological liquids, and the low temperatures further mitigate the problem.

Risk of falling from heights

This risk relates to work performed on raised platforms, devoid of protection on the operational side or endowed with a simple foot guard. This hazard will be reduced by the progressive introduction of adjustable platforms in stationary stations to replace the hand-positionable platforms, allowing the execution of various manoeuvres at a height that is appropriate for the work at hand.

Ergonomic risks

Ergonomic risks relate to the manual handling of loads. After the rapid chilling tunnel guideways are no longer automated. The sides of meat are moved with the aid of a side pushing machine, while smaller cuts are handled manually. This topic is tackled in greater detail in the “Ergonomics” section.

4 – Actions

Hostile microclimate

With regard to the easing of hostile microclimatic conditions (work in cold environments), some measures should be adopted. Firstly, workers should be endowed with adequate clothing for access to units at 0°C. With regard to actual work areas, where cutting, finishing, etc. operations are performed, and where workers spend a lot of their time, a compromise solution has been adopted, as mentioned previously, with a room temperature of about 12°C, as compared with the original temperature envisaged by the production cycle of 0-4°C. This solution, adopted after consultations with supervisory authorities, has produced positive results, improving working conditions without harming the quality of the product.

Wounds caused by knives

Measures adopted relate to the use of PPE on the part of single operators, in particular protection of the unarmed upper limb (for hand knives) or of the limb that does not operate the machine’s on/off button (for electric knives or frame saws). Use of the steel mesh smock to protect the worker’s trunk is also recommended.

Risk of falling loads

In this phase head protection is used. This measure is felt to be adequate. As already mentioned however, it is necessary to introduce system to protect against the risk of pulleys coming off guideway runners. Such systems should also be automated in order to drastically reduce ergonomic risks deriving from the manual handling of loads.

Flooring

With regard to the risk of falls owing to slips, measures adopted relate to the use of nonslip footwear. It is believed that the new type of nonslip floors, currently being tried out in cold storage units, can in the future be adopted for these rooms too.

If hygienic requirements laid down by existing food hygiene legislation can be met (such elements are still to be acquired), this solution may be a significant turning point for a serious and widespread risk.

Risk of falling from heights

This risk is not particularly high in the phase examined, and refers to work performed on platforms whose height is no more than one metre from the ground. It is still thought necessary however to introduce railings on height-adjustable platforms which, due to the characteristics of such platforms, could be adopted without interfering with the work zone.

PIG BUTCHERY AND MEAT CUTTING CYCLE

Preamble

To guarantee the continuity of information and connections for the reader, let us resume the description of the cycle published in February 1999 by ISPESL and the Istituto Zooprofilattico Sperimentale of the Triveneto region. The original text has been updated with additions acquired from the recent study, while respecting the original structure and numbering of phases.

The description in each datasheet refers to those phases of the cycle in which comments are felt to be useful in explaining synthetic data given in the general datasheet. One sheet may refer to more than one phase of the cycle if there are no significant differences in terms of risk.

It should be noted that the majority of risks (microclimate, noise and vibrations, biological risk and anti-ergonomic factors) have already been examined in the sector document, and are only partially mentioned in the datasheets below.

For the prevention of injuries, below are some aspects that will be frequently referred to in the analysis of single phases:

Use of knives

The use of knives exposes the worker to risk, affecting both hands (including the hand holding the tool), the upper limbs, lower limbs (especially thighs) and trunk (chest and abdomen). There is also the danger of causing wounds to other workers if they are working at a close distance.

The only technical requirements that knives must conform to are a nonslip grip and a separating hilt between the handle and the thread, which prevents fingers from sliding towards the thread especially if the tool stumbles.

The use of knives should therefore be accompanied by the wearing of PPE for workers, normally consisting of:

- full glove (or “three-fingered glove”) made from steel mesh or “wizard” fabric that may be integrated with cuff and forearm for greater protection when working on large pieces, such as sides of meat;

- leather, metal mesh or metal plate aprons.

Portable tools.

The risks deriving from the use of these tools, already high owing to the need to hold the tool manually and the presence of parts under pressure or electrically powered, is compounded by the frequent absence (and impossibility of installing) any sort of device that can isolate the working part.

If there is an emergency or unexpected event, the tool may escape from the worker’s hands and strike the worker’s body while the working part is still moving.

Tools whose working parts are endowed with a single snap movement (e.g. pincers, shears), and once operating comes to a stop only at the end of that cycle (the snap movement). They must be endowed with a dual grip, with a on/off button for each handles endowed with “simultaneous” control.

The rivet guns (and similar tools) projecting from a nozzle must be endowed with an “approval” device, whereby the rivet is released only if the nozzle is pressed against the piece to be riveted, thus avoiding non-segregated shots.

Other tools endowed with rotating working parts or similar (band saw) must have the possibility of a double grip, and on/off control, possibly single, but of the “press-down” type.

Band saws must have the band completely isolated, except for the part strictly required for working.

It would be preferable to use suspended portable tools to avoid additional risks owing to pain to the upper limbs if the full weight of the tool is borne by the worker.

Floors

The materials used must guarantee three different requirements:

- a good friction coefficient to limit slipperiness;

- discharge of wash water to guarantee rapid drying;

- roadworthiness of wheeled vehicles, both manual and motorised, with surface finishing to ensure smoothness.

The final two requirements are difficult to reconcile, so depending on the use of single areas, one of these factors will be given priority over the other.

In general, for specific butchery activities priority must be given to the draining of wash water, choosing non-smooth surface materials that can guarantee a good friction coefficient. In butchery halls the passage of wheeled vehicles is not a priority, as almost everything is transported via overhead guideways.

The floors of work platforms do not require the passage of wheeled vehicles either, and the other two needs can be satisfied more easily.

Floors and work platforms should have suitable rail guards in raised positions or guards that prevent against the risk of falls at the front (point of access) and at the back (guideway side).

On the latter side it is more difficult to guarantee guards, which would cause interference with the flow of materials on the guideway. At the end of the platform a “footguard” may be installed, at a height of 15 cm. The best solution, where possible, is to locate the guideway and platform along the walls of the room, making a natural guard, or to extend the platform behind the guideway to construct a guard that does not interfere with the material.

Transportation via overhead lines

(see also “Injuries in the meat industry”, USL, 16/19, point 2.3.1 page 55).

Overhead handling plants, very common in the sector, consist of support rails anchored to the supporting structure of the building, along which a device runs (a hook fixed to a bracket connected to a pulley that runs along the rail). Three or four-way exchanges handled by the operator help to convey loads to units or cold stores.

The main danger of these plants is the possible falling of loads.

Electrical installations.

Because of greater risks deriving from wet or very humid work areas, the electrical system (both for lighting and utility power) must guarantee a degree of protection of at least IP 44 or IP 55, depending on the washing system used in the room.

All areas must be under differential protection, coordinated with the earthing system which, in turn, requires special guarantees for internal equipotential connections.

Portable tools (stunning gripper, splitting saw, etc.) must be powered at a very low safety voltage (50 V), or via insulating transformer.

As usual, the installation of the earthing system must be reported (within 30 days) to the competent local ISPESL office for controls on new installations and subsequent periodical controls (carried out by AUSL).

Work equipment pursuant to Presidential Decree 459/96 (implementing “machinery” directive)

Work equipment (which, as per the specific definition of art. 34 of Legislative Decree 626/94, is “..any machinery, equipment, tool or installation destined for use during work”) manufactured after 20/9/1996 comes under the provisions of Presidential Decree 459/96, which imposes technical and manufacturing obligations and the furnishing of documentation that constitutes “presumption of conformity”.

This has also led to procedural changes for the categories of machines that Presidential Decree 547/55 requires undergo initial installation “testing”. The existence of technical-manufacturing documentation is considered equivalent to traditional testing.

For such categories of machines periodical controls must be carried out by the competent local AUSL, during the machine’s life cycle, since the manufacturer’s precautions cannot prevent its incorrect use over time, such as to impair its safety.

All working equipment constructed after 20/9/96, even if it is not subject to testing requirements, must possess CE marking, formal recognition that the manufacturer has conformed to the obligations of Presidential Decree 459/96. These obligations are particularly necessary for equipment in slaughterhouses, where risks are very high because of workers’ close contact with working parts (portable and suspended equipment, de-hairing machines and other stationary machines, etc.) and the wet or very humid conditions.

Equipment built before 20/9/1996 does not come under the provisions of Presidential Decree 459/96, and therefore does not require CE marking and is not subject to the above technical-manufacturing constraints and relative documentation. These machines must operate in compliance with legislative obligations in place when they were built (Presidential Decree 547/55 and subsequent amendments) and with the provisions of Title III of Legislative Decree 626/94, on the basis of which employers must bring machinery into line with some requirements, such as the emergency stop device for machines in the butchery cycle.

User’s handbook and information/training obligations pursuant to art. 21/22 of Legislative Decree 626/94.

The use of machines must conform fully to instructions given by the manufacturer in the “User’s handbook” which, in accordance with Presidential Decree 459/96, must be drafted by the manufacturer and supplied to the buyer with the machinery, and must remain with the machinery throughout its working life, even if the machine is sold in the second hand market.

“Improper use” of the machine for works other than those for which it was intended and the “tampering” of parts and operating methods are to be avoided.

The User’s handbook deals with events and methods of use. This will be the point of reference for the acquiring employer and user for fulfilling worker information and training obligations, on the basis of art. 21/22 of Legislative Decree 626/94.

The handbook must accordingly specify the obligations, interdictions and above all correct and incorrect uses and relative limitations. The handbook must also be integrated by the employer with information on all machine events, such as breakdowns, malfunctions, unexpected events, etc.), a knowledge of which is useful for prevention purposes.

Maintenance

The ageing of machines and more generally their continuous use make it obligatory for the employer to arrange regular and frequent machine servicing to prevent normal use and wear and tear from causing lower safety levels, in terms of both hygiene (noise, vibrations, sundry emissions, etc.) and accidents (faulty safety devices, delayed stopping, sundry unexpected events, etc.).

The user’s handbook must give detailed information on this obligation of the employer, describing the procedure (frequency and type of intervention) and the practical aspects of single actions.

Notes should be kept in the Handbook about servicing activity and about repairs of breakdowns occurring despite servicing.

LAIRAGE

The phase examined includes:

1. reception of pigs

2. unloading

3.1 lairage and showering

3.2 ante-mortem examination

Description

Reception of pigs

The butchery cycle begins with the reception of livestock, namely pigs for slaughter. Specially designed trucks used to transport pigs can be one- or two-storeyed. They must be easy to wash and disinfect, guarantee the wellbeing of animals and prevent liquid manure from dirtying public places. They must be authorised by the Veterinary Service.

After unloading, trucks must be washed and disinfected. In larger slaughterhouses there is an ad hoc station for the cleaning of trucks, using water or pressure steam.

In larger slaughterhouses there are specific pathways to separate dirty from clean trucks, and shallow tanks containing a disinfectant, over which tyres pass when entering and exiting the plant.

After entering the plant, the truck goes to the weighing station. The weight of livestock serves for payment of the goods and to calculate so-called butchery percentages.

Transport workers may not be employees of the slaughterhouse. They may work for independent haulage firms that perform the specific activity of livestock transportation for a number of plants, and in slaughterhouses help with unloading and the cleaning of their vehicles.

Photo 1/S: reception of pigs.

Unloading

After weighing operations are complete, the truck moves close to an ad hoc ramp for unloading the pigs, which takes animals to the lairage area or, in small-scale slaughterhouses, directly to the kill box.

Unloading is a critical operation for the wellbeing of animals, and must be performed with ramps having an acceptable incline, without frightening or placing too much stress on pigs. The use of electrostimulation equipment must be kept to a minimum.

Respect for the wellbeing of animals is also of economic importance for the slaughterhouse, since it has a bearing on pre-slaughter mortality and on the quality of meat and of top cuts, such as hams destined for seasoning.

The operator first induces animals to climb off the vehicle, using prods, through the truck’s side openings. It may then be necessary to climb onto the vehicle to get the last animals to exit.

Lairage and showering.

In the lairage area pigs are allowed to rest, and are washed prior to slaughter. The aim of this phase is to reduce post-transportation stress for the wellbeing of the animal.

Pigs are kept in boxes, taking groups of origin into account, to prevent leadership battles.

Pigs are washed with automatic sprayers placed above the boxes.

Photo 2/S: lairage.

For reasons relating to the hygienic production of meat, tasks involving the management of pigs in the lairage area can be associated with unloading or stunning operations but not with other stations in the production cycle.

Ante-mortem examination

In the period between unloading and slaughter, the ASL Veterinary Officer carries out the ante-mortem examination, and may exclude suspect animals from the slaughter process. Animals that may have some pathologies transmissible to animals or man are isolated in separate boxes or quarantine units pending further analysis.

Risk of accidents and preventive measures in pig reception phase

Possible risks for workers in this phase include: traumas caused by being knocked down by trucks, being crushed between the truck’s racks, slips and falls owing to floors made dirty by liquid manure or icy conditions, injuries caused by water jets or pressure steam and traumas caused by animals.

Possible allergies, sensitisation or injuries caused by chemical agents present in detergents and disinfectants.

Exposure to biological agents is possible due to direct contact with potentially infected animals or carriers of zoonoses and with their faeces and urine, or equipment contaminated by the latter.

The climate is hostile owing to the extreme temperatures in the summer and winter seasons and contact with cleaning water.

Noise is caused especially by the squealing emitted by pigs and by cleaning compressors.

Risk of accidents and preventive measures when unloading pigs

These operations are performed by haulage operators or by lairage personnel. In low throughput slaughterhouses this task may be performed by other workers.

Risks relating directly to this task include traumas caused by animals and the crushing of workers’ bodies owing to the falling of truck racks.

Staff being knocked down during truck manoeuvres in yard areas:

- define and signpost paths for trucks separate from personnel paths, limit speed, help driver when reversing, guarantee training.

Electrocution owing to use of electrostimulators: see Electrical installations.

Workers falling on pig unloading ramp:

- install nonslip devices on ramp (milled plates, crosswise retainer bars and the like), provide workers with nonslip footwear (see safety footwear).

Electrocution in truck cleaning unit: see Electrical installations. If moreover trucks are washed in a stationary structure in the yard area, the relative metallic structure must be connected to the general earthing system of the production unit, and the electrical installations of the structure must ensure a degree of protection of at least IP 55, and be endowed with suitable differential protection installed on the power line of the stationary cleaning structure.

Biological risk deriving from direct contact with infected animals and with the squirts of urine and faeces that may strike the operator on the conjunctiva or mucosa.

Respect for the nature of pigs during unloading operations and efforts to limit stress and agitation for animals also reduces the squirts of organic material, squeals emitted by animals and risks for workers.

The climate may be hostile for open-air work. As already mentioned, noise levels may be high owing to animal cries.

Risk of accidents and preventive measures during lairage, showering and ante-mortem examination

(Lairage and quarantining, liquid manure trough and tunnel leading to stunning box).

Falls owing to presence of slippery organic materials and water left by frequent washing:

- provide workers with nonslip footwear (see safety footwear section).

General risk of injuries deriving from poor lighting:

- improve lighting to guarantee good readability even in shaded areas.

Contact with infected liquids and/or drowning after falling in tank:

- avoid contact with sludge/liquid manure, and provide workers with impermeable work clothing;

- guarantee regular railing around the tank.

Possible traumas caused by knocks against structures or knock-downs caused by animals.

As regards biological risk, contact is high with animals, faeces and urine. Suspended drops of liquid caused by the high degree of humidity may convey pathogens to respiratory tracts. Risk of pathology caused by organic dust (hair, skin desquamation, mites, dried faeces, etc.).

Risks are related to prolonged stays in environments having particularly hostile microclimates due to the high temperatures in the summer season, high levels of humidity due to the presence of animals and stagnation of gases of the animal metabolism (carbon dioxide, hydrogen sulphide, ammonia).

Noise levels are high owing to the cries of pigs.

BUTCHERY

Part I

The phase examined includes:

4. stunning

5.1 jugulation

5.2 initial hooking

6. bleeding

Description

Stunning

Pigs are led to the tunnel, which in turn leads to the stunning box, by one or more workers endowed with electric prods or rubber tubes to stimulate animals. In some plants, there are self-moving gates to partly automate the operation.

The tunnel consists of a pathway through metal piping that obliges the animal to move towards the stunning box. In some slaughterhouses there are self-moving rollers that imprison and then transport the pig to the stunning box.

The stunning of animals has the aim of making the animal unconscious for ethical reasons and to avoid dangerous reactions for operators. Stunning must not stop the cardiac muscle so as not to jeopardise the subsequent bleeding operation. Stunning is compulsory by law, regulated by specific legislation and subject to veterinary control.

Electrocution is a method still commonly used for pigs, with the application of electrodes on the animal’s head. This operation is usually performed manually by a worker that uses an instrument called a wand. The wand is insulated, and an additional plastic base is often present. Different combinations of voltage, intensity and time are used, such as 200V and 2A for 1 second.

Some slaughterhouses use equipment that carries out automatic electric stunning without an operator.

One alternative (detected in this study) to electric stunning is the use of carbon dioxide. In this case, at the end of the stunning box the pig enters an elevator that goes down into a cabin containing CO₂ from gas cylinders. The speed of the elevator is adjusted so as to asphyxiate the animal before full rotation brings it back to the surface.

To complete the picture, we recall that in rural, family-run butcheries the captive bolt gun is used, in which an explosive cartridge provides a retractable tip with the energy required to perforate the pig’s skullcap.

Stunning errors cause suffering to the animal, dangers for the operator, incomplete bleeding and damage to meat. A number of operators have said that difficulties of this sort have not been observed with the C0₂ process.

Jugulation

Jugulation consists of cutting with a knife the jugular vein or other large vessels of the neck or trunk. This is a manual operation carried out by the operator that carries out stunning, or by a worker placed next to the start of the conveyor belt, where the stunned animal automatically slides from the CO₂ chamber.

Initial hooking

Immediately after jugulation, a second worker in the industrial cycle hooks the butchered animal to the chain (slaughtering machine), often using a metallic sliding knot or noose.

Photo 3/S - 4/S: hooking the pig.

Bleeding

Complete bleeding, necessary for forming a favourable opinion of the health of meat, is performed on horizontal rollers, vertically with the carcass suspended or using a combination of both of these methods.

Blood is collected separately from wastewater, stored in ad hoc receptacles and sent to firms that transform waste products of animal origin.

Risk of accidents and preventive measures in stunning phase

Specific risks relating to this task are the use of electricity in environments where water and humidity are abundant. With the use of carbon dioxide, chiefly maintenance workers are exposed to the risk of asphyxia when performing operations in the stunning box.

Possible traumas owing to reaction of animals, especially with the use of the captive bolt gun.

To avoid blows and crushes owing to movement of elevator (if CO₂):

- segregate areas at risk with permanent guards or block off the area.

To avoid asphyxia owing to the leakage of CO₂, affecting workers and maintenance staff when descending chamber:

- install devices warning of CO₂ leakage from chamber;

- for maintenance works, provide workers with breathing apparatus.

Prevention of electrocution (for electric wand): see electrical installations.

The microclimate is characterised by high rates of humidity and draughts caused by communication with the lairage area. In a few cases gas is present due to animal metabolism and organic dust.

The work is monotonous and repetitive: killing animals may have psychological effects.

Noise is high, originating especially from livestock walking in the tunnel.

Risk of accidents in jugulation, initial hooking and bleeding phases

Traumas. In the event of stunning errors, animal reactions may cause bruises and wounds from cuts to the arm used for jugulation.

Risk deriving from biological agents owing to direct contact with animals and with blood in particular.

Knife wounds: see Use of knives.

Knocks against the edges and ends of overhead guideways.

Hit by objects falling from overhead guideways: see Guideway transportation.

Slips owing to greasy floors.

- regular washing of floor, provide workers with nonslip footwear.

The microclimate is characterised by high rates of humidity and draughts due to communication with the lairage area. In a few cases, the presence of gases deriving from animal metabolism and organic dust.

Noise comes mainly from livestock in a neighbouring environment, but also from transportation systems (rollers and chain).

Work is monotonous and repetitive: killing animals may have a psychological impact.

The main aspects of physical ergonomics have been studied and are summarised in the ERGONOMIC ANALYSIS TABLES (see sector document) for work tasks up to the preliminary cutting of meat.

In modern slaughterhouses, there was no significant cumulative overload for the upper limbs or the backbone for the jugulation and initial hooking phases.

BUTCHERY

Part II

The phase examined includes:

7. scalding

8. depilation

9. removal of claws

10. singeing

11. finishing

Description

Scalding

The aim of scalding is to soften the cutaneous appendages of the carcass (bristles and claws) to facilitate subsequent mechanical removal. This is usually performed by immersing carcasses in a water bath at a temperature of about 62°C for a few minutes.

In low throughput and full throughput slaughterhouses, carcasses go in and out of the bath automatically.

If the temperature or time in the bath are insufficient, it is difficult to remove bristles, while excessive heat treatment damages meat.

In modern lines experiments have been undertaken to eliminate the scalding bath.

Depilation

The depilation machine has the job of removing pig bristles using rotating rubber whips that brush against the skin surface.

In rural settings or low throughput plants, depilation may be performed manually using knives or suitable rasps.

Photo 5/S: low throughput finishing in next phase, on sides of meat

Removal of claws

The removal of claws is a manual operation using hooks and an energetic tearing movement.

There are aids that limit physical exertion in this manual operation.

Singeing

This entails treating the carcass with a gas flame to burn off the remaining hairs that have not been removed by the depilation machine.

After depilation, the carcasses hung up on chains enter a box where they are subjected to a violent sheet of flame for about 1-2 seconds.

Finishing

This entails the removal of remaining bristles and skin charred in the previous phase and a final shower. The removal of remaining bristles, when needed, is a manual operation to be performed with knives (see previous photo).

The ruggedness of bristles depends on factors pertaining to the animals, such as the pig’s genetics or the temperature they have been kept at, and on technological elements, such as scalding temperature and time, the efficiency of whips, etc. In some cases this task may not be necessary.

Prior to evisceration, the carcass is washed in an ad hoc box, being sprayed with jets of water and scrubbed with rotating brushes.

Risk of accidents and preventive measures in scalding, depilation and claw removal phases

Possible traumas caused by slips on grimy floor covered in water and hairs. Possible contact with biological agents in the animal’s hair and skin and squirts of scalding water contaminated by faeces.

Falling into water baths:

- guarantee the presence of guards around the bath.

Burns caused by contact with boiling water:

- keep at safe distance or provide workers with protective clothing.

Contact with tubes at scalding temperature:

- avoid contact or wear heat-insulating gloves.

Crushing and blows caused by moving parts of depilation machine:

- keep at safe distance and, if necessary, intervene only when machine is switched off;

- guarantee presence of emergency stop device.

Knocks against the edges and ends of overhead guideways.

Hit by objects falling from overhead guideways: see Guideway transportation.

Slips owing to greasy floors: regular washing of floor, provide workers with nonslip footwear.

Removal of claws:

Shearing of parts of the body while using shearing tools whose working parts are not isolated:

- see portable tools;

Hit by compressed machine parts:

- regular controls of compressed parts;

- verify maximum pressure limits, keep at safe distance;

Knocks against the edges and ends of overhead guideways.

Hit by objects falling from overhead guideways: see Guideway transportation.

The microclimate is particularly hostile (especially in the summer) owing to the heat and steam generated by the scalding bath. This activity is particularly monotonous in full throughput slaughterhouses, where it is performed throughout the working shift without rotating in other stations.

Risk of accidents and preventive measures in singeing and finishing phases

Risk of injuries deriving from presence of gas installations (explosions, burns).

Singeing: explosion and fire caused by use of methane gas in production unit:

- methane network compliant with relative UNI standards and Law 46/90;

- methane damper outside work area;

- presence of flame detectors with methane block;

- electrical installations and ventilation compliant with CEI standard 64-2.

Knocks against the edges and ends of overhead guideways.

Hit by objects falling from overhead guideways: see Guideway transportation.

Possible traumas caused by slips on wet and slippery floors and owing to falling pulleys or carcasses from the guideway.

The noise produced by operating technological installations (singeing machine, depilation machine, etc.) may be relevant.

Risk deriving from knife cutting in finishing phase.

Risk deriving from guideways.

With regard to biological agents, contact is made with the skin and bristles of the animal, and it is possible to inhale the aerosol produced by the cleaning and brushing of the carcass.

The microclimate is characterised by high levels of humidity coming from the bath and from evaporating carcasses.

Manual finishing is a highly repetitive operation and posturally demanding for the dominant arm (see “Ergonomics” table for low throughput slaughterhouses).

BUTCHERY

Part III

The phase examined includes:

12. evisceration

12a dressing of thoracic offal

12b dressing of abdominal offal

13.1 side splitting

13.2 post-mortem examination

14. removal of heads

15. finishing

16. meat health marking

Description

Evisceration

Evisceration entails the opening up of the carcass and removal of internal organs and offal.

This is an extremely critical operation for the hygienic production of meat, with errors soiling the meat product: accidental cuts of the intestine, stomach, bladder or gall bladder cause contaminating organic material to escape.

In one plant under review the first phase of evisceration was automated: the emptying and removal of distal part of the intestine (the “bowels”). A second automated element is connected to this equipment, which “guillotines” the hip (removal of anchetta bone), a demanding physical operation if carried out manually.

Photo 6/S: bowel cutting robot.

Photo 7/S: close-up of bowel cutting robot

Another full throughput slaughterhouse resorts to a semi-automatic instrument, called “bowel cutting gun”.

Other operations are always performed manually using knives, with workers making cuts of the carcass in the throat region, isolating the pharynges/larynges, cutting the linea alba, isolating the penis and rectum and detaching the intestinal pack from its natural connections.

Photo 8/S: bowel cutting gun.

Photo 9/S: eversion of tongue.

Photo 10/S: evisceration 1.

Photo 11/S: evisceration 2.

The intestinal pack (stomach, pancreas, small and large intestine, rectum, bladder and genital organs) is placed in ad hoc bowls on a second chain following the same course as the carcass chain, or alternatively falls into a pneumatic conduit that takes it to the tripery unit.

The thoracic-abdominal organs, called offal (heart, liver, lungs, trachea and tongue), are isolated by an incision of the tendinous part of the diaphragm, taken away by the side chain mentioned above.

Photo 12/S: intestinal pack chain.

Dressing of thoracic organs (and liver)

The offal room is an area or room lying off the main meat side line, where the chain transports thoracic-abdominal organs, or offal, after the health examination.

Workers remove, in sequence, the liver, heart, lungs and tongue, and place them on separate frames.

All operations are manual, with knives only being used.

In some plants the various organs are sent for chilling and packing via conveyor belts.

The parts not destined for human consumption are placed in receptacles for waste of animal origin, to be sent for the conversion of these by-products.

Dressing of abdominal offal

This work is performed in areas known as tripery rooms, separated for hygienic reasons from the main conversion line.

The intestinal pack is transported to these areas via pneumatic tubes or a secondary line of bowls. Operators take out, empty and clean stomachs and sundry intestinal tracts that are then sent for further processing.

A part of the materials obtained is destined for human consumption, while another part constitutes waste of animal origin. The type of work involved is very diversified from one slaughterhouse to another, ranging from the collection of intestinal packs to be sent to other plants to the production of semi-finished goods for sausage/salami factories and collection of organotherapeutic products for the pharmaceutical industry.

Side splitting

This entails sawing the hip and backbone from the pubis to the atlas, to split the carcass into two equal halves. In low throughput cycles the head is further cut, sagittally, using an axe, while in industrial plants the whole head is removed from the side of meat using a shear or knife.

Workers split the carcass into sides manually using a water-cooled band saw, suspended on a balance/rocker arm that bears its weight.

In full throughput slaughterhouses the operation is carried out by only a few workers, as it requires particular expertise.

In rural settings the whole operation is performed with an axe.

This station is usually placed immediately after evisceration and before the post-mortem examination.

Photo 13/S: industrial splitting saw.

Photo 14/S: head splitting axe.

Photo 15/S: cutting of atlas.

Photo 16/S: head section.

Post-mortem examination

All organs and offal are submitted, together with the original sides of meat, to the post-mortem station where the Veterinary Officer expresses an opinion on the wholesomeness of the produce.

If the opinion is favourable, the meat and offal move on along the production line, while if the judgement is suspended or negative, pieces are removed to secondary lines (towards the observation unit) or seized and assigned as waste of animal origin.

Removal of heads

(see above: splitting into sides)

The head is cut by hand and placed on suitable collectors. No sort of automation is used, except occasionally for the previous crosscut of the backbone.

Heads are usually sent to laboratories not belonging to the full throughput slaughterhouse that specialise in mincing.

Finishing (see too 11)

The sides of meat can finally be finished using a knife to eliminate any dirt, hair, abscesses or other imperfections.

This operation can be performed on the main line or secondary line for parts under observation.

Meat health marking

The health marking of meat comes under veterinary control for meat that has passed the health examination. Health marking is performed using appropriate inks for hot-branding, scorched by a gas torch or electric heater. In some full throughput plants equipment is used for automated branding.

This operation is often associated with qualitative choices and the sending of meat to different storage areas.

The actual butchery phase concludes with the cleaning of sides of meat in a cabin using jets of water.

The sides of meat from the butchery unit can be stored directly cold storage units, if they are sold directly, or be subjected to a “hot” cutting process.

Risk of accidents and preventive measures in evisceration phase

Traumas caused by falls from raised platforms, falling of pulleys or carcasses (see Safety of guideways), wounds caused by cuts (see Use of knives).

Possible contact with biological agents through handling of all parts of the animal (blood, faeces, urine, organs and parenchyms, etc.).

Slips owing to greasiness of floor: regular washing of floor, provide workers with nonslip footwear.

Microclimate characterised by high rates of humidity owing to natural evaporation of carcasses and offal.

The noise generated by splitting saw, chains, pulley impact and banging, etc. should be assessed for each single establishment.

Intense work rates and long hours, monotonous and repetitive tasks. The ergonomics tables give a detailed analysis of the risks of cumulative overload in full and low throughput cycles for the upper limbs, especially dominant shoulder and hand (repetitiveness, exertion, posture) and for the backbone (posture and manual handling of offal using one hand).

The code of practice datasheets disseminated by ISPESL and available online highlight:

· the bowel and symphysis cutting robots (see previous photo);

· the construction of lines where evisceration, collection of intestinal pack that falls by gravity onto a chain of plates and the hanging of offal onto a chain of hooks take place on the same plane, so that workers do not have to handle weights and rotate trunk.

Photo 17/S: evisceration, hanging of offal.

Risk of accidents and preventive measures in thoracic and abdominal offal handling phase

Environmental contamination and intense and prolonged contact with animal organs and offal expose workers to biological risk. Workers’ skins are often worn by the continuous contact with water. Possible wounds caused by knife cuts (see Use of knives).

Slips owing to greasiness of floor: regular washing of floor, provide workers with nonslip footwear.

Repetitiveness, noise generated by transport mechanisms and refrigerating or ventilation systems.

Risk of accidents and preventive measures in the side-splitting and post-mortem examination phases

The worker responsible for splitting carcasses into sides of meat is exposed to the intense noise of the splitting saw. The squirts of water used to cool the saw blade scour the carcass and wet the worker, exposing him to biological agents.

Knocks against the edges and ends of overhead guideways.

Hit by objects falling from overhead guideways: see Guideway transportation.

Possible cuts to body parts caused by use of tools with unprotected working parts or during actions to replace blade: see Portable tools.

Wounds caused by use of axe for final detachment of meat sides with sagittal cutting of cranium:

- use of safety footwear reaching up to knees.

Electrocution owing to use of electrically-powered tools: see Electrical installations.

Possible traumas caused by falls from platforms; slips owing to greasiness of floor:

- regular washing of floor, provide workers with nonslip footwear.

With regard to hazards faced by the Veterinary Officer, there is the risk of traumas owing to falls from the platform, slips on dirty stairways and floors, the falling of pulleys and suspended sides of meat, wounds caused by cuts, exposure to noise and biological agents due to the handling of infected organs and offal.

Modern organisation has made it possible to concentrate in a single field of view sides of meat, heads, offal and intestinal pack, while in other situations the veterinary officer has to concentrate on pieces located in different areas, thus having to make a mental effort to recognise the origin of single animals (see ISPESL’s code of practice datasheets).

In the evisceration phase work is monotonous and repetitive, often with long working hours, and requires a certain physical exertion. Posturally demanding especially for the left shoulder, and contact with vibrations (see ergonomics tables).

Risk of accidents in head removal, finishing and

health marking phases

Traumas caused by cut wounds, slips or falling of sides of meat and pulleys; burns caused by use of hot-branding; possible explosions if gas and cylinders are used; contact with animal blood and tissues: possible carriers of biological risk.

Cumulative overload for dominant arm, posture problems: bent backbone.

CHILLING, CUTTING, PACKING, SHIPMENT

The phase examined includes:

17. primal meat cutting

18. cold storage

19. packing

20. shipment of goods

Description

Primal meat cutting

Photo 18/S: cutting of backbone.

The aim of cutting operations is to make primal cuts from the sides of meat to be sold directly to retailers (loins, lard, etc.) or to be sent for further processing (pork neck, hams, etc.). Some slaughterhouses, both full and low throughput, extend their working cycle to a secondary cutting phase and processing up to the end product available for consumers, obviating retailer intervention: this is the case for sausages and sausage meat/salami in general, kebabs and other pieces. This processing is not covered within the present study, which concentrates on butchery and primal cutting (Items B e C of the veterinary glossary).

Primal cutting comprises chiefly manual activities using only a knife, with a high degree of individual specialisation (e.g. short individual cycles, single task).

Photo 19/S: removal of loin.

In low throughput plants operations are mostly the same as those in the industrial cycle, but they are often grouped together: a worker performs a longer cycle than a colleague from the industrial cycle, but performs more tasks, often handling loads and moving pieces onto the work table or conveyor belt.

Working conditions are variable and intermediate, with the rotation of workers for numerous tasks and varying degrees of specialisation. The employment relationship is important for the subsequent organisation of work, work rates being affected by collective bargaining, productivity bonuses and work contracted out to third parties.

Photo 20/S: manual handling in low throughput slaughterhouses

Photo 21/S: exertion of shoulders.

Photo 22/S: manual hanging of hams.

In the low throughput cycle, and especially in industrial-scale plants, common tools other than knives are used (shearer, skinning machines), or other instruments that are sometimes devised locally and made “to measure” (bazooka for removal of joints; hide stripper; trotter shearers).

Photo 23/S: cutting of ham.

Cutting operations directly connected with the butchery cycle are called “hot”, since they are usually performed on non-chilled sides of meat.

Interesting experiments are however assessing the precooling of sides of meat to be worked on as a useful measure for bring the hygiene of the product and compliance with international standards into line with the need for a greater thermal wellbeing for workers: precooling would in fact make it possible to work at room temperatures of 15-16°C, higher than the current 12°C, without damaging the product.

In a full throughput plant cutting is performed with the use of a main conveyor belt branching off to secondary belts for cuts of meat that are gradually made.

The various cuts are detached in sequence from the side. These cuts then undergo finishing treatment on the side belts.

At the end of each line, the various cuts are suspended, manually or mechanically, to metal supports, collectors and frames, and sent to cold storage units via lift trucks. In more automated plants, most handling is via conveyor belts or overhead lines. Final cuts are branded with meat health marking.

Photo 24/S: hanging of pork neck.

Photo 25/S: mechanical hoist 1.

Photo 26/S: mechanical hoist 2.

Cuts obtained include: hams and pork collar for seasoning; shoulder, for production of cooked products; jowl, minced meat and trimmings, destined for sausage and salami production; loin and spare-rib destined for immediate consumption; lard and pork belly for salami production; melted fats for production of lard.

The process also produces huge amounts of by-products, which are destined for industrial conversion as waste of animal origin.

Photo 27/S: deboning of pork collar.

Photo 28/S: deboning of shoulder.

Photo 29/S: removal of trimmings.

Photo 30/S: cleaning of loin.

“Cold” cutting is structured in a similar manner, the difference being that the raw material of the production unit is formed by cuts of meat that are already cooled. This is the case for ham trimming, an important source of value added in the primal cutting phase: refrigerated hams, after subsequent manual cutting operations, take on their final form, to be sent for seasoning. Trimmed hams, hung up on ad hoc collectors, finally return to cold storage, via lift trucks, pending shipment. Pork collar is another important cutting product subjected to cold trimming.

Photo 31/S: trimming of hams 1.

Photo 32/S: trimming of hams 2.

The following page outlines primal cutting phases in a full throughput cycle.

PRIMAL CUTTING OF PIG MEAT: INDUSTRIAL CYCLE

17. PRIMAL CUTTING OF MEAT

17.1 REMOVAL OF PORK LARD

17.2 CUTTING OF BACKBONE WITH SAW

17.3 REMOVAL OF HAM

17.4 REMOVAL OF PORK COLLAR

17.5 CUTTING OF LOINS

17.6 REMOVAL OF “PANNARA” SHREDS AND SHOULDER

17.7 REMOVAL OF UNDERBELLY AND JOWL

17.8 REMOVAL OF TRIMMINGS

17.9 CLEANING AND REMOVAL OF LARD

17.10 REMOVAL OF SECONDARY LARD AND COLLECTION OF JOWL

17.11 HANGING OF LARD

17.12 CUTTING OF HAMS

17.12.1 CUTTING OF TROTTERS WITH SHEARERS

17.12.2. BRANDING AND CLEANING OF ANCHETTA BONE

17.12.3. CUTTING OF ANCHETTA BONE

17.12.4. REMOVAL OF ANCHETTA BONE

17.12.5. INSERTION OF HOOKS

17.12.6. HOOKING OF HAMS TO CHAIN

17.12.7. TRIMMING OF HAM

17.12.7.1. SELECTION AND HANDLING OF HAMS

17.12.7.2. CLEANING OF ANCHETTA BONE AND AITCHBONE

17.12.7. 3. CUTTING OF PESCE

17.12.7.4. REMOVAL OF MEAT SHREDS

17.12.7.5. TRIMMING OF AITCHBONE

17.12.7.6. REVISION

17.12.7.7.1. CLEANING OF HAM TRIMMINGS AND SHREDS

17.12.7.7.2. SECONDARY CLEANING OF HAM SHREDS

17.12.7.8. SUSPENSION OF HAMS

17.12.7.9. HANDLING OF SCALES

17.13. PORK NECK PROCESSING

17.13.1. HANGING OF PORK NECK

17.13.2. UNLOADING OF PORK NECK FOR PROCESSING

17.13.3. REMOVAL OF “BARDELLE” AND BRANDING OF PORK NECK

17.13.4. DEBONING OF NECK

17.13.5. COMPLETE DEBONING

17.13.6. TRIMMING OF PORK NECK

17.13.7. SORTING OF TRIMMINGS

17.13.8. SORTING OF PROCESSED PORK NECK

17.14. CUTTING OF LOINS

17.14.1. CLEANING OF LOINS

17.14.2. CUTTING OF LOINS AND ATTACHMENT OF TAPE

17.14.3. HANGING OF LOINS

17.15. CUTTING OF SHOULDERS

17.15.1 DE-GREASING OF SHOULDERS AND PREPARATION OF TROTTER SKIN

17.15.2 DEHIDING, REMOVAL OF HOOVES

17.15.3 BRANDING OF SHOULDER BLADE

17.15.4. REMOVAL OF BLADE-BONE (POSSIBLY USING BAZOOKA)

17.15.5 DEBONING OF FORELEGS (SIFTERS)

17.15.6. HANGING OF SHOULDERS.

17.15.7. SORTING OF TROTTER SKIN.

17.16. HANGING OF UNDERBELLIES

17. 17. GULLETS

17.17.1. FLAYING MACHINE

17.17.2. HANGING OF GULLETS AND LARD

17.17.3. SORTING OF TRIMMING AND SHREDS

Cold storage

All meat from the hot cutting phase is stored in refrigerators prior to being shipped or sent to subsequent cold cutting units.

The meat, hung up on collectors or frames, is handled using lift trucks and pallet trucks.

In some plants pieces of meat reach the storage area via overhead lines.

A part of these goods, loose or packed, is destined for freezing in ad hoc storage units. Sometimes treatment involving a rapid freezing tunnel is carried out.

In full throughput slaughterhouses the job forklift truck driver is the exclusive domain of some workers.

Packing

Packing involves putting meat in specially made protective wrapping and then in cardboard boxes. These packs are not destined for end consumers but for further processing.

Casing and cardboard must be prepared in other units for hygienic reasons.

Only cooled or frozen meat is subject to packing. Packed meat is usually destined for subsequent storage in preservation units until shipment.

Photo 33/S: packing.

Shipment of goods

All products destined for human consumption produced via the production process go to the shipment room. This meat is destined partly for direct consumption (for example loins) and partly for further processing at other plants, such as the seasoning of hams or production of sausage meat/salami.

Photo 34/S: warehouse

Operations to be performed include the preparation of deliveries, weighing of goods and loading of the refrigerated truck. Meat is either packed or hung up on collectors and frames.

Porters, lift truck drivers, administrative and sales staff work in the shipment room.

In full throughput plants, the outside shipment yard consists of areas where trucks can manoeuvre, the shipment is weighed, the inside of refrigerated trucks is cleaned, used collectors returning from dumping are collected. Finally there is a reception area.

Risk of accidents in the primal cutting phase

Traditional risks for this sort of job include traumas caused by cut wounds, in particular arm, hand or abdomen wounds. In most cases they are caused by knives and are self-inflicted, but sometimes they are caused by other workers working too close to colleagues. Less common but more serious are wounds caused by automated cutting tools such as band saws.

Possible traumas caused by slipping on dirty floors, the falling of pulleys and sides of meat, getting knocked down by lift trucks or overturning of collectors.

Risk of electrocution due to use of electrical instruments and knife sterilisers.

In the past there had been a high incidence of recurring hand verrucas. The number of verrucas has since gone down, probably because of the adoption of hygiene measures (avoid immersion of tools and hands in collective disinfection bowls).

Ergonomics

Stressful work rates and shifts, repetitive tasks.

Details of osteo-articular and musculo-tendinous overload of upper limbs in a number of tasks in both full and low throughput cycles, and handling of loads (especially in latter cycle) are given in illustrative ergonomics tables.

Preventive measures

Physical ergonomics:

Full throughput and (to a lesser extent) low throughput plants have worked to considerably reduce the manual handling of loads in many jobs.

In the code of practice datasheets disseminated online by ISPESL, equipment is mentioned that reduces overload for the upper limbs and/or backbone, such as:

· looped hooking devices (see previous photo: fastening)

· automatic unhooking/unfastening devices

Photo 35/S: automatic unhooking.

· trotter cutting shearers;

Photo 36/S: manual cutting of trotters.

Photo 37/S: shearing of trotters.

· mechanical joint cutters;

Photo 38/S: manual removal of blade-bone.

Photo 39/S: removal of blade-bone using bazooka.

· various types of rind cutters for shoulders (horizontal types are ergonomically preferable;

Photo 40/S: vertical dehider.

Photo 41/S: horizontal dehider 1

Photo 42/S: horizontal dehider 2.

· tray rollers with chutes, latches, hanging or hooking devices.

Photo 43/S: chute.

Photo 44/S: robotised ham hanger.

Other devices: electric knives.

Photo 45/S: electric knife.

In the general part on physical ergonomics technical-organisational measures are outlined that can be useful in reducing the risk of cumulative overload.

Microclimate: in addition to experiments on the precooling of meat to raise room temperatures, diffusers are being used to prevent direct exposure to draughts (e.g. liners/muffs/sleeves with tiny holes that break up the flow of cold air).

Risk of accidents and preventive measures in the cold storage and packing phases

The handling of collectors and frames using lift trucks exposes workers to the risk of wounds and crushing if the load overturns, and being knocked down by forklift trucks.

Cold storage units.

To avoid being trapped in cold storage units:

- ensure that each unit has an opening device on the inside of the entrance/exit doors that operates manually and is easy to located, even in the dark.

Possible dust-related allergies in the preparation of cardboard for packing.

Ensure regular maintenance, controls on maximum pressure, ventilation devices for rooms, provide workers with breathing apparatus for repair work following breakdowns.

Workers are subjected to sudden falls and rises in temperature as they constantly go in and out of cold storage units. There are also high levels of humidity and strong draughts: devices are sometimes installed allowing for the automatic interruption of forced ventilation of cold air when the unit door is opened.

Risk of accidents in the shipment phase

Possible traumas caused by slipping, being knocked down by lift trucks, overturning of collectors or stacks of frames.

Microclimate characterised by draughts owing to openings for loading of trucks and doors of cold storage units. For hygiene reasons these are air conditioned rooms where the temperature should not exceed 12°C.

21. MAINTENANCE

Description

The technological levels of Italian slaughterhouses and cutting plants vary considerably depending on production capacity, the period in which the plant was designed, the level of plant automation. A heat generator is usually present for the production of hot water and/or steam, to be used for the scalding bath, the cleaning and sanification of rooms and structures, washbasins, heating and knife sterilisers, when they are not electrically powered. The cold storage units of large-scale plants are powered by a central refrigerating unit, with compressors for the ammonia or freon. Other compressors provide compressed air for hydraulically-controlled devices.

Butchery activities require a great quantity of water, which is usually supplied by artesian wells, with relative pumps and tanks, and possibly with chlorination plants.

Full throughput plants have a motor-generator to prevent damage to refrigerated and frozen goods when electrical energy supplies are cut off.

Slaughterhouse structures deteriorate very rapidly because of the continuous presence of water, blood, grease, detergents, sudden heat changes, etc. Maintenance work must accordingly be continuous.

In smaller plants, maintenance is carried out by traders tradesmen called for this purpose. In full throughput slaughterhouses maintenance staff are employees of the firm. They perform in all the aforementioned zones of the establishment and in utility rooms that are almost entirely under their control.

They usually perform a broad range of tasks, and undertake any type of repair. They are occasionally engaged in the actual production line.

Risk of accidents

These workers are exposed to many risks, including falling from raised stations, falls, bruises, cut wounds caused by machine tools, etc.

Burns may be caused by accidents involving heating appliances, gas explosions, pressure steam, causticising substances, ammonia leaks, gas torches, etc.

The risk of electrocution is always present, as is contact with equipment contaminated by biological agents.

Possible allergies and sensitisation due to contact with various kinds of chemical products (oils, grease, solvents, paints, etc.).

Sundry risks connected with microclimate, noise, posture and handling.

22.1 CLEANING OF MOVABLE EQUIPMENT

22.2 CLEANING AND SANIFICATION OF ROOMS

Description

Cleaning of movable equipment

The various meat cuts obtained from the cutting phase are hung onto collectors or placed on steel or galvanised iron frames. This equipment is used to store meat in cold storage units and, partly, for shipment. Cleaning and sanification is performed in separate areas, manually using jets of pressurised hot water or semi-automatic equipment. Larger slaughterhouses employ workers just to perform this specific task.

Cleaning and sanification of rooms

Butchery activity produces a great amount of organic by-products (grease, blood, scraps of meat, etc.), which seriously contaminate walls, floors and equipment.

Cleaning and sanification operations are particularly complex, and must be performed in hours other than those when production is active. In full throughput slaughterhouses these operations are performed late in the evening or at night, and are often contracted out.

Risk of accidents

Personnel responsible for these tasks often work at different times or places from other workers.

There is the risk of injury deriving from contact with acids and alkali used for environmental cleaning.

Jets of steam and hot water may cause injuries, particularly to the eyes if the operator makes a mistake or piping burst.

Possible traumas due to falls and slips.

Risk of electrocution owing to water jets reaching control units or other devices.

Health risks due to sensitisation and allergies resulting from contact with chemical protection used.

Biological risk is present, deriving from contact with organic materials to be removed and the vaporisation of this material caused by high-pressure water jets.

In service rooms (cleaning of equipment, equipment storeroom, etc.):

Slipping owing to greasy floor:

- regular washing of floor, and provide workers with nonslip footwear;

Being hit by parts breaking under steam/water pressure:

- guarantee regular controls on parts under pressure;

- verify maximum pressure limits;

- verify maximum temperature limits, respect safety distances.

The microclimate is characterised by extremely high humidity levels.

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Occupational safety and health

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TABLE OF CONTENTS

Preamble …………………………………………………………………………….Page 1

Description of project ……………………………………………………………….Page 5

Flow-chart – cattle ..................................................... .............................................Page 18

Flow-chart – pigs......................................................... ........................................Page 20

SECTOR DOCUMENT

Geographic, historical and social background …………………………………………Page 22

Outsourcing ………………………………………………………………Page 30

External risk ………………………………………………………………………….Page 32

Equipment, machinery and plants ……………………………………………………Page 35

Surveyed damage …………………………………………………………………Page 43

General risks:

- Biological risk …………………………………………………………….………Page 72

- Physical ergonomics: risks and preventive measures …………………………………Page 94

- Microclimate …………………………………………………………………….Page 129

- Noise and vibrations …………………………………………………………… Page 137

- Personal protective equipment………………………………………….………….Page 140

PHASE DOCUMENT

Preamble ……………………………………………………………………………Page 151

Beef butchery cycle …………………………………………………………...Page 152

Pork butchery cycle …………………………………………………………….Page 199

Bibliography …………………………………………………………………………Page 232