1. - GENERAL ON THE SECTOR.

This research examines the production sector of wine production plants, i.e. wine production from the grape (wine-making), bottling and packaging.

This sector is part of the “Beverages Industry” production sector identified by code 15.9 according to the ISTAT-ATECO ’91 classification.

Tab. 1 – Classification ISTAT-ATECO ’91 of the production sector

“Beverages industry” (code 15.9).

Code of activity ISTAT–aTECO ’91	Name of activity
Code of activity ISTAT–aTECO ’91	Name of activity
15.91	- Manufacturing of distilled alcoholic beverages.
15.92	- Manufacturing of fermented ethyl alcohol.
15.93.0	- Manufacturing of wine from grapes (not own production).
15.93.1	- Manufacturing of wines (excluding special wines).
15.93.2	- Manufacturing of special wines.
15.94	- Production of cider and other wines based on fruit.
15.95	- Production of other fermented non-distilled beverages.
15.96	- Manufacturing of beer.
15.97	- Manufacturing of malt.
15.98	- Production of mineral water and soft drinks.
15.99	- Manufacturing of other alcoholic beverages.

Vineyard cultivation and production enterprises (producing wine from grapes of their own production), on the other hand, are identified by the ISTAT-ATECO ’91 code for the classification of the economic activities: 01.13.1 – “Vineyard cultivation and grape and wine producing enterprises”. This sector is part of the production sector of the “Cultivation of fruit, fruit with shells, products for the preparation of beverages and spices” (code 01.13).

It is important to note that most of the producers registered in the Chamber of Commerce as “Code of activity: 01.13.1 - Vineyard cultivation and grape and wine producing enterprises” do not undertake wine-making themselves, but only cultivation of vineyards and the harvesting of grapes. Nevertheless, the same code of activity is also used for enterprises undertaking winemaking themselves.

Research made by the Chamber of Commerce (Unioncamere) in 1999, taken up by A.R.P.A.T. by the S.I.R.A. technical department and developed by the CEDIF technical department, has given the results shown in the following tables.

Tab. 2 - Number of local units for the cultivation of vineyards and for wine production – Tuscany - 1999.

Code of activity	Description OF activity	total Local units Tuscany Region	Number of local units subdivided by province
Code of activity	Description OF activity	total Local units Tuscany Region	AR	FI	GR	LI	LU	MS	PI	PO	PT	SI
01.13.1	Vineyard cultivation and grape and wine-producing enterprises	4,219	644	1.436	262	112	165	27	391	39	137	1.005
15.93.0	Manufacturing of wine from grapes (not own production)	20	-	9	-	-	1	1	1	-	2	6
15.93.1	Manufacturing of wines (excluding special wines)	115	6	36	8	6	3	-	5	2	6	43
15.93.2	Manufacturing of special wines	1	-	1	-	-	-	-	-	-	-	-
TOTAL		4,355	650	1.482	270	118	169	28	397	41	145	1,054

Source: - ARPAT processing of Chamber of Commerce data (Unioncamere).

Tab. 3 - Number of dependent workers for the cultivation of vineyards and for wine production – Tuscany - 1999.

Code of Activity	Description OF activity	Total workers Tuscany Region	Number of dependent workers subdivided by province
Code of Activity	Description OF activity	Total workers Tuscany Region	AR	FI	GR	LI	LU	MS	PI	PO	PT	SI
01.13.1	Vineyard cultivation and grape and wine-producing enterprises.	2,784	274	777	141	53	93	6	205	25	57	1.153
15.93.0	Manufacturing of wine from grapes (not own production).	100	-	16	-	-	9	0	9	-	23	43
15.93.1	Manufacturing of wines (excluding special wines).	744	29	366	31	11	26	-	29	5	20	227
15.93.2	Manufacturing of special wines.	0	-	0	-	-	-	-	-	-	-	-
TOTAL		3,628	303	1.159	172	64	128	6	243	30	100	1,423

Source: - ARPAT processing of Chamber of Commerce data (Unioncamere).

Tab. 4 – Classification of local units on the basis of the number of employees

“Code of Activity: 15.93.0 - Manufacturing of wine from grapes (not own production)”– Tuscany - 1999.

Code of Activity	Description OF activity	total Tuscany Region	Number of local units subdivided by province
Code of Activity	Description OF activity	total Tuscany Region	AR	FI	GR	LI	LU	MS	PI	PO	PT	SI
15.93.0	Manufacturing of wine from grapes (not own production).	20	-	9	-	-	1	1	1	-	2	6
Of which:
With 0 employees		10	-	7	-	-	-	1	-	-	-	2
With 1-3 employees		2	-	-	-	-	-	-	-	-	-	2
With 4-10 employees		5	-	2	-	-	1	-	1	-	-	1
With 11-15 employees		2	-	-	-	-	-	-	-	-	2	-
With 31 employees		1	-	-	-	-	-	-	-	-	-	1
Over 31 employees		-	-	-	-	-	-	-	-	-	-	-

Source: - ARPAT processing of Chamber of Commerce data (Unioncamere).

Tab. 5 – Classification of local units on the basis of the number of employees

“Code of activity: 15.93.1 - Manufacturing of wines (excluding special wines)”– Tuscany - 1999.

Code of Activity	Description activity	total Region Tuscany	Number of local units subdivided by province
Code of Activity	Description activity	total Region Tuscany	AR	FI	GR	LI	LU	MS	PI	PO	PT	SI
15.93.1	Manufacturing of wines (excluding special wines)	115	6	36	8	6	3	-	5	2	6	43
Of which:
With 0 employees		34	1	8	4	4	1	-	-	1	2	13
With 1-3 employees		36	2	10	-	1	1	-	4	-	2	15
With 4-10 employees		24	2	9	3	1	-	-	-	1	1	7
With 11-15 employees		11	1	3	1	-	-	-	-	-	1	5
With 16-30 employees		7	-	3	-	-	1	-	1	-	-	2
With 31-71 employees		4	-	3	-	-	-	-	-	-	-	1
Over 71 employees		-	-	-	-	-	-	-	-	-	-	-

Source: - ARPAT processing of Chamber of Commerce data (Unioncamere).

Tab. 6 – Classification of local units on the basis of the number of employees

“Code of activity: 01.13.1 - Vineyard cultivation and grape and wine-producing enterprises” - Tuscany - 1999.

Code of Activity	Description activity	total Tuscany Region	Number of local units subdivided by province
Code of Activity	Description activity	total Tuscany Region	AR	FI	GR	LI	LU	MS	PI	PO	PT	SI
01.13.1	Vineyard cultivation and grape and wine-producing enterprises	4,219	644	1.437	262	112	165	27	391	39	137	1.005
Of which:
With 0 employees		2,737	437	986	156	81	107	21	225	26	90	608
With 1-3 employee		1,368	201	418	105	28	54	6	163	12	46	335
With 4-10 employees		92	6	28	1	3	4	-	2	1	1	46
With 11-15 employees		10	-	2	-	-	-	-	1	-	-	7
With 16-30 employees		10	-	2	-	-	-	-	1	-	-	7
With 31-52 employees		2	-	-	-	-	-	-	-	-	-	2
With 137 employees		1	-	-	-	-	-	-	-	-	-	1
Over 137 employees		-	-		-	-	-	-	-	-	-	-

Source: - ARPAT processing of Chamber of Commerce data (Unioncamere).

With regard to the number of workers it is important to note that the data shown above do not include the owners and partners of local units, or seasonal labourers, who nevertheless have considerable numbers.

With regard to the number of owners and partners of local units, we can consider the number of local units without dependent workers (e.g. farm enterprises registered at the Chamber of Commerce as individual or family firms and other forms of companies). Tables 4, 5 and 6 show that, there are as many as 2.782 local units with zero employees, of which:

- n. 2.737 classified as “Vineyard cultivation and grape and wine-producing enterprises (code of activity: 01.13.1)”;

- n. 10 classified as “Manufacturing of wine from grapes not own production (code of activity: 15.93.0)”;

- n. 34 classified come “Manufacturing of wines excluding special wines (code of activity: 15.93.1)”;

- n. 1 classified as “Manufacturing of special wines (code of activity: 15.93.2)”.

There are also many seasonal labourers (especially the period of the grape harvest), many of whom are foreign immigrants.

All this, together with the fact that many enterprises registered in the chamber of Commerce as “Vineyard cultivation and grape and wine-producing enterprises (code of activity: 01.13.1)” undertake their own cultivation and wine-making, makes it hard to estimate the number of workers in Tuscany in the wine-making sector.

This survey covers wine production plants (wine production) - excluding the cultivation of vineyards and the grape harvest – with the latter aspect being covered in the risk profile for agriculture.

The above tables (Tab. 2 to Tab. 6) show that the Florence and Siena areas are those where this sector is most present, and they have thus been chosen as reference areas for this research.

Table 7 - Accidents reported and compensated at INAIL in the period 1996-2000.

Production sector “Production of wine (wine production plants)” in Tuscany Region.

Years	Number of Accidents	Number of fatal accidents
1996	55	0
1997	44	0
1998	48	1
1999	37	0
2000	39	0
Total	223	1

Source: INAIL

Table 8 - Occupational diseases reported to INAIL in the period 1996-2000.

Production sector “Production of wine (wine production plants)” in Tuscany Region.

Year

Type of consequence

Code of occupational disease

Type of occupational disease

Number

of cases

1996

PERMANENT

UNLISTED DISEASES

Source: INAIL

2. – GENERAL DESCRIPTION OF THE PROCESSING CYCLE

The main phases del production cycle of the enterprises in the sector may be summarised as follows:

Delivery of grapes, weighing, sample taking, analysis of sugar content, unloading, pressing-stem removal, sulphur dioxide treatment, fast fermentation, racking off, pressing sediment, slow fermentation, processing, ageing, treatments and corrections, bottling (removal of bottles from pallets, washing or rinsing of bottles, pasteurisation, filling, corking, incapsulating, labelling, boxing, placing on pallets), other types of packaging (bagging boxes), storage, shipping and delivery, heating plant and steam production, refrigerator plants, mechanical maintenance, decanting and processing of dregs, maintenance and cleaning of wine vats, maintenance and cleaning of rooms.

The following figure shows a general block diagram of the production cycle, with particular reference to the production of red wines.

ANALYSIS OF RISKS AND SOLUTIONS

DELIVERY, WEIGHING, TAKING OF SAMPLE, UNLOADING OF GRAPES, PRESSING-STEM REMOVAL, TRANSPORT OF MUST AND STEMS

DESCRIPTION OF PHASE

The grapes may be brought to the wine production plant in various ways; generally on trolleys towed by tractors or on dump trucks, but often also in baskets on board ordinary cars (this case is frequent in wine-making co-operatives to which the grapes harvested are brought by many small producers).

The bottom of the trolleys (or the loading platform of the truck) are sometimes covered with a plastic sheet on which to put the grapes, in order to protect the grapes from soiling and to avoid the loss of grape juice during transport.

When the vehicle loaded with grapes reaches the wine production plant it is weighed in the yard outside the plant. At that time a sample of grapes is taken for the analysis of the sugar content to be made in the laboratory of the plant. Sampling is done manually, or by a small portable screw. In the former case the worker takes a few bunches and places them in a bucket and then presses them with a hand tool to obtain the juice. In the latter case the worker turns the screw, collecting several samples in various points of the load and the juice obtained is collected in a bucket attached laterally to the screw. In both cases, the juice obtained is poured manually the bucket into the analysis instrument, which after a few seconds displays the sugar content. The latter affects the alcoholic content of the wine obtained and may vary according to whether the grapes are dry or wet; therefore, in case of rain the grapes are covered during transport, and in case of rain harvesting should preferably take place after the grapes have had sufficient time to dry.

Fig. 1. Vehicle weighing area with weighbridge and portable screw for the taking of grape sample.

The alcohol in the wine (ethyl alcohol) is the result of the conversion of sugar by the yeast in the grapes. Starting from grapes with high sugar content there will naturally be a higher alcohol content of the wine produced.

Once the analysis is made, the grapes are unloaded in special hopper with a screw on the bottom.

A wine production plant may have several hoppers used for the various types of grapes that may arrive at the plant at the same time (the first distinction is for green and red grapes).

The screw in the hopper pushes the grapes directly into pressing machine (or press-stem remover) according to the type of wine to be produced.

In enterprises with a small production capacity, the set of machinery consisting of the hopper with screw-press-stem remover is also called “gramola” (grape processor).

The stem remover has the function of separating the single grapes from the woody part (stems). The latter are temporarily accumulated at the output of the stem remover, while all the rest, i.e. the so-called must (a mass consisting of juice, pulp, peeling and grape seeds) is conveyed to the fermentation vats.

The operation of pressing - stem removal is automatic, and the workers need only occasionally check the proper functioning of the plant.

The stems are removed from the stem remover pneumatically, and in large capacity plants, conveyed through pipes to a collecting point where they are later taken to be sent to their final destination. When the stems taken from the stem remover are accumulated in the yard in front of the plant, they are removed using dump trucks. Otherwise, the stems are dropped into bins.

The processing can change according to the type of wine to be produced:

- For red wines, pressing (or squeezing) takes place together with stem removal.

- In the case of new wine, the grapes are not first pressed but inserted directly in the vats (in this cement vats are usually used) and fermentation takes place in the grapes.

- For white wines, the grapes are loaded from the hopper with screw into pneumatic presses designed to crush the grapes gently enough to obtain a relatively clean must. The must is separated form peeling and other solid parts of the bunch immediately after pressing. Before starting fermentation, the must is usually fined (see the fining phase).

- Rosé wines are left in contact with the peeling for very short period (24-36 hours) and then separated and fined come as for white wines.

- For muscatel wines the stem removal is not conducted.

The first pressing results the so-called flower of wine must (from 100 kg of grapes pressed approximately 65-70 kg of flower of wine must are obtained); another 5-10% of liquid must is obtained from subsequent pressing (pressing of sediment); the remaining part consists of solid residue.

Generally the press-stem remover is near the fermenting vats into which the must is conveyed directly through a pipe with the use of a fixed pump. Nevertheless, in some enterprises, especially those with a large production of grapes from their own vineyards, there are several press-stem removers in the farms for grape production, and tank trucks are used for the transport of must to the winemaking plant.

In this working phase no waste is produced. The stems are sent for distillation (as is the sediment or lees; see the phase on pressing sediment).

EQUIPMENT AND MACHINERY

Portable screw for the taking of sample of grapes

This is an electrically powered screw with helicoidal profile, oriented with a mechanical arm, which is mounted on a trolley also having the controls of the machine (Fig. 1). The screw is operated by a button requiring pressing by the operator in order to keep the screw in rotation. This is also due to the fact that the purpose is to take a small amount of grapes.

Hopper with screw

This basically consists in a trapezoidal stainless steel container (hopper) on the bottom of which there are one or more electrically powered screws (i.e. helicoidal profile endless screws) (Fig. 2 and 3); the screws turn on their axis and cause the grapes to advance towards the end of the hopper to convey them to the output. In this action also causes light pressing. In some enterprises, there are trapezoidal instead of helicoidal screws, and the bottom of the hopper has a conveyor belt; this allows for the much more delicate conveying of the grapes.

Fig. 2. - Manual unloading of a basket of green grapes in the processor.

Stem remover

This basically consists of a stainless steel rotating drum with holds. The holes on the drum are sufficiently large to allow for the easy passage of single grapes, while the stems kept inside the drum and then pumped out. The stem removal takes place by centrifugal force and/or thanks to the action of an axle with paddles.

Fig. 3. Horizontal axis stem remover (seen from above) under the hopper (see the end part where the grapes are pushed into the stem remover); on the right is the spiral staircase to reach the level where the stem remover is located.

Fig. 4. Detail of mechanical parts of the stem remover with shield removed for cleaning (seen from above). On the left, the conveyor belt from the bottom of the hopper and on the right the holed steel cylinder of the stem remover.

Fig. 5. Pneumatic system of stem extraction from the stem remover (above right. the outlet cyclone and under the top the conveyor pipe).

Fixed pump

This is generally a large electrically powered piston pump or rotating blade pump.

Tank trucks

The tanks are generally made of stainless steel, with a walkway on the top for worker access during the operations of filling or washing.

Fig. 6. Tank trucks for the transport of must from grape and wine-producing enterprises to the main wine production plant.

RISK FACTORS

In this working phase, the following main occupational risks are potentially present:

Transit of vehicles

description

The vehicles delivering the grapes pass in yards outside the production plant with the following path: from the entry gate to the weighing station; then to the unloading of grapes in the hopper; then again to the weighing station (to calculate the difference of weight); finally to the exit gate, often the same as the entrance gate (eventually after stopping in a parking area). In the period of the grape harvest traffic of vehicles may be considerable and can involve the risk of workers being run over and the risk of collision between vehicles.

expected harm

Traumatic injuries for being run over by vehicles or collisions of vehicles.

prevention

Installing and using horizontal and vertical signals to mark separate paths for pedestrians and vehicles. Establishing and indicating the speed limit of 5 Km/h. According to the sizes of the yard, assessing whether to establish and indicate one-way paths.

legislative references

- Art. 8 “Roads, dangerous zones, floors and passages” Pres. Decree n. 547 of 27.04.1955.

- Leg. Decree n. 626/1994 and subsequent amendments and additions.

Falling from above onto moving mechanical parts

description

Working near the hopper, there is the risk of falling in it from above. In order to favour the unloading of grapes, the hopfor thes below floor level.

Falling into the hopper could take place due to loss of balance or slipping during the manual unloading of baskets, or for being hit by vehicles moving near the hopper.

Another possible cause of falling, could be the operation of shaking of the plastic sheet (on the bottom of the dump truck). This operation is necessary for completing the unloading when some bunches of grapes remain on the sheet. In this case the worker who shakes the sheet could be tempted to “climb up” dangerously, for example climbing on the wheels of the truck, or worse, climbing up on the parapet of the hopper.

In case of falling into the hopper the worker can come into contact with the moving parts on the bottom of the machine, which due to their shape are dangerous even when the machine is off.

expected harm

In case of falling from above into the hopper traumatic harm such as contusions and injuries may occur. Falling onto moving parts in operation may lead to fatal consequences.

preventive measures

Prevention can consist in installing fixed parapets of adequate height on the side of the hopper where the unloading of grapes takes place manually from baskets. Where this is not possible, for example on the side of the hopper where the unloading of grapes takes place by tilting the container of the truck, the parapet may be mobile, for example consisting of an electric bar to raise for unloading (Fig. 7) and to lower just after. The mobile parapet, whatever the type, may be combined with an interblocking device to stop the moving parts at the opening of the del parapet and prevent starting until it is closed.

In some enterprises a photocell is also installed (Fig. 8) to block the moving parts in case a worker goes near the hopper. The photocell must be considered as an additional safety device not replacing the mobile parapet, since is it is necessary to first of all avoid the risk of falling from above into the hopper.

If during the unloading of large amounts of grapes, to facilitate the flow, it is necessary to turn on the screw with the parapet raised or with the photocell off, this must be allowed only with the buttons requiring operator pressure, excluding the main control panel. These buttons may be very useful also to operate safely in case of maintenance and cleaning.

Particular attention must be paid when the vehicle reverses to the hopper to reach the correct unloading position. A worker on the ground should supervise this operation, both in order to indicate to the driver who is reversing the distance lacking to the correct position for unloading, and at the same time to verify that there is no other personnel within range. For the shaking of the plastic sheet on the bottom of the truck bed, near the hopper there should be a ladder - with a platform with a parapet and mounted on a trolley for shifting manually – in order to climb up easily and safely. It is important for this operation to be conducted by non-seasonal dependent workers who are suitably informed and trained, while the drivers of the vehicles delivering the grapes must not be admitted to the operating zone.

legislative references

- Pres. Decree n. 547 of 27.04.1955 “Regulations for the prevention of accidents”.

- Leg. Decree 626 of 1994.

Fig. 7. Unloading in the hopper with screw of red grapes from a dump truck. Note the plastic sheet on the bottom of the bed, the moving part (screw) on the bottom of the hopper, the bar acting as a mobile parapet to prevent falling persons from falling from above into the hopper.

Fig. 8. Detail of winemaking equipment (in loading phase) equipped with a photocell blocking the movement of the screw in case a worker approaches the running machine.

Work near moving mechanical parts

Portable screw for the taking of samples of grapes

description

The portable screw (Fig. 1) used for the taking of samples of grapes to be analysed can involve accident risks if the moving part is not adequately protected. Although the screw is shielded along the longitudinal part, the end part - immersed in the load of grapes - is left uncovered to take the bunches. This can involve a danger of catching in case of contact with workers’ hands.

The risk is considerably reduced when the operation is conducted by only one worker. In this case, in fact, he controls the screw by the buttons at a distance from the moving part, and cannot come into contact with the latter. The case in which a second worker approaches the screw when it is still turning is different, for example to take the bucket attached laterally to collect the juice.

The mechanical arm of portable screw, during lateral movement, may hit persons who might come within its range of action.

expected harm

Injuries and contusions.

preventive measures

Prevention can consist in protecting the end part of the portable screw with mobile protection leaving it uncovered only during immersion in the load of grapes and automatically goes back to the original position once the screw is extracted.

The operation should in any case be conducted by one worker only, who must be adequately trained. He should verify that the driver of the vehicle delivering the grapes (who may not be an employee of the wine production plant, but rather the employee of a transport firm or a small producer), stays away from the operational area.

Stem remover

description

The moving mechanical parts of the stem remover (Figures 3 and 4) can involve the risk of catching and dragging in case of contact with the upper limbs of the worker. During the normal functioning of the machine, the accident risk is extremely low since the machine works automatically without the presence of the worker; the risk is substantially linked to the cleaning and maintenance of the machine.

expected harm

Injuries and contusions.

preventive measures

Prevention can consist in protecting moving mechanical by fixed shields or with interblocking devices to block movement in case of opening of the shield and to prevent start-up as long as the shield is open. If it is necessary to turn on the machine with shields open, for example in case of maintenance or cleaning, this must be allowed only for specialised personnel using controls allowing for advancement by impulse requiring them to press the button and which, once inserted, bypasses the control panel.

legislative references

- Art. 6 “Duties of workers” Pres. Decree n. 547 of 27.04.1955.

- Art. 41 “Protection and safety of machinery” Pres. Decree n. 547 of 27.04.1955.

- Tit. III, Part III "Transmission and gears" Pres. Decree n. 547 of 27.04.1955.

- Art. 68 “Protection of moving parts and zones of operation of machinery” Pres. Decree n. 547 of 27.04.1955.

- Art. 72 “Blockage of protection devices” Pres. Decree n. 547 of 27.04.1955.

- Art. 73 “Opening of power supply and unloading of machinery” Pres. Decree n. 547 of 27.04.1955.

- Art. 76 and 77 "Control devices for starting up of machinery" Pres. Decree n. 547 of 27.04.1955.

- Art. 81 "Control with multiple blockage device" Pres. Decree n. 547 of 27.04.1955.

- Art. 82 "Blockage of machine stop position" Pres. Decree n. 547 of 27.04.1955.

- Art. 233 "Control and operation devices" Pres. Decree n. 547 of 27.04.1955.

- Tit. IX "Maintenance and repair" Pres. Decree n. 547 of 27.04.1955.

- Art. 4 "Obligations of employers, managers and employees" Leg. Decree n. 626 of 19.09.1994.

- Tit. III “On work equipment” Leg. Decree n. 626 of 19.09.1994.

- Pres. Decree n.459 of 24.07.1996 (Machinery Directive).

- Standards UNI EN 291/2, 291/2, 614/1, 294, 349, 811, 418, 1037, 1088, 574, 982, 983, 1012/1, 1012/2

Work near openings in the floor

description

The stem remover is generally below floor level under the hopper; thus there is the risk of falling from above if openings are not adequately protected. Any material that could fall from above could hit the workers

expected harm

Injuries and contusions.

preventive measures

Install a normal parapet with a footguard around opening towards the drop. The access to the steps to go down into the lower area where the stem remover is installed may be protected with a small gate.

The stairs per to go down to the lower floor (generally a spiral staircase) must be permanently foxed, made of slip-proof material (for example metal grill), equipped with a railing and footguard.

legislative references

- Tit. II of Pres. Decree n. 547 of 27.04.1955 “Regulations for the prevention of accidents”.

- Leg. Decree n. 626 of 1994 and subsequent amendments and additions

Work in raised positions

description

The operations of filling tank trucks and/or wine vats generally involve the need to reach raised positions, with the consequent risk of falling from above. Also for the operations cleaning the tank trucks, the worker goes to the top of them with the risk of falling from above.

expected harm

Traumatic injuries due to falling from above (risk of fatal accident).

prevention

Arranging safe access to raised positions above wine vats with stable and slip-proof steps, parapets, footguards, etc… as required by laws in force.

Access to the upper part of tank trucks must also be safe, for example with a sturdy ladder having stable and slip-proof steps, while the top of the tank should have a slip-proof walkway(for example a metallic grill) with reclinable railing and parapet, which the worker can raise before going to the walkway.

According to the situations PPD may be necessary (slip-proof shoes, harness with retaining system to prevent falling from above).

legislative references

- Art. 386 “Safety belts” Pres. Decree n. 547 of 27.04.1955.

- Tit. II “Areas and places for work and passage” Pres. Decree n. 547 of 27.04.1955.

- Standards UNI EN 361, 363, 795

- Annexe IV, part B, sect. II Directive EEC/CEEA/EC n. 57 of 24.06.1992: "Directive of the Council of 24 June 1992 regarding minimum rules for safety and health to implement in temporary or mobile wine producing plants (8^th particular directive pursuant to Art. 16, paragraph 1 of Directive 89/391/EEC)."

Manual handling of loads

description

In the smaller enterprises or in winemaking co-operatives, when the grapes are brought to the plant in baskets, the operations of collecting these from the vehicle to then be tipped into the hoppers of for the grapes can involve the need to manually lift and carry the full baskets, which may have a weight of several dozen kilograms. In case of falling of a basket during manual handling (for example for breakage of a handle) the workers’ feet may be hit.

expected harm

Muscular-skeletal trouble.

Injuries and contusions to the feet.

prevention

- Verify that the handles of the baskets are in good conditions and that there is no danger of breakage due to weight when the basket is full.

- Use smaller baskets to reduce the weight when they are full.

- Use two workers to handle full.

- Use mechanical aids for the handling of full baskets.

- Assess the possibility of mechanising the operation.

- Wear PPD (safety shoes with metal reinforced tow-guard).

- Information and training of workers.

legislative references

- Tit. V and Annexe 6 of Leg. Decree n. 626 of 10.09.1994.

- Standard UNI ISO 938

Exposure to noise

description

During the work near pressing, stem removing or wine making machinery the workers may be exposed to noise with equivalent levels that may exceed 85 dB(A). Nevertheless, personal exposure of workers is not generally continuous during the working day and lasts a few days a year.

expected harm

Continuous exposure to medium-high noise levels may cause harm to hearing (hypoacusis due to noise) and/or non-hearing disturbances which may also occur for exposure to levels under those for which regulations require particular preventive measures.

Trouble in communication and job performance may also occur.

preventive measures

Noise assessment is required pursuant to Leg. Decree 277/1991, use machinery that is less noisy and kept in a good state of maintenance.

In cases of levels of personal exposure exceeding 80 dB(A), the preventive measures set forth in Leg. Decree 277/91 shall be applicable, summarised in the table “Ceiling levels of exposure to noise”, shown in this document in the Chapter “General legislative references”.

legislative references

- Art. 24 "Noise and vibrations" Pres. Decree n.303 of 19.03.1956.

- Part IV “Protection of workers against risks of exposure to noise during work” Leg. Decree n.277 of 15.08.1991.

- Pres. Decree n.459 of 24.07.1996 “Regulation for the implementation of Directives 89/392/EEC, 91/368/EEC, 93/44/EEC and 93/68/EEC concerning the harmonisation of the legislation of Member States for machinery” (Machinery Directive).

EXTERNAL CONTRACTING

Distilling takes place in a distillation plant, which is generally, is an outside firm. Also the transport of stems by truck and must in tank trucks (where applicable) is contracted to outside enterprises specialised in transport.

EXTERNAL IMPACT

Induced vehicle traffic

The vehicles delivering the grapes harvested and the tank trucks delivering the must can lead to considerable induced vehicle traffic especially in some periods of the year corresponding to the grape harvest and the first processing of the grapes.

Diffusion of noise

Noise is produced by the vehicles mentioned above, and machinery such as screws, conveyors and pumps. This can cause disturbance to the population that may reside near the plant. Less noisy machinery should be used, and submitted to adequate maintenance; the noisiest machinery should be soundproofed, and placed in the area of the plant furthest from homes, arranging noise-proof barriers where necessary.

Spillage of grape juice and must

During the delivery and transfer of grapes and must accidental spillage may occur. The yard in front of the plant should be designed in such a way as to collect rainwater and any spillage, with collection shafts before sending to the treatment plant or external sewer.

FAST FERMENTATION, SULPHUR DIOXIDE TREATMENT, PRESSING

DESCRIPTION OF PHASE

The must is pumped into containers (wine vats) in which fermentation takes place (therefore these wine vats are also called fermentation vats or simply vats).

Generally this processing takes place on ground level, directly in the open and sometimes under shelters or in rooms.

The must, obtained from the grapes after the initial pressing, is a semi-dense sugary liquid, composed of various substances that were in 5h3 grapes and to be transferred to the wine. It is a living element containing 65-80% water and 15-30% of sugar, mostly fructose and glucose. Most of the latter is then converted into alcohol during fermentation, thanks to the action of yeast. Not all the sugar is converted into alcohol during fermentation; considerable amounts of unfermented sugar are contained in sweet and liqueur wines, but also in small amounts in dry wines.

The yeast consists of complexes of microorganisms that can cause fermentation through the enzymes they produce. Those present naturally in the grapes are able to start the fermentation of the must on their own; nevertheless, to complete or enhance perfect alcoholic fermentation, is normal to add others with different characteristics according to the result required. There are, in fact, thousands of types of yeast, each used for various purposes: some are particularly resistant to alcohol, others to sulphur dioxide, others to the cold, etc. Yeast is likewise fundamental in producing sparkling wines, being added to obtain refermentation that will develop the carbon dioxide producing the bubbles.

Carbon dioxide (CO₂) develops naturally in the wine as a consequence of the various processes of fermentation; its presence is evident in spumante and other sparkling wines, but it is also present, in minimum doses, in ordinary wine and serves to balance them, keeping the scent and taste more alive and fresh, as long as fizziness is not excessive. Any external addition of CO₂ must be shown on the label.

For the production of the novello or new wine (un particular type of wine ready a few weeks after the grape harvest) the carbonic steeping procedure is used, also called aromatic fermentation due to the fact that a very scented wine is produced. As mentioned in the previous phase, the grapes for this type of production are not pressed in the ordinary way but placed whole into a container (generally of cement enamelled inside). The latter is kept hermetically sealed for 7-20 days at a temperature of approximately 30°C, saturated with carbon dioxide. The CO₂ inside the container partly develops naturally from the fermentation of a minimum amount of grape juice running on the bottom (because the grapes on the bottom are crushed by the weight of those above), and partly with external addition from tanks. The ambient saturated with CO₂in the container triggers fermentation in the grapes. In other parole, because of the sealed environment, the permeability of the peeling alters and the steeping takes place even if the bunch is whole. At the end of the periods of carbonic steeping, the entire mass is then pressed and placed in the fermentation vat where, after or three days, the conversion of sugar into alcohol is completed, to be immediately bottled and if possible drunk after not too much time.

In the production of red wines, the action of carbon dioxide in must during the fermentation causes sediment to appear on the surface; in order to optimise the process it must again be immersed and mixed. This takes place by pressing and stirring. In the first case the sediment is pressed under with moving parts that may be incorporated in modern steel vats, or with external tools lowered into vats (this takes place for wooden vats); in the second case, on the other hand, the liquid is pumped from a faucet at the base of the vat and put back in from above on the sediment. Pressing and stirring also have the purpose of airing the must and activating, thanks to the oxygen in the air, the fermentation yeast. Nevertheless, it should be recalled that the air must be properly dosed since excessive contact of the must with the air favours the development of vinegar bacteria and alters the colours, bleaching red wines and darkening whites. This is particularly important for the subsequent phases of ageing of the wine. The pressing and stirring processes, more common in medium or large size vats, are conducted frequently to prevent the surface of the sediment from turning into vinegar and altering the entire mass. Furthermore, in order to avoid excessive oxidation due to contact with the air, when racking the must or the wine afterwards to fill a larger vat, the operation is preceded by placing an inert gas (generally nitrogen) in the vat.

For the preparation of ordinary wines sulphur dioxide (SO₂) is often put into the must, mainly to select the yeast present. This operation (called sulphur dioxide treatment or sulphuration) generally takes place immediately after the first pressing of the grapes, but sometimes also later in the fermentation vats, and can regard must and wine. The sulphur dioxide poured into the liquid acts as an antiseptic that prevents the reproduction of unwanted yeast such as apiculatus and other microorganisms, while the yeast required for the fermentation of the must, such as ellipsoideus yeast, are very resistant to this treatment. Besides the sterilisation effect, the sulphur dioxide is sometimes used to dissolve colouring substances and to enhance the increase of the alcohol content of the wine. The sulphur dioxide (SO₂) placed in must is spread in two forms: combined with the compounds present in the wine (in particular with glucose, fructose, colouring substances) and free. The balance between the two forms, typical per each wine, is influenced by the temperature. The free fraction decreases over time, not only due to the combinations, but also due to evaporation, oxidation and reduction to hydrogen sulphide. For the quality of the product (the Italian law sets a maximum limit for the presence of SO₂ in wine), sulphur dioxide tends to be used in winemaking enterprises only for the real needs of the must as shown by chemical analysis. The entire process of fermentation is, in fact, kept under control by periodical sampling and laboratory analysis.

As mentioned above, the temperature plays a basic role. During alcoholic fermentation heat is produced, but the process can stop only of the temperature rises too much, up to 35-38 °C, and the must is ruined due to so-called mannite fermentation. To avoid this it is necessary to cool the must. The opposite case may also occur, i.e. an excessively low ambient temperature (10°C) may prevent the triggering of fermentation; in this case it is necessary to heat the must.

For these reasons, in modern wine production plants fermentation generally takes place in recipients with controlled temperature, with the possibility of heating or cooling the must.

When the wine experts decide that the right time has arrived, they undertake the operation called racking off, which consists in removing from the fermentation vat the most liquid part of the fermented must (called wine flower), while the solid part is conveyed, by a screw, to pressing (racking off and pressing are further described in the subsequent paragraphs).

Up to racking off the fermentation is also called fast fermentation to distinguish it from slow fermentation that also continues in the subsequent phases of the wine production process.

EQUIPMENT AND MACHINERY

Decanting pump

This is a mobile pump on wheels that has the function of aspirating the liquid from a container and at the same time putting it into another one. There are various sizes and the larger ones can reach a considerable weight (for example 560 Kg.).

Fig. 9. Medium size decanting pumps.

Fermentation vats

These are containers in which the must is fermented. There are various types with the differences regarding material, accessories, capacity, shape and size.

The material of which the most modern fermentation vats are made is stainless steel, while the older ones besides wood, are made of metal enamelled on the outside and painted inside with epoxy paint making the surfaces like glass. There are often fermentation vats in reinforced concrete coated internally with mortar that is in turn covered with tiles or vitrifying paint. There are also fibreglass fermentation vats.

The shape is generally cylindrical, especially for the steel vats, and there are also some with a parallelepiped shape, especially for cement vats. The latter have the advantage of allowing the better use of the space in the production plant.

The vats are equipped with: spouts (generally two) for the decanting of the liquid with pumps and flexible tubes; a lateral door (also called manhole and placed laterally a little above the base of the vat, generally between the two spouts); a lower door (placed base of the vat and generally used for removing the sediment); an upper door (placed at the top of the vat). Sometimes at top of the vat there is also a safety valve for the exit of excess gas when the pressure inside the container rises beyond a certain limit.

The vats may be equipped internally with shaking and/or pressing elements moved by the electric motors or pneumatic systems.

Some fermentation vats are insulated and/or equipped with temperature control systems (heating / cooling) that affect the process of fermentation.

The cooling is sometimes achieved by running cold water over the walls of the vat; for this purpose the top of the vat as a ring of plastic tube with holes, while a gutter is placed all around the base of the vat to collect the water running on the walls. The water collected is then sent to the cooling plant before being circulated again.

Other more modern systems include vats equipped with double walls (airspace) where a cooling or heating liquid runs to control the temperature of the process.

Wooden vats have generally been replaced with steel vats (also cement or other materials mentioned) since they make for easier installation of the accessories mentioned, easier maintenance and compared to wood do not have reductions due to evaporation since their permeability is minimum.

For the wooden vats the cooling / heating of must takes place thanks to hollow metallic plates in which a cooling / heating liquid is circulated.

Fig. 10. Plates for the cooling / heating of must during the fermentation in wooden vats.

Portable tanks for carbon dioxide

These are steel tanks of the type normally used to contain compressed gas.

Portable tanks for nitrogen

These are steel tanks of the type normally used to contain compressed gas.

Nitrogen generator

In the larger enterprises, instead of being used in tanks, the nitrogen is produced directly at the plant in the amount and purity required, by a specific continuous generator. In this case the nitrogen is obtained by separation from the other components of the atmosphere (this avoids a series of problems connected with the use of tanks such the replacement of empty with full ones, the use of trolleys, filters, etc.).

According to the volume, the nitrogen generators may have a built-in or external compressor.

Portable tanks for sulphur dioxide

Generally compressed sulphur dioxide in steel tanks is used (the pressure is approximately 3 atm at 20°C) from which it is removed in the gaseous state to be used in the sterilization of recipients, or in the liquid state for the sulphurisation of must and wines (in the latter case the tank is kept upside down).

Equipment of sulphur dioxide treatment

Small trolleys holding a tank of SO₂ (kept upside down) are often used, and a sulphur dioxide meter which is device to ensure the dosing of the correct amount of sulphur dioxide and filled by decanting from the tank. The sulphur dioxide meter basically consists of a cylinder with a part having a transparent wall (generally in resistant glass) showing a graduated scale used to measure the required amount of liquid sulphur dioxide. The connection between the tank of SO₂ and the sulphur dioxide meter is through a copper tube. Sulphur dioxide meters are generally equipped with three taps: one opens the SO₂, inlet hole; one is an air outlet and the third one for pumping the SO₂ into the vats. The capacity of the sulphur dioxide meter generally varies from 2 a 5 Kg. The sulphur dioxide treatment equipment generally includes a metallic rod for injecting sulphur dioxide and other gasses into the tanks, through the special valve. It may be telescopic in order to avoid having to take it apart.

Stirring device

The stirring device is equipment used to press down the top formed by the sediment, which tends to rise to the surface of the must in the vats. Generally this is a stainless steel cross element secured to the base of a pneumatically powered piston. The device runs along a monorail attached to the ceiling above the row of vats.

Cooling compressors

See the phase “refrigeration system”

Fig. 11. Cement vats.

Fig. 12. Row of fermentation vats equipped with shakers (note motors on the upper left).

Fig. 13. Nitrogen inlet between the insulated fermentation vats.

Fig. 14. Nitrogen generator.

Fig. 15. Top of a stainless steel wine vat, capacity 3,500 hectolitres.

Fig. 16. Base of a stainless steel wine vat, capacity 3,500 hectolitres. Note the manhole, the three spouts and the graduated scale for measuring the amount of wine in the container.

Fig. 17. Small trolley for the transport of a tank of nitrogen and a tank of sulphur dioxide.

RISK FACTORS

Working in high places

description

There are many reasons why the workers climb on top of the vats, of which we can recall the following:

- During the filling of the vat, for a sight check of the complete filling of the recipient, giving indications to another worker controlling the pump.

- During the pressing operations, to use the stirring device.

- During the mixing operations, to check the proper mixing of the top.

- For possible maintenance to the cooling / heating circuit with water flow.

- For the introduction / extraction of the cooling / heating plates.

The worker goes to the top of the vat, using a ladder or a fixed metallic structure consisting of stairs and walkways along the top of the vats.

The above operations expose workers to the danger of falling from above (outwards or inside the vat full of must).

When there are walkways (e.g. made of metal grills) above the vats in which the upper inlets of the vats are located, of the latter are left open, the workers may trip and fall (into the vat or outwards). In the case of several vats in a row, there may be several inlets on the floor of the raised walkway, a in a row or raised with respect to the walkway floor.

The presence of any asphyxiating (carbon dioxide) or toxic gas (sulphur dioxide) and of alcoholic vapours may aggravate the risk of falling from above.

expected harm

- Injuries and contusions due to falling from above to the ground.

- Drowning in case of falling into the vat full of must, especially if the worker has become unconscious due to the presence of asphyxiating gas.

In both cases there is a risk of fatal accident.

preventive measures

The workers who climb to the top of the vats must be able to carry out their work safely; for example, if the operation of pressing is conducted at the top of wooden vats reached by a ladder, the worker must wear a safety belt or harness adequately fixed to the monorail or the ceiling and the ladder must be equipped with suitable hooks to be secured to the upper edge of the vat and of support bases on the floor with reinforcement in slip-proof rubber.

Fig. 18. Pressing device on an overhead monorail with a cross-shaped stirring device and pneumatic movement. The monorail secured to the ceiling runs over the wooden vats. Note that the worker is wearing a safety belt secured to the monorail. The ladder is equipped with suitable hooks to be secured to the upper edge of the vat and support bases on the floor with reinforcement in slip-proof rubber.

When the fermentation vats are equipped with a fixed access with steps and walkways, they must be permanently fixed, made of slip-proof material (for example metallic grill), equipped with parapets and footguards.

It is necessary adopt measures to reduce the risk of tripping or falling in the upper inlets of the vats, especially when these are on the floor of walkways; for example, a possible solution could be to make the grilled walkway so that the upper inlet of the vat is on the same level or also a few centimetres lower than the floor level, with a “hatch” hinged to the grill that may be opened to remove the cover of the inlet of the vat and then immediately closed while leaving the inlet itself open. In this way, with the inlet of the vat open or closed, the walkway would always be without openings and obstacles. There may be a smaller hinged hatch (inside the large one) for the easier passage of the tubes used replacements, washing etc…

Fig. 19. Steel vat seen from above with the grilled floor of the walkway and the upper inlet open.

The possibility of adopting all the organisational and technological measures for avoiding or reducing the need to conduct work in high places, as in the following examples.

- Use level indicators which, also from the ground, show the level of filling of the vat; this may be achieved by a transparent plastic tube along the top of the vat next to a graduated scale. The filling of the level indicator tube can take place by a small tap on the base of the vat (the tube is filled with liquid on the basis of the principle of communicating vessels); in case of very high vats, the workers may be supplied with pocket binoculars to make level reading easier.

In the case of vats in the open, the transparent plastic tube may deteriorate easily (especially if the plastic material is rigid and not very resistant to thermal stress due to weather) thus requiring periodical replacement. To facilitate the replacement it is possible to use a flexible plastic tube with the end tied to a cord which, through a winch, may be lowered to the ground, so that while the old tube is removed the new one is inserted, without having to go top of the vat; likewise soft plastic seems to have the advantage of requiring less frequent replacement.

- Use fermentation vats with their own internal devices for pressing / stirring the must, so that it is not necessary to use the external stirring device placed in the vat from above. This seems to require the replacement of wooden fermentation vats with stainless steel vats; this should have no negative influence on the wine produced since the replacement of wood with stainless steel could regard only the fermentation vats (where the fast fermentation takes place) and not the barrels or casks (where slow fermentation, refining and ageing of the wine take place).

legislative references

- Art. 386 “Safety belts”, Pres. Decree n. 547 of 27.04.1955.

- Tit. II “Areas and places for work and passage”, Pres. Decree n. 547 of 27.04.1955.

- Standard UNI EN 361 of 30.11.93 “Personal protection devices against falling from above. Body harnesses”. Specifies the requirements, the test methods, the instructions for use, the marking and packaging for the body harnesses. Other types of supports for the body are defined in EN 358. The devices to prevent falling are specified in EN 263.

- UNI EN 363 of 31.12.93 “Personal protection devices against falling from above. Systems to prevent falling”. Specifies the terminology and general requirements for the systems to prevent falling to act as protection devices against falling from above. It likewise provides examples as how to connect components or groups of components to a system to prevent falling. These examples should allow the purchaser or user to set up all the components correctly and to create a system to prevent falling.

- UNI EN 795 of 01.05.98 “Protection against falling from above - Anchoring devices - Requirements and tests”. Specifies the requirements, the test methods and the instructions for use and the marking of anchoring devices designed exclusively for use with personal protection devices against falling from above.

-

Leg. Decree n. 626 of 1994.

Fig. 20. The inside of a fermentation vat in stainless steel equipped with pressing equipment (looking upwards).

Exposure to sulphur dioxide

description

The various operations related to the phase of sulphur dioxide treatment described above (storage and handling of SO₂ tanks, filling the sulphur dioxide meter, sulphur dioxide treatment of the must) can cause exposure of workers to sulphur dioxide (SO₂). This is a gas heavier than air that thus tends to accumulate downwards in poorly ventilated wine production plants.

Once in smaller wine production plants a rubber balloon with sulphur dioxide gas was inflated directly from the tank; the balloon was then left to deflate in the must in order to release the gas. This involved a high risk for the workers since the balloon could break or be dropped with the consequence of being hit by a cloud of sulphur dioxide to cause fainting and fatal risks.

The balloon has now been replaced by the sulphur dioxide meter with considerable reduction of the risk. Nevertheless, also with the sulphur dioxide meter there is still a risk, especially during the filling operation.

estimate

Sampling conducted in previous surveys in some winemaking enterprises have shown ambient values of between 0.011 and 0.16 mg/m³; these are rather low when compared with the TLV-TWA = 5.2 mg/m³ and with the TLV-STEL = 13 mg/m³ (TLV values in ACGIH 2000), while the values of personal exposure during the filling of the sulphur dioxide meter and during the sulphur dioxide treatment in the vat range between 0.43 and 52.3 mg/m³[2]. It should in any case be pointed out that the operation of filling the sulphur dioxide meter is occasional and of short duration.

expected harm

Sulphur dioxide is classified as: T (toxic), R23 (toxic by inhaling), C (corrosive), R34 (causes burns). It is an irritant of moderately high level. The irritating action is due to its conversion into acid upon contact with the damp of ocular and nasal mucous membranes and the skin, then arriving into the respiratory system causing bronchial constriction, with symptoms of asphyxiation for high and/or prolonged exposure.

preventive measures

Particular attention must be paid by the workers during the filling of the sulphur dioxide meter. Before proceeding with this operation, it is always necessary to verify the good state of the tubes used for the transfer, and the taps of the tank and the sulphur dioxide meter.

The workers for filling the sulphur dioxide meter and in sulphur dioxide treatment of must are required to wear adequate PPD such as facemasks with specific filter for SO₂ (type A3) for the protection of the respiratory tract and the eyes, gloves, aprons and footwear resistant to corrosion.

The filling of the sulphur dioxide meter should take place outdoors near an emergency shower equipped with eye-washer, which can be immediately used by workers in case of contamination with the dangerous product. The worker in the operation should be watched by another worker who stays at a certain distance while also wearing PPD in order to be able to intervene immediately in case of emergency.

If sulphur dioxide treatment is conducted in fermentation vats placed inside rooms of the plant, the latter must be equipped with suitable airing systems, placing air extractors if possible on the lower parts of the walls.

Once used, the sulphur dioxide meter should be put in a safe place, away from atmospheric agents, far from sources of heat and from possible accidental hitting by workers or vehicles in transit, if possible in a room or locker with lock and key with access reserved to workers and having a suitable sign. All the containers must be equipped with the required labelling.

The workers must be adequately informed and trained on the correct procedure of processing and procedures for managing emergencies and first aid.

It should be assessed whether to replace the sulphur dioxide with other less dangerous anti-fermentation substances [9].

legislative references

- Royal Decree n. 49 of 09.01.1927 (toxic gas).

- Pres. Decree 547/1955 and subsequent amendments and additions

- Pres. Decree n. 303/1956 and subsequent amendments and additions

- Leg. Decree n. 626/1994 and subsequent amendments and additions

Exposure to carbon dioxide

description

The carbon dioxide produced naturally by the fermentation of the must can accumulate in the working environment with consequent decrease of the oxygen in the air. It should be recalled that carbon dioxide has a greater density than air and thus tends to accumulate in low places. This risk is real in situations in which the vats of fermentation are located inside rooms of the plant and poorly ventilated.

Exposure to carbon dioxide may also take place during the operations of pressing with hand-operated tools.

Carbon dioxide is a colourless and odourless gas also found in small amounts in the atmospheric air (approximately 0.035 %); it is not combustible and is easily soluble in water.

expected harm

A worker entering a room where there is a high concentration of carbon dioxide risks fainting and dying of asphyxia, also due to the reduction of oxygen in the air.

Exposures of short duration to levels of concentration of CO2 under 2% (2000 ppm) have not been associated with harmful effects. At higher concentrations effects occur on respiration and the central nervous system.

The inhaling of carbon dioxide at a concentration of 5% causes dyspnoea, tachycardia, perspiration, headache, dizziness, disorientation, distorted sight etc.; in the long term there may be alterations of the acid-base metabolism and of the respiratory and vascular function.

Furthermore, the presence of carbon dioxide can increase the risk of falling from above, for example when the workers are on top of the vats (see the risk factor working in high places). Falling can be on the ground with consequent traumatic injuries, and into the full vat with the risk of drowning in the must.

preventive measures

In enterprises where the fermentation vats are located inside rooms, CO₂ detectors should be placed in the significant points of the risk zones, since the gas is odourless. Furthermore, the working areas must be well ventilated. The workers who first enter the plant at the start of the working day to air it, before doing this, must verify the state of the CO₂ detectors to ensure their own safety. It may be advisable to connect the CO₂ detectors to an automatic ventilation system.

legislative references

- Pres. Decree 547/1955 and subsequent amendments and additions

- Pres. Decree n. 303/1956 and subsequent amendments and additions

- Leg. Decree n. 626/1994 and subsequent amendments and additions

Exposure to ethyl alcohol vapours

description

During the operations conducted in this phase the workers may be exposed to ethyl alcohol vapours produced during the fermentation of the must.

Ethyl alcohol is easily volatile and has a characteristic odour recognisable at 1/5 – 1/10 of the concentration provided for in TLV.

expected harm

In the occupation filed there is no evidence of alcoholic intoxication similar to the type produced by drinking, due to exposure by inhaling and of short duration, and also thanks to the characteristic odour recognisable as ethyl alcohol.

In the presence of high concentrations ethyl alcohol vapour there may be a depression of the central nervous system, headache, nausea, somnolence, dizziness, lack of co-ordination and confusion.

Increase of the risk of slipping and falling from above.

preventive measures

Guarantee adequate natural or forced ventilation of the work environment.

Air small rooms before entering.

Information and training of workers.

legislative references

- Pres. Decree 547/1955 and subsequent amendments and additions

- Pres. Decree n. 303/1956 and subsequent amendments and additions

- Leg. Decree n. 626/1994 and subsequent amendments and additions

Use and storage of tanks containing gas under pressure

description

The tanks containing gas under pressure (sulphur dioxide, carbon dioxide, nitrogen) may involve the risk of explosion if the internal pressure grows excessively. This may be caused by the increase of the temperature.

Another risk is the possibility that the tanks may be hit, for example by falling; this can involve the breakage of the valve with consequent detaching and the release of gas from the tank at very high pressure and thus with a strong force.

Furthermore, there is the specific risk of inhaling the gas contained in the tanks (see risk factors “exposure ad sulphur dioxide”, “exposure to nitrogen”, “exposure to carbon dioxide”), besides the fact that skin contact with nitrogen or carbon dioxide can cause cold burns due to their very low temperature.

The nitrogen to be converted into a liquid is cooled at very low temperatures (approximately – 210 °C) while the CO₂ liquefies at the temperature of 0 °C at a pressure of 36-40 atm. (or also 30 °C at a pressure of 77 atm.).

expected harm

Fainting, asphyxia due to inhaling gas in high concentration.

Lesion from cold burns due to contact with cold gas.

preventive measures

The tanks must be equipped with the required labelling, stored in a specific room, aired and protected from sunlight, far from other inflammable materials or those that may form a high rate of fire. Furthermore, the tanks stored must be secured so that it is impossible for them to fall. The valve must be protected against possible accidental hitting by a steel cap. Particular caution is required in the handling of tanks, for which special trolleys should be used.

The workers must be adequately informed and trained.

legislative references

- Royal Decree n.147 of 09.01.1927 “Approval of special regulation for the use of toxic gas”.

- Single Law 1265/34 and Decree of the Min. Health 05.09.94 (Unhealthy Industries).

- Tit. VIII "Dangerous or harmful materials and products" Pres. Decree n. 547 of 27.04.1955.

- Tit. II, Art. 9 “Airing of closed workplaces” and Part II “Defence from harmful agents” of Pres. Decree n.303 of 19.03.1956 “General standards for occupational hygiene”.

- Art. 3 “General protective measures” of Leg. Decree n. 626 of 19.09.1994.

- Art. 4 "Obligations of employers, managers and employees" Leg. Decree n. 626 of 19.09.1994.

- Tit. IV of Leg. Decree n. 626 of 19.09.1994 “Use of personal protection devices”.

- Tit. VII of Leg. Decree n. 626/94 “Protection from cancer-causing agents”, as amended by Leg. Decree n. 66 of 25.02.2000.

- Pres. Decree n. 336 of 1994 (Occupational diseases).

- Standard UNI EN 1964-1:2001 of 31.05.2001 “Portable tanks for gas - Specifications for the design and manufacturing of rechargeable and portable steel tanks without welding, with a capacity in water of between 0.5 litres and 150 litres inclusive - Steel tanks without welding having an Rm value under 1,100 MPa”. Summary: this standard is the official version in Italian of European standard EN 1964-1 (edition January 1999) and takes into account the corrections of July 1999 (AC:1999). The standard specifies the minimum requirements for materials, design, manufacturing and processing, the processes of manufacturing and tests on the manufacturing of rechargeable and portable steel tanks for gas without welding, with a capacity in water of between 0.5 litres and 150 litres, for pressurised, liquid or dissolved gas. The standard applies to steel tanks with Rm value under 1,100 MPa.

- The director of the management unit for vehicles and transport safety of the Ministry of Infrastructures and Transport, in relation to the Decree of 15 March 2001 concerning the "Maximum charge pressure of tanks of argon, air, nitrogen, krypton, helium, neon and oxygen" which is allowed for transport and use in Italy for these gasses, of tanks with charge pressure of 300 bar and considering the publication of standard UNI EN 1964-1 and the need to limit the total weight total of recipients, also tanks in compound material, has issued the Decree of 18 October 2001 by which: 1) Annexe 1 to the Decree of 15 March 2001 is abrogated; 2) the maximum charge pressure allowed for the aforesaid tanks of compressed gas and for the mixtures of these gasses is 300 bar. For the steel tanks without welding with charge pressure over 250 bar must be designed, built and subjected to approval and initial verification according to the specific UNI standards or European draft laws.

Manual handling of loads

description

The decanting pumps (equipped with wheels) are often pushed manually by the workers from one point to another of the wine production plant in order to use them from time to time where necessary. The weight of these pumps varies according to their size and capacity, for example in enterprises in the sector with industrial production using pumps weighing up to 560 Kg.; pushing them manually thus requires a certain physical effort. If there are different levels between the various sections of the plant where the decanting pumps must be used, and the sections are connected by stretches of sloping floor, pushing the pumps along these paths can involve considerably greater physical strength according to the slope of the slide.

Besides the physical effort necessary for shifting the items, there is also the risk of accidents by crushing of feet by the wheels and the risk of being hit if the worker does not manage to hold the pump along the sloping path. The shock may be considerable if the pump, left free to move along the slide, gains speed.

expected harm

Muscular-skeletal trouble.

Traumatic injuries by shock, collision, crushing.

preventive measures

As far as possible, differences in level should be avoided between sectors where the use of decanting pumps is required; where this is not possible, the slope of slides connecting sectors at different levels should be as limited as possible; two workers should push the load, or better, use elevator equipment to reach the different levels.

The wheels of the pumps should be equipped with devices to prevent the catching of feet and a mechanical braking system; for example, there may be brake inserted automatically when the worker releases the lever under the bar used to push the pump (a similar device is used on baggage trolleys commonly used in railway stations).

The workers must be adequately informed and trained.

legislative references

- Tit. V and Annexe 6 of Leg. Decree n. 626 of 10.09.1994.

- Standard UNI ISO 938

Work outdoors

description

In many enterprises the fermentation vats are installed outdoors, and thus the performance of the operations described above exposes the workers to the weather (sun and heat in the summer months; rain and cold in the winter months).

expected harm

Illness from cold during the cold season.

Excessive fatigue, sunstroke, heat stress during the hot season.

preventive measures

It should be assessed whether to install sheds for the protection of workers from the weather; the workers must have adequate protective clothing available; the work must be organised in order to minimise the exposure times and providing rest pauses in areas with heating/air conditioning. The workers must be informed and trained.

legislative references

- Art. 378 "Clothing" and Art. 379 "Protective clothing" Pres. Decree n. 547 of 27.04.1955.

- Title V "Manual handling of loads", Annexe VI "Reference elements" of Leg. Decree n. 626/1994.

Use of electric equipment in damp areas

description

The risk derives mainly from the use of electrically powered pumps and shakers in a work environment that generally is wet due to frequent washing (and for the possible spillage of liquids in processing). The damp environment increases the accident risk in case of direct or indirect accidental contacts with live wires.

Furthermore, power supply cables of portable machinery (e.g. mobile pumps on wheels), can cause accident risks because the workers might trip and fall. The latter risk is increased by the fact that wet floors may be slippery.

expected harm

- Electrocution due to direct / indirect contact with live wires.

- Traumatic injuries due to falling.

preventive measures

The electric plant must be adequate for the classification (according to CEI standards) of the danger of the place where it is installed and protected by risks deriving from possible direct / indirect contacts with live wires. Particular attention is required to the insulation standards (IP) of the plant and the type of electric plugs (avoid triple plugs, multiple extensions etc, but use interblocked industrial plugs, with one device for each plug).

Before using electric portable machinery (pumps etc.) the worker must verify the good state of insulation of the electric cables and place them in such a way as to not interfere with the normal passage of the workers and vehicles (in particular the latter can deteriorate the cables if they drive over them). The waterproof connections of the electric panels of machinery must be periodically checked and the workers must report any defects to the head of department. The maintenance of the electric parts must be reserved to specialised personnel, and the information and training of workers is required.

legislative references

- Law n. 791 of 18.10.1977 "Implementation of Directive of the Council of the European Community (n. 72/23/EEC) regarding guarantees of safety required for electric material required to be used within certain voltage limits".

- Title VII of Pres. Decree n. 547/1955 "Plant machinery and various equipment"

- Decree of the Ministry of Industry of 13.03.1987 "Publication of the list summarising harmonised regulations together with the implementation and publication of further (4th group) Italian texts of the corresponding harmonised C.E.I. standards, as in Art. 3 of Law 18 October 1977, n. 791, on the implementation of Directive n. 73/23/EEC regarding safety guarantees of electric material"

- Decree of the Ministry of Industry 12.02.1996 "Publication of the list summarising harmonised regulations together with the implementation and publication of further (4th group) Italian texts of the corresponding harmonised C.E.I. standards, as in Art. 3 of Law 18 October 1977, n. 791, on the implementation of Directive n. 73/23/EEC regarding safety guarantees of electric material".

- Leg. Decree n. 626 of 25.11.1996 "Implementation of Directive 93/68/EEC, on EC marking of electric material to be used within certain voltage limits".

- Leg. Decree n. 277 of 31.07.1997 "Amendments to Leg. Decree 25 November 1996, n. 626 (2), with implementation of Directive 93/68/EEC on EC marking of electric material to be used within certain voltage limits".

- Decree of the Ministry of Industry of 13.06.1989 "List of organisations and models of seals of compliance, publication of the list summarising harmonised regulations, together with the implementation and publication of further (5th group) Italian texts of the corresponding harmonised C.E.I. standards, as in L. 18 October 1977, n. 791, on the implementation of Directive n. 73/23/EEC, for safety guarantees of electric material".

- Decree of the Ministry of Industry of 01.03.1989 "Implementation of directive EEC/88/571, on the updating to technical progress of the methods of protection of fire-proof electric material"

- Art. 5, 6, 7 sect. II; Art. 9 sect. III, of Directive EEC/CEEA/EC n. 656 of 30.11.1989: " Directive of the Council of 30 November 1989 on minimum standards for safety and health for use by workers of personal protection devices (PPD) during work (third special Directive pursuant to Art. 16, paragraph 1 of Directive 89/391/EEC)".

- Law n. 46 of 05.03.1990 "Regulations for the safety of plant "

- Ministry Decree n. 322 of 24.6.1991 “Regulations of the services of the Higher Institute for Occupational Prevention and Safety”.

- Pres. Decree n. 447 of 06.12.1991 “Implementation regulations of L. n.46 of 05.03.1990 for safety of plant”.

- CEI Standards.

EXTERNAL CONTRACTING

The running of the nitrogen generator is sometimes entrusted to an external firm, which may own the equipment although it is installed at the wine production plant; in this case the winemaking company pays the consumption of the nitrogen and the leasing of the equipment to the supplier firm dealing with the management and maintenance of the plant.

EXTERNAL IMPACT

Release of gas into the atmosphere (carbon dioxide, nitrogen, sulphur dioxide)

The carbon dioxide deriving from the fermentation of the must, the nitrogen used to prevent the oxidation of the product in case of tanks filled partially, the sulphur dioxide used for sulphur dioxide treatment of the must, are all gasses released into the atmosphere by diffusion (without be being conveyed or filtered).

Diffusion of noise

The noise in this working phase derives mainly from the pumps. This can cause disturbance to the population that may reside near the plant. Less noisy machinery should be used, and submitted to adequate maintenance; the noisiest machinery should be soundproofed, and placed in the area of the plant furthest from homes, arranging noise-proof barriers where necessary.

Spillage of must

In case of accidental breakage of pipes, pumps or tanks accidental spillage may occur. The floor of the plant should be designed in such a way as to allow the collection of liquid with collector shafts before the liquid is sent to the treatment plant or external sewer.

Fig. 21. Exterior view of the stainless steel fermentation vats. The two lower vats in the foreground are equipped with piston devices for the pressing of the must (note pistons protruding from the upper part of the vats).

RACKING OFF

DESCRIPTION OF PHASE

After fast fermentation, racking off is performed. It consists removing from the fermentation vat, using a pump, the most liquid part of the must to sent it, after gross filtering, into other wine vats where the ageing of the wine takes place; after the removal of the liquid part, the solid part of the must (sediment, grape stones etc…) remaining in the fermentation vat is removed manually with rakes and shovels and placed in a hopper with screw and pump that conveys the material for pressing (the latter working phase is further described in the next paragraph). In order to complete the extraction of sediment from the vat, one or two workers go inside it through the lateral manhole, while a third worker stays outside to feed the hopper with screw and pump.

EQUIPMENT AND MACHINERY

Vibration filter

This is an electrically powered vibration filter, mounted on board a small trolley on wheels. The purpose is to conduct an initial rough filtration of the liquid part of the must taken from vat. The sediment is collected in the upper part of the filter and due to the vibrations fall into an external collection container, from which it may be removed with shovels to be put into larger containers (transportable with forklifts) and/or into the “menestrina”.

Fig. 22. Rough filtration of the liquid part of the must after racking with a vibration filter. The vibrations cause the sediment to advance on the surface of the filter until it falls into a collection container, from which it is then removed with a shovel and placed in the “menestrina” which feeds the sediment press.

Hopper with screw and pump - ““menestrina””

In some enterprises the hopper with screw used for the racking off is fixed and placed on the base of the fermentation vats directly under the lower hatches (a single long hopper serves a row of fermentation vats, or is in the middle of two rows of fermentation vats). In this case the pump conveying the sediment towards the press may be fixed or mobile on wheels to be used also for other decanting.

In other enterprises a smaller machine is used, equipped with wheels, consisting of a hopper, screw and pump in a single body. Inside the hopper, near the screw, there are also other shaking devices which have the function of favouring the conveying of sediment by the screw pushing it into the pump. This machine, called also “menestrina”, is pushed manually from time to time on the base of the fermentation vat being racked off.

Fig. 23. Racking off of vats inside the wine production plant. After removing the liquid part of the must from the vat, the worker uses a rake to remove the sediment remaining in the vat, depositing it in the “menestrina”.

Fig. 24. Detail of previous figure. Note the protection grill for moving parts.

Fig. 25. A worker in the extraction of sediment inside the vat to complete the operation.

Fig. 26. Hopper with fixed screw place between two rows of fermentation vats outdoors, used for conveying to the press for the solid part of the must remaining after racking off (protection of the screw removed for maintenance).

RISK FACTORS

Work near moving mechanical parts

description

The moving parts of the “menestrina” and the screw involve a danger of catching and dragging of the workers’ limbs.

expected harm

Injuries and contusions. Danger of fatal accident.

preventive measures

A possible solution consists in protecting the moving parts by metallic grills. Given the density of the sediment a tight net grill does not seem to be applicable, e.g. of a type not allowing a finger to pass. We can thus adopt a grill which, though allowing the passage of the sediment, does not allow the passage of the hands and is installed in such a way that the distance from moving parts is such that they cannot be touched with the fingers.

If necessary, start the machine with protection removed, for example for operations of cleaning and maintenance, the operation may be conducted by impulse buttons which must be pressed by the worker for operation and which once inserted bypass the control panel. The information and training of workers are fundamental.