OSHA Inspection: BERRY PLASTICS CORP.

Issued

Nov 13, 2015

Abate by

Dec 18, 2015

Penalty

Initial $7,000 · Current $5,850 Reduced

General-duty citation text

29 CFR 1910.147(c)(4)(i): Procedures were not developed, documented and utilized for the control of potentially hazardous energy when employees were engaged in activities covered by this section:     a)  Extrusion Department, Plastic Resin Hoppers, Upper Platform.  On or about May 15 2015, employees performing servicing and maintenance tasks inside the hoppers including inspection of air cylinder gaskets, cleaning plastic resin from screens and lids and other troubleshooting did not utilize established lockout/tagout procedures and were exposed to getting their fingers caught in the pinch points of the pneumatic cylinders in the event of unexpected energization or startup, exposing them to amputation and laceration hazards if the cylinders closed.  A method of alternative protection was not provided.     Abatement documentation is required in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Nov 13, 2015

Abate by

Dec 18, 2015

Penalty

Initial $7,000 · Current $0 Reduced

General-duty citation text

29 CFR 1910.147(c)(7)(i): The employer did not provide training to ensure that the purpose and function of the energy control program were understood by employees and that the knowledge and skills required for the safe application, usage, and removal of the energy controls were acquired by employees:     a) Extrusion Department, Plastic Resin Hoppers, Upper Platform.  On or about May 15, 2015, employees who performed servicing and maintenance activities inside the hoppers such as inspection of air cylinder gaskets, cleaning plastic resin from hopper screens and lids and other troubleshooting of malfunctioning hoppers were exposed to amputation and laceration hazards to hands and fingers. The employer did not ensure that lockout/tagout training was provided to all authorized and affected employees who were assigned such tasks to ensure that the purpose and function of the energy control program were understood by employees and that the knowledge and skills required for the safe application, usage and removal of the energy controls were acquired by employees.           Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d)

Issued

Nov 13, 2015

Penalty

Initial $5,500 · Current $0 Reduced

General-duty citation text

29 CFR 1910.305(g)(1)(iv)(A): Flexible cords and/or cables were used as a substitute for the fixed wiring of a structure:    Extrusion Department, Lower Level.  Flexible cords were plugged into extension cords and run along vertical and horizontal pipes and other surfaces to plug into ceiling quad boxes to power condensation pumps for the following blender lines, exposing employees to risk of fire and electrical shock hazards:    a) Line #21    b) Line #22    c) Line #19    d) Line #16    e) Line #14    f) Line #13    g) Line #12    h) Line #11    i) Line #10

Issued

Nov 13, 2015

Abate by

Dec 18, 2015

Penalty

Initial $0 · Current $5,850

General-duty citation text

29 CFR 1910.147(d): Application of control. The established procedures for the application of energy control (the lockout or tagout procedures) shall cover the following elements and actions and shall be done in the following sequence:     a) Extrusion Department, Plastic Resin Hoppers, Upper Platform.   On or about May 15, 2015, employees who performed servicing and maintenance tasks on resin hoppers including inspection of air cylinder gaskets, cleaning plastic resin from hopper screens and lids and other troubleshooting of malfunctioning hoppers, were not required to control hazardous energy sources in the following sequence:     1) turn off and shut down the machines,   2) physically locate and operate energy isolating devices in such a manner as to isolate the machines or equipment from the energy source(s),   3) affix lockout or tagout devices to each energy isolating device,   4) verify that isolation and deenergization of the machines or equipment have been accomplished.     Employees were exposed to caught-in hazards likely to result in amputation and lacerations to hands/fingers from unexpected start up and/or energy release.     Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).