OSHA Inspection: APCO PACKAGING

Issued

Nov 3, 2015

Penalty

Initial $2,100 · Current $1,470 Reduced

General-duty citation text

29 CFR 1910.134(e)(1): The employer did not provide a medical evaluation to determine the employee's ability to use a respirator, before the employee was fit tested or required to use the respirator in the workplace:  a.  On or about June 8, 2015,  in the facility, the employer did not provide a medical evaluation for employee(s) required to wear air purifying negative pressure respirators during enzyme blending and liquid blending.

Issued

Nov 3, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.134(f)(1): The employer did not ensure that employee(s) required to use a tight-fitting facepiece respirator passed the appropriate qualitative fit test (QLFT) or quantitative fit test (QNFT):  a. On or about June 8, 2015,  in the facility, employees were required to wear half-mask air-purifying respirators during enzyme blending and liquid blending.  The employer did not ensure that employees using tight-fitting respirators were fit tested prior to initial use of the respirator and at least annually thereafter.

Issued

Nov 3, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.134(k): The employer did not provide comprehensive, understandable training which did not occur annually and/or more often if necessary:   a.  On or about June 8, 2015, employees that perform enzyme blending use negative pressure respirators.  The employer did not train employees required to use air filtering respirators annually.

Issued

Nov 3, 2015

Abate by

Dec 1, 2015

Penalty

Initial $4,900 · Current $3,430 Reduced

General-duty citation text

29 CFR 1910.178(p)(1):   Powered industrial truck(s) found to be in need of repair, defective, or in any way unsafe, was not taken out of service until it had been restored to safe operating condition:  a.  On or about June 11, 2015, in the facility, powered industrial truck(s) with defect or in any way unsafe had not been withdrawn from service until responded to safe operating condition as follows:  Nissan 40 Serial Number CPJ02-9P5875 - The fork lift truck was emitting 4.4% carbon monoxide and the emergency brake was not functional.    Nissan 30 Serial Number CPJ01-9N0890 - The fork lift truck was emitting 4% carbon monoxide and the emergency brake would not hold when moving forward.    Clark Serial Number 9444 FB - The strobe light was not working.    Hyster 560XL Serial Number C187V01922N - The fork lift truck was emitting 2.1% of carbon monoxide and it was missing a backrest extension.    Clark Serial Number 6853KF - The left headlight was out and the strobe light was missing leaving exposed wires.    Hyster 30 Serial Number C010H05103W - The emergency brake was not working.   Nissan 50 Serial Number KCPH02P908156 - Back rest extension is missing; the seat belt is missing; front left headlight is out;   the right turn signal does not work; the backup alarm does not work; the rear light is not functional.    Hyster S50 Serial Number A18V03791G - The fork lift is emmiting 2.9% carbon monoxide.  The emergency brake is not functional; the left headlight is broken and the strobe light is not working.    Komatsu FG-20  Serial Number 104287 - No seat belt; the rear brake light does not work; the left reverse light does not function.    Nissan 50 Serial Number APJ02-941662 - The fork lift truck is emitting 3.4% of carbon monoxide.  The emergency brake is not holding.    Nissan 35 Serial Number CPJ01-9N4423 - The fork lift truck is emitting 2.0% of carbon monoxide.  The rear lights do not function.    Nissan 40 Serial Number CPJ02 -9W5739 - The emergency brake is not holding;  the right brake light is out;  the back up lights are not functional.  Mitsubishi FGCIS Serial Number AF81B-53102 - No emergency brake; the strobe light is not functional.  Caterpillar Serial Number AT8200235 - Missing back rest extension; the emergency brake will not hold; strobe light is not functional; the headlights are not functional.

Issued

Nov 3, 2015

Abate by

Dec 22, 2015

Penalty

Initial $4,900 · Current $3,430 Reduced

Hazardous substances 0560

General-duty citation text

29 CFR 1910.1000(a)(2): Employee(s) were exposed to an airborne concentration of carbon monoxide listed in Table Z-1 in excess of the 8 hour Time Weighted Average concentration of 50 ppm:  On or about June 8, 2015,  in the facility,  employee(s) were exposed to excessive concentrations of carbon monoxide while working in the vicinity of 15 propane powered fork lift trucks as follows:     a. Employee "Jaime Flores"  (calculation L78559) was exposed to carbon monoxide (CO) during a 500 minute occupational exposure at a mean calculated 183.3 ppm CO level (SAE = 0.275). The %COHb in the employee's blood reached a calculated peak level of 21.9%. Atmospheric pressure, height, weight, activity levels, tobacco smoking behavior, and other factors were taken into account. The 8- hour TWA exposure was 183.3 ppm CO (SAE = 0.275), which is 3.67 times the OSHA PEL of 50 ppm CO.  The exposure limit is established to prevent headaches,  nausea, dizziness, hypoxia and asphyxiation.    b. Employee "Marta Arrezola" (calculation L78560) was exposed to carbon monoxide (CO) during a 420 minute occupational exposure at a mean calculated 177.1 ppm CO level (SAE = 0.288). The %COHb in the employee's blood reached a calculated peak level of 21.6%. Atmospheric pressure, height, weight, activity levels, tobacco smoking behavior, and other factors were taken into account. The 8-hour TWA exposure was 154.9 ppm CO (SAE = 0.289), which is 3.10 times the OSHA PEL of 50 ppm CO. The exposure limit is established to prevent headaches,  nausea, dizziness, hypoxia and asphyxiation.    c. Employee "Francisco Valencia" (calculation L78561) was exposed to carbon monoxide (CO) during a 360 minute occupational exposure at a mean calculated 216.1 ppm CO level (SAE = 0.230). The % COHb in the employee's blood reached a calculated peak level of 24.4%. Atmospheric pressure, height, weight, activity levels, tobacco smoking behavior, and other factors were taken into account. The 8-hour TWA exposure was 162.0 ppm CO (SAE = 0.229), which is 3.24 times the OSHA PEL of 50 ppm CO. The exposure limit is established to prevent headaches,  nausea, dizziness, hypoxia and asphyxiation.    d. Employee "Marisol Mozo" (calculation L78562) was exposed to carbon monoxide (CO) during a 361 minute occupational exposure at a mean calculated 117.2 ppm CO level (SAE = 0.334). The %COHb in the employee's blood reached a calculated peak level of 15.2%. Atmospheric pressure, height, weight, activity levels, tobacco smoking behavior, and other factors were taken into account. The 8-hour TWA exposure was 88.1 ppm CO (SAE = 0.337), which is 1.76 times the OSHA PEL of 50 ppm CO. The exposure limit is established to prevent headaches,  nausea, dizziness, hypoxia and asphyxiation.    e. Employee "Marshon Strong" (calculation L78563) was exposed to carbon monoxide (CO) during a 445minute occupational exposure at a mean calculated 184.6 ppm CO level (SAE = 0.242). The %COHb in the employee's blood reached a calculated peak level of 22.1%. Atmospheric pressure, height, weight, activity levels, tobacco smoking behavior, and other factors were taken into account. The 8-hour TWA exposure was 171.1 ppm CO (SAE = 0.242), which is 3.42 times the OSHA PEL of 50 ppm CO. The exposure limit is established to prevent headaches,  nausea, dizziness, hypoxia and asphyxiation.    f. Employee "Jesse Bello" (calculation L78564) was exposed to carbon monoxide (CO) during a 500 minute occupational exposure at a mean calculated 194.2 ppm CO level (SAE = 0.241). The %COHb in the employee's blood reached a calculated peak level of 23.1%. Atmospheric pressure, height, weight, activity levels, tobacco smoking behavior, and other factors were taken into account. The 8-hour TWA exposure was 194.2 ppm CO (SAE = 0.241), which is 3.88 times the OSHA PEL of 50 ppm CO.  The exposure limit is established to prevent headaches,  nausea, dizziness, hypoxia and asphyxiation.    g.  Employee "Eugene Devivo" (calculation L78565) was exposed to carbon monoxide (CO) during a 580 minute occupational exposure at a mean calculated 206.6 ppm CO level (SAE = 0.240). The % COHb in the employee's blood reached a calculated peak level of 24.2%. Atmospheric pressure, height, weight, activity levels, tobacco smoking behavior, and other factors were taken into account. The 8-hour TWA exposure was 206.6 ppm CO (SAE = 0.240), which is 4.13 times the OSHA PEL of 50 ppm CO. The exposure limit is established to prevent headaches, nausea, dizziness, hypoxia and asphyxiation.    h. Employee "Dean Kowalski" (calculation L78566) was exposed to carbon monoxide (CO) during a 433 minute occupational exposure at a mean calculated 221.8 ppm CO level (SAE = 0.220). The % COHb in the employee's blood reached a calculated peak level of 24.8%. Atmospheric pressure, height, weight, activity levels, tobacco smoking behavior, and other factors were taken into account. The 8-hour TWA exposure was 200.1 ppm CO (SAE = 0.220), which is 4.00 times the OSHA PEL of 50 ppm CO. The exposure limit is established to prevent headaches,  nausea, dizziness, hypoxia and asphyxiation.

Issued

Nov 3, 2015

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

Hazardous substances 0560

General-duty citation text

29 CFR 1910.1000(e): Feasible administrative or engineering controls were not determined and implemented to achieve compliance with the limits prescribed in 29 CFR 1910.1000(a) through (d):  On or about June 8, 2015,  in the facility,  7 employee(s) were exposed to carbon monoxide in excess of the PEL (See Citation 1 Item 1).  To achieve compliance with paragraphs (a) through (d) of this section,  feasible engineering or administrative controls were not determined and implemented.      General engineering methods of control applicable in these circumstances include, but are not limited to, the following:  1. Periodic carbon monoxide emissions testing and maintenance on fork lift trucks in operation.    2.  Utilize available HVAC system to control exposure.    3.  Provide a dilution rate of 10,000 CFM per propane-fueled lift truck  4. Limit carbon monoxide emissions of propane-fueled fork lift trucks to 1 percent.    Administrative controls applicable in these circumstances include, but are not limited to, the following:  1.  Train employees in hazards and symptoms of exposure to carbon monoxide.    2.  Substitute propane-fueled lift trucks with electric lift trucks.   3.  Limit the usage of propane-fueled lift trucks to half of the work day.    Reference: American Conference of Governmental Industrial Hygienists Ventilation Manual (Volume 1,  Section 13),  26th Edition

Issued

Nov 3, 2015

Penalty

Initial $2,800 · Current $1,960 Reduced

Hazardous substances 0560

General-duty citation text

29 CFR 1910.1200(h)(3): The employee training did not include the requirements of 29 CFR 1910.1200(h)(3)(i) through (h)(3)(iv):    a.  On or about July 8, 2015, in the facility, employees are required to use potentially hazardous chemicals during blending and packaging of powered detergents .  The chemicals used included but not limited to sodium metabisulfite, sodium sulfite, sodium silicate, enzymes, carbon monoxide, hydrogen peroxide, sodium percarbonate, soda ash and sulfuric acid.  The employer did not provide each employee with the required training.