OSHA Inspection: PRIME-PAK FOODS, INC.

Issued

Feb 25, 2016

Abate by

Mar 22, 2016

Penalty

Initial $5,400 · Current $1,350 Reduced

General-duty citation text

29 CFR 1910.24(f): Rise height and tread width were not uniform throughout any flight of stairs including any foundation structure used as one or more treads of the stairs:      On or about September 14, 2015, employees were exposed to trip hazards when the risers on the following were not uniform:    a. the risers on the steps to the mezzanine where the automated chicken weighing system was located on line 2 varied from 9 1/4 inches to 10 3/4 inches  b. the risers on the steps that transitioned from the fully cooked room to the oven room measured 8 1/2 inches, 6 inches, and approximately 10 inches.      In accordance with 29 CFR 1903.19(c), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Feb 25, 2016

Abate by

Mar 22, 2016

Penalty

Initial $2,700 · Current $1,500 Reduced

General-duty citation text

29 CFR 1910.36(d)(1): Employee(s) were not able to open an exit route door from the inside at all times without keys, tools, or special knowledge:    On or about September 14, 2015, employees were exposed to fire hazards when the lobby exit door would not open unless the person leaving had knowledge of the special trick required to open the door.        In accordance with 29 CFR 1903.19(c), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Feb 25, 2016

Abate by

Mar 22, 2016

Penalty

Initial $2,700 · Current $1,350 Reduced

General-duty citation text

29 CFR 1910.37(b)(4): Signs were not posted along the exit access indicating the direction of travel to the nearest exit and exit discharge when the direction of travel to the exit or exit discharge was not immediately apparent:    On or about September 14, 2015, employees were exposed to fire hazards when exits or exit signs could not been seen from the following:  a.     The main aisle between lines 1 and 2.    b.     The fryer room.      No abatement certification or documentation is required for this item.

Issued

Feb 25, 2016

Penalty

Initial $3,060 · Current $1,500 Reduced

General-duty citation text

29 CFR 1910.37(b)(6): Each exit sign was not illuminated to a surface value of at least five foot-candles (54 lux) by a reliable light source and be distinctive in color:    On or about September 14, 2015, employees were exposed to smoke hazards when the exit sign from the hallway into the breakroom was not lit.     No abatement certification or documentation is required for this item.

Issued

Feb 25, 2016

Abate by

Mar 22, 2016

Penalty

Initial $6,300 · Current $6,300

General-duty citation text

29 CFR 1910.147(c)(4)(ii)(C): The energy control procedure did not clearly and specifically outline the steps for placement, removal and transfer of lockout devices or tagout devices and the responsibility for them.    On or about September 14, 2015, employees were exposed to struck-by, caught-in, and electrical hazards:  c.     The QA lockout summary provided to OSHA specifies yellow, red, and blue locks but does not indicate the significance of the color.    In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET), and in addition, documentation demonstrating that abatement is complete must be included with your certification.  This documentation may include, but is not limited to, evidence of the purchase or repair of the equipment, photographic or video evidence of abatement, or other written records.

Issued

Feb 25, 2016

Abate by

Mar 22, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(d)(6): Prior to starting work on machines or equipment that had been locked out or tagged out, the authorized employee did not verify that isolation and deenergization of the machine or equipment had been accomplished:  On or about October 17, 2015, employees were exposed to caught-in and struck-by hazards when the employees did not verify that the lock had effectively isolated the equipment from the energy source.   In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET), and in addition, documentation demonstrating that abatement is complete must be included with your certification.  This documentation may include, but is not limited to, evidence of the purchase or repair of the equipment, photographic or video evidence of abatement, or other written records.

Issued

Feb 25, 2016

Abate by

Mar 22, 2016

Penalty

Initial $0 · Current $6,300

General-duty citation text

29 CFR 1910.147(c)(6)(ii): The periodic inspection certification of energy control procedures did not contain the required documentation on identification of the machine or equipment, inspection date, employees included, and the person performing the inspection:      On or about September 14, 2015, employees were exposed to struck-by, caught-in, and electrical hazards when the annual audit did not include identification of the machine or equipment.  Identification was generic such as 'conveyor'.    In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET), and in addition, documentation demonstrating that abatement is complete must be included with your certification.  This documentation may include, but is not limited to, evidence of the purchase or repair of the equipment, photographic or video evidence of abatement, or other written records.

Issued

Feb 25, 2016

Abate by

Mar 22, 2016

Penalty

Initial $6,300 · Current $6,300

General-duty citation text

29 CFR 1910.212(a)(1): One or more methods of machine guarding was not provided to protect the operator and other employees in the machine area from hazards such as those created by point of operation, ingoing nip points, rotating parts, flying chips and sparks:    On or about September 14, 2015, employees were exposed to caught-in and struck-by hazards when the following were not guarded or were inadequately guarded:    a.  inadequate guarding at the chicken grinder hopper:  the metal bars that flip over into the hopper do not prevent an employee from reaching past the bars to the auger at the bottom of the hopper.      b.  no guarding on the sealer rollers on line three:  employees hold the top of the bag as the bag passes through the rollers.     c.  no guarding on the backup sealer rollers on line three:  employees hold the top of the bag as the bag passes through the rollers      d. there are holes in the wall of the guard that are used to attach a marker to the sealer machine where the sealer bars are located on line two.  The interlock on the doors does not work and doors are not latched.        e. Batter applicator drive on line 2 has a bent guard exposing employees to rotating equipment.       h. pinch point on conveyor as it passes over the roller on line 3 at end of scoop station    i. pinch point on conveyor as it passes over the roller on line 3 at the start of scoop station    j. pinch point on conveyor as it passes over the roller on  line 3 upstream from scoop station    k. pinch point on conveyor as it passes over the roller on  line 2 at transition from metal detector and pack out    l. pinch point on conveyor as it passes over the roller on line 2 at pack out     m. pinch point on conveyor as it passes over the roller on line 2 at the XL breader.    n. pinch point on conveyor as it passes over the roller on line 1 at the exit end of the breader where operators handle the chicken before it goes into the fryer.      o. pinch point on lay-on conveyor as it passes over the roller on line 1    p. pinch point at conveyor drive roller at entrance to the fryer on line 1    q. pinch point on conveyor as it passes over the roller on line 2 during clean up        In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET), and in addition, documentation demonstrating that abatement is complete must be included with your certification.  This documentation may include, but is not limited to, evidence of the purchase or repair of the equipment, photographic or video evidence of abatement, or other written records.

Issued

Feb 25, 2016

Abate by

Mar 15, 2016

Penalty

Initial $4,500 · Current $4,500

General-duty citation text

29 CFR 1910.212(a)(3)(ii): Point(s) of operation of machinery were not guarded to prevent employee(s) from having any part of their body in the danger zone(s) during operating cycle(s):  On or about September 14, 2015, employees were exposed to amputation hazards when the grinder head exit end was not guarded.  An employee's finger was amputated by the blade when he reached into the end of the machine.  No abatement certification or documentation is required for this item.

Issued

Feb 25, 2016

Abate by

Mar 22, 2016

Penalty

Initial $4,500 · Current $4,500

General-duty citation text

29 CFR 1910.212(a)(4): Revolving drum(s), barrel(s), or container(s) were not guarded by enclosure(s) which were interlocked with the drive mechanism so that the barrel(s), drum(s), or container(s) could not revolve unless the enclosure(s) were in place:  On or about October 17, 2015, employees were exposed to caught-in hazards when the following drums were not guarded or were inadequately guarded or did not have an interlocked guard: a. drum breader on line two does not have interlocked guards over the drum and is operated during cleanup with the guards up.   b. drum tumbler on line one:  The guard on the drive mechanism is missing a nut and is not interlocked.  The gap between the guard and the drum supports permits clothing and small fingers to be trapped.  On or about September 14, 2015, employees were exposed to caught-in hazards when the following drum was not guarded or was inadequately guarded or did not have an interlocked guard: c.drum breader on line one:  the drum support rollers are not guarded and the cover is not interlocked.  Photo of additional guarding provided by the employer.  In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET), and in addition, documentation demonstrating that abatement is complete must be included with your certification.  This documentation may include, but is not limited to, evidence of the purchase or repair of the equipment, photographic or video evidence of abatement, or other written records.

Issued

Feb 25, 2016

Penalty

Initial $3,600 · Current $3,600

General-duty citation text

29 CFR 1910.212(a)(5): Fan blade guards, where the periphery of the blades was less than seven feet above the floor or working level, had openings larger than one half inch:  On or about September 14, 2015, employees were exposed to struck-by hazards when the exhaust hose that was designed to cover the exhaust fan blades on the sealer on line number 3 was not secured to the fan housing.  The fan blades were exposed.  The employer had attempted to use tape to hold the hose in position.   No abatement certification or documentation is required for this item.

Issued

Feb 25, 2016

Abate by

Mar 22, 2016

Penalty

Initial $900 · Current $900

General-duty citation text

29 CFR 1904.29(b)(1): A Log of all recordable work-related injuries and illnesses (OSHA From 300 or equivalent), was not completed in detail as required by the regulation:  On or about September 14, 2015, the OSHA 300 logs for 2015 had the following errors: a. Case 11 dated 8/28 was not classified.  Column L was blank.  Injury (strain/abrasion) was missing from column F.  Employee had ten days of light duty. b. Case 12 dated 9/9 was not classified.  Column K and Column L were blank.  Amputation with five days away from work and ten days of light duty.       In accordance with 29 CFR 1903.19(c), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Feb 25, 2016

Abate by

Mar 2, 2016

Penalty

Initial $4,500 · Current $4,500

General-duty citation text

29 CFR 1904.39(a)(2): The employer did not report an in-patient hospitalization, amputation, or loss of an eye as a result of a work-related incident to OSHA within twenty-four (24) hours.   On or about September 9, 2015, the employer did not report the finger amputation that took place on 9/9/2015 at the grinder.  No abatement certification or documentation is required for this item.

Issued

Feb 25, 2016

Abate by

Mar 22, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.1200(g)(1): Employers did not have a safety data sheet in the workplace for each hazardous chemical which they use:  The employer failed to provide SDS or updated SDS for all chemicals used or stored at the site.  There were no SDS for a.  carbon dioxide used to flash freeze product b.  ammonia used as a refrigerant c.  food grade machine oil used on the machines.     None of the MSDS in the binder had pictograms.   In accordance with 29 CFR 1903.19(c), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).