The Human and Financial Costs of Injuries in the Food & Beverage Industry

The food and beverage industry is dangerous. Amputations are alarmingly common; some injuries are fatal. However, workplace injuries in the food and beverage industry are also preventable.

Worker Safety Deserves to Be a Priority

When you think about safety in the food and beverage industry, you probably think of food safety and protocols to prevent contamination. However, as Food Engineering points out, worker injuries impact operations to an extent that’s on par with, or even more severe than, a product recall.

Mike Zblewski, director of safety services for Sentry Insurance, spoke to Food Engineering about the role of supervisors in worker safety in food and beverage manufacturing. “Successful companies have supervisors that can coach, teach and mentor employees. They’ve invested in that training, which takes both time and resources—there’s a process around that system. If you’re successful in those two areas, you should be able to start a good workplace program, if you will, when it comes to safety,” Zblewski says. These days, supervisors have more on their plates and are dealing with new forms of robotics and automation. However, some don’t have the necessary leadership skills. Training and mentorship are critical for establishing a culture of worker safety.

An Alarming Number of Serious Injuries

The food manufacturing industry has a higher-than-average rate of nonfatal injuries. According to the BLS, the average rate for all industries was 3.0 per 100 full-time workers in 2022, whereas the rate for food manufacturing was 4.6.

Many of these injuries are severe. In fact, OSHA has published a hazard alert to warn the food industry about the “alarming number of serious preventable injuries, including deaths, in poultry, meat and other food processing establishments.” Between 2015 and 2022, there were nearly 800 severe injury reports related to food and beverage processing machinery.

Amputations Are Common

According to the Economic Policy Institute, meatpacking and poultry companies are among the most dangerous. Tyson Foods, for example, reported 279 severe injuries between 2015 and 2022, which was the fifth-highest number of severe injuries.

An analysis from the Bureau of Investigative Journalism found that U.S. meat workers are three times more likely to experience severe injury compared to the average American worker. Amputations were common, often involving fingers or fingertips but sometimes involving hands, arms, and toes.

However, an injury doesn’t need to result in amputation for it to be serious. Common workers’ compensation claims involve strains, slip and falls, repetitive trauma, and overexertion when lifting.

The Aftermath of Injuries

Workplace injuries take a toll on food manufacturing companies. Depending on the nature and severity of the injury, production may have to stop while the area and machines are cleaned and cleared for safe usage. The injured worker may miss a significant amount of work, assuming he or she ever returns to the job. On top of that, the company may face workplace morale problems.

Injuries may also result in expensive workers’ compensation claims and OSHA fines. The following are just a few examples:

• According to WPCO, OSHA cited a food processing plant in Ohio after a worker fell into an industrial blender while cleaning it. His leg had to be amputated as a result of his injuries. OSHA determined that the employer did not train workers on how to lock equipment properly before cleaning it.
• The Seattle Times reports that the Department of Labor and Industries has fined a dairy and bottling plant in Washington approximately $2 million due to violations that led to broken bones and amputations. The employer allegedly did not train employees properly, maintain machinery, or enforce standard control procedures.
• According to EHS Daily Advisor, OSHA is fining an Illinois pizza manufacturer more than $2.8 million after a temporary worker died while cleaning the conveyor. OSHA inspectors determined that the employer did not give temporary workers proper training nor the authority to stop the equipment before cleaning it.

Preventing Injuries in the Food and Beverage Industry

As with all workplaces, it’s important to keep floors clear of slip, trip and fall hazards, such as spills and items in the walkways, and to develop an emergency response plan and train workers to follow it. Food manufacturers should also be aware of hazards specific to the industry, such as the use of ammonia in refrigeration units and the use of machinery, from forklifts to industrial ovens.

Creating a culture of safety requires management buy-in, supervisor safety training and a strong safety committee. Ideally, incidents will be avoided, but if they occur, a root cause analysis can prevent reoccurrence.

OSHA says the following measures can reduce preventable injuries:

• Adhering to FLSA rules that prohibit child labor. Many food processing jobs are considered too dangerous for minors. See the DOL’s list of jobs that are off limits for minors.
• Identifying hazards. All workers need to be able to recognize hazards in a worksite. Employers should conduct hazard assessments and communicate hazards to subcontractors tasked with cleaning and sanitizing. To learn about amputation hazards, see OSHA’s Safeguarding Equipment and Protecting Employees from Amputations.
• Following Lockout/Tagout rules. Workers and subcontractors should receive comprehensive training in a language they understand. Supervisors and managers should ensure compliance and conduct regular evaluations. See OSHA’s Control of Hazardous Energy Lockout/Tagout.

Do you need more guidance on reducing injuries in the food and beverage industry? In addition to comprehensive insurance programs, Propel offers onsite risk management education. Our team will work with a risk management expert from the insurance carrier to help your worksite improve its safety. We can also suggest other training options. To learn more, contact Sasha Peranteau.