Page 1 Health Hazard Evaluation Report 2009-0131-3171 Evaluation of Sensitization and Exposure to Flour Dust, Spices, and Other Ingredients Among Poultry Breading Workers Report No. 2009-0131-3171 April 2013 Elena H



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Page 3

Health Hazard Evaluation Report 2009-0131-3171



Results 

First Site Visit

Previous sampling by the plant found employee exposures to total dust (comprised mainly 

of flour) at concentrations that exceeded the OSHA PEL of 15 mg/m

3

 for particulates not 



otherwise regulated. In addition to flour dust, other ingredients used in the plant have been 

reported in the medical literature to cause asthma including garlic, onion, soy, and corn. 

Spicy flour used in the plant contained paprika and capsaicin, which can cause mucous 

membrane and respiratory irritation.

Our review of the OSHA Logs revealed one employee diagnosed with baker’s asthma in 2005. 

We interviewed 47 of more than 400 production employees. Twelve of the 47 were identified 

from a list provided by the union of 18 employees who had reported work-related symptoms; 

the other six on the union list were not at work at the time of our visit. The remaining 35 

interviewed employees were serially selected from job categories with the greatest potential 

for flour dust exposure. Twenty-five reported no work-related symptoms. Of the remaining 22, 

six reported using an inhaler for work-related respiratory symptoms, and four reported being 

Table 1. Employee exposure groups*

Lower exposure

Higher exposure

Clerk in office

Bread and batter

Fork lift operator

Lay-on


Bagger operators

Oven operators

Trash dock and trash removal

Marination

Receiving employees

Foremax operators

Scale operators

Line leader

Box makers

Quality assurance 

technicians

Frozen shipping employees

Bone checker

Tub washers

Utility

Temperature checkers



Checker/sorter

Stackers


Quality assurance production and 

support


Packers

Cups 


Warehouse ingredient handlers

Graders


Pallet jack operators

*Employees were classified on the basis of a review of work 

processes, historical sampling data, and the professional 

judgment of NIOSH investigators.




Page 4

Health Hazard Evaluation Report 2009-0131-3171

diagnosed with breathing problems due to flour dust. Eleven of these 22 employees reported 

work-related shortness of breath, 10 reported work-related cough, 9 reported work-related 

nasal symptoms, 8 reported work-related sneezing, 6 reported work-related eye symptoms,  

5 reported work-related wheezing, and 3 reported work-related chest tightness. 



Second site visit 

We collected 100 personal breathing zone air samples throughout the plant. Table 2 

summarizes the air sampling results for inhalable flour dust, wheat, and soy by exposure 

group. Tables A1–A3 in Appendix A list these personal breathing zone results by the job 

category observed on the day of sampling. Median airborne inhalable flour dust, wheat, 

and soy concentrations were higher for the higher-exposure group than the lower-exposure 

group, but there was overlap, and exposures were documented in all areas of the plant (Table 

2). Concentrations of inhalable wheat (r = 0.89, P < 0.01) and soy (r = 0.79, P < 0.01) were 

positively correlated with the inhalable flour dust concentrations.

Of 402 employees present during the site visit, 375 (93%) completed the questionnaire. Of 

these, 242 (64%) allowed their blood to be drawn.

Table 3 lists the prevalences of work-related symptoms comparing the higher-exposure 

group to the lower-exposure group, showing both the statistically significant (bolded) and the 

nonsignificant differences. Participants in the higher-exposure group were significantly more 

likely to report episodes of coughing, rhinitis symptoms, and rhinoconjunctivitis symptoms 

in the last 12 months than lower-exposure participants. Table 4 lists the prevalences of work-

related symptoms comparing those currently in the higher-exposure group and those who 

previously held jobs in the higher-exposure group to the lower-exposure group, showing 

both the statistically significant (bolded) and the nonsignificant differences. Participants 

Table 2. Summary of air sampling results by exposure group as 

observed on the day of sampling

Higher-exposure 

group

Lower-exposure 



group

# of PBZ samples

65

35

Inhalable flour dust



Median

8.21 mg/m

3

1.03 mg/m



3

Range 


0.59 to 93 mg/m

3

0.22 to 15 mg/m



3

Inhalable wheat

Median


0.188 mg/m

3

0.00321 mg/m



3

Range 


ND to 1.8 mg/m

3

ND to 0.44 mg/m



3

Inhalable soy

Median


0.341 µg/m

3

ND



Range 

ND to 7.2 µg/m

3

ND to 0.32 µg/m



3


Page 5

Health Hazard Evaluation Report 2009-0131-3171

either currently in the higher-exposure group or who had previously held jobs in that group 

were significantly more likely to report asthma symptoms in the last 12 months, including 

wheezing or whistling in the chest and attacks of asthma, than employees in the lower-

exposure group. 

Of the 244 participants who reported having held other jobs at the plant, 45 reported having 

changed jobs for health reasons. Significantly more participants reported changing jobs for 

health reasons in the lower-exposure group than in the higher-exposure group (24% vs. 12%, 

P = 0.01). Twenty-three participants reported changing jobs because of respiratory tract or 

mucous membrane problems. Twelve of 375 participants reported having been diagnosed by 

a healthcare professional with allergy to flour.

Table 3. Prevalence of work-related symptoms in the last 12 months* by current exposure group

Work-related symptom

Higher-


exposure group

n=158–161†

Number (%)

Lower-exposure 

group

n=212–213†



Number (%)

Prevalence ratio

(95% confidence 

interval)



Episodes of coughing

43 (27)


39 (18)

1.46 (1.00, 2.15)

Asthma symptoms§

54 (34)


55 (26)

1.29 (0.94, 1.77)‡ 

Wheezing or whistling in chest

41 (25)


32 (15)

1.69 (1.12, 2.58)

Woken up with feeling of tightness in 

the chest

24 (15)


22 (10)

1.42 (0.83, 2.46)‡

Attack of asthma

11 (7)


12 (6)

1.24 (0.55, 2.76)‡

Currently taking medicine for breathing 

problems or asthma

22 (14)

19 (9)


1.53 (0.86, 2.77)‡

Rhinitis symptoms

Problem with sneezing or a runny 

nose or a blocked nose when did not 

have a cold or flu

71 (44)

65 (31)


1.45 (1.11, 1.90)

Rhinoconjunctivitis symptoms

Rhinitis symptoms accompanied by 

itchy watery eyes

51 (32)


46 (22)

1.49 (1.06, 2.10)

*Or since beginning current job if in that job for less than 12 months 

†Denominators vary because of missing information

‡Controlled for smoking status 

§Work-related asthma symptoms based upon a positive answer to one or more of four questions 

below it in table




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