ࡱ> 57234 'bjbjΚΚ yO..!!N"N"N"$r"r"r"P"D#$r"h*%*%4^%^%^%&&&ggggggg,iBlgN"&&"&&&g5+!!^%^%{g5+5+5+&!8^%N"^%g5+&g5+5+ Z 6"QgPE'Feqgg0hqfl5+lQg5+N"Qg &&&gg5+&&&hl&&&&&&&&&. :   * INTERPRETATION - "Department" means College/School/Department/Centre/Unit as relevant. 18.29.1 INTRODUCTION Most of the equipment and facilities used in the preparation, cooking and serving of food are so familiar that it is easy to overlook the hazards that they may present. In addition, hazards are also present during the necessary cleaning and necessary routine maintenance of the equipment. Due to the wide variety of catering equipment in the different areas, the relevant Heads of Departments must comply with the relevant legal constraints concerning training, instruction, supervision, competency, fire safety and evacuation procedures, accident reporting procedures, protective equipment, first aid, etc. These obligations and responsibilities have already been clearly set out in Document 1 of this Safety Statement Work Manual. It cannot be over-emphasised that every staff member must be trained in basic safety and hygiene procedures during induction and these principles should be applied equally to part-time staff, as well as permanent staff. 18.29.2 HAZARDS The main hazards associated with the use of all catering equipment and the associated facilities and services are accidents and ill health resulting in: Hand & Limb injuriesScalds, BurnsElectrical shockManual Handling injuriesElectric ShockAbrasionsFires (Gas & others)Hearing impairmentAmputationsEye injuriesExplosionsSlips, Trips and FallsSkin allergies e.g. dermatitisCuts, Stabs.Ejection of particlesHypothermia  Most accidents at food preparation machinery happen to users during normal activities or when cleaning. Examples of the range of equipment and other materials used in these areas include: MEAT PREPARATIONKITCHENSFOOD PREPARATIONOTHERKnives, Cleavers & HandsawsOvens & RangesFood processorsDish Washing machinesBandsawsSteaming ovensBread slicers, sandwich makersHeated rinsing sinksMincersDeep fat fryersChip cuttersFlambe lamps Mixers/MincersSlicing, grating & chippingMixers, MincersUrns, Burko boilersBowl cuttersBoiling pans & tilting kettlesKnives, choppers Hot serving countersSlicersKettlesWater boilersWaste disposal unitsPatty forming machinesBrat pansCaf setsWaste compactorsSausage machinesMicrowave ovensCold rooms and fridgesChill roomsGravity feed slicers GrillersPlanetary mixersCleaning chemicals Bacon slicersMulti-purpose cookers Pie and Tart machinesToasters In addition, the working environment presents a range of risks to health & safety if the layout, condition of floors (often wet/slippery), lighting, temperature, housekeeping etc. is not to a satisfactory standard. Due to the variety of energy sources from gas, electricity, steam which are required additional hazards may be presented. Also accidents occur to cleaners, untrained operators, electricians, maintenance personnel when they are setting up, faultfinding or making repairs, with all types of machinery. 18.29.3 RISKS The risks associated with the aforementioned hazards are to be assessed by the Department (using the appropriate technical input where necessary). These assessments shall be carried out using: Check lists provided (where applicable) and Departmental Hazard Identification/Risk Assessment Work Sheets contained in Document No.3 i.e. Departmental Hazard Risk Assessment (D.H.R.A.). 18.29.4 Arrangements and Controls Required For Food Preparation Areas, Kitchens etc., These hazards and risks will be minimised by the arrangements overleaf and controls in each sub-section following: 18.29.4 ARRANGEMENTS AND CONTROLS REQUIRED (Cont.) WORKING ENVIRONMENT FIRST AID REPORTING ACCIDENTS & OTHER INCIDENTS ELECTRICAL SAFETY GAS SAFETY STEAM SAFETY KNIFES AND CLEAVERS & HANDSAWS PRINCIPLES OF SAFEGUARDING MACHINERY AND CATERING EQUIPMENT ALL CATERING EQUIPMENT SLICERS GRAVITY FEED SLICERS HORIZONTAL FEED SLICERS BACON SLICERS BANDSAWS (TABLE TOP) FREE-STANDING BANDSAWS BOWL CUTTERS MINCERS MIXER/MINCERS PATTY FORMING MACHINES MEAT TENDERISERS PLANETARY MIXERS FOOD PROCESSORS PIE & TART MACHINES BREAD SLICERS ROTARY CHIP CUTTERS RECIPROCATING CHIP CUTTERS OVENS & RANGES STEAMING OVENS GRILLERS DEEP FAT FRYERS MULTI-PURPOSE COOKING PANS BOILING PANS & TILTING KETTLES MICROWAVE OVENS WATER BOILERS/CAF SETS URNS SAUSAGE FILLING MACHINES WORKPLACE ENVIRONMENT The following requirements shall apply to all areas where food preparation, cooking and catering is carried out. Layout While this will depend on its area and the amount of equipment used, there should always be enough room around equipment for staff to move around without bumping into each other. This is particularly important where staff use knifes and hand tools to prevent accidentally stabbing from occurring, due to cramped conditions. There should enough room to carry trays or move trolleys safely around exposed hot surfaces. Doors must be clearly marked IN and OUT, if only one door is available it should contain a panel of safety glass to enable one to see a person coming in the opposite direction. Canteens should be regularly checked for shortfalls in cleaning, hygiene and housekeeping. In particular, tables and chairs should be examined for stability and condition. Floors Slips, trips and falls are a major cause of accidents in kitchens.(see Section 18.5 Slips, Trips & Falls) Non-slip floor surfaces must be provided in all areas. Footwear should be appropriate e.g. no sandals, high heels. Adequate drains should be provided to remove water, steam drips etc. The floors should be kept in good condition and clear of spilled fat, grease, food etc. Signs and barriers should be used to warn of hazardous conditions. Cleaning should be done outside normal working hours whenever possible to reduce exposure of wet floors. Chemical cleaners must be thoroughly rinsed off floors to prevent floor damage or reaction with other products. Lighting This must be sufficient to enable staff to see equipment and products effectively. Light fittings should provide an even light throughout without glare or shadows and must be cleaned regularly. The illumination standards required are: preparation and cutting rooms 540 lumen kitchens 300 lumen passage and store rooms 150 lumen Temperature High temperatures and humidity are common in kitchens & cooking areas. This can affect the health, comfort and efficiency of kitchen staff. Ventilation, with sufficient general air changes must be provided to counteract the humidity and cool the workplace. Additional local extraction ventilation units should be sited at areas where the general ventilation is inadequate. Noise Noise levels in working areas vary considerably with the type of equipment being used and also with the level of activity being carried out. Excessive noise can increase stress and interfere with the health and efficiency of staff The background noise levels of fans, motors should be acoustically designed to reduce the levels as far as possible. Refer to Section 18.3 Noise for the requirements to protect workers hearing from excessive noise levels. Equipment Stability All equipment should be secure and on a level base. Equipment with side or bottom hinged doors that open just above floor level, should not obstruct a gangway. Shelves should not be placed above open top ranges or deep fat fryers next to sinks. Smaller pieces of equipment that sit on worktops should be stable and difficult to dislodge. Cleaning While this section cannot deal with all aspects of food hygiene practice, cleaning equipment and cleaning agents it will indicate good practices to be used. To ensure that risks of serious injury or ill-health do not occur to staff from exposure to hazardous situations, it is necessary that supervisors and managers set down safe cleaning methods and procedures. It is also important that these are monitored to see that these are established and followed out. For instance, personnel may have to work near hot surfaces or empty hot liquids from equipment, and be exposed to burns or scalds. Cleaning (Cont.) Catering equipment must be cleaned at the end of the day so that the equipment is left clean overnight. All electrical catering equipment should be isolated from the mains before work commences. Never clean equipment with pressurised jets of water, unless its wiring and circuit are specially protected from moisture ingress. Other catering equipment which are gas fed, should be also isolated with the gas supply, including pilot lights, turned off. All heating equipment should be allowed to cool before cleaning starts. Fume Extractors Maintenance and cleaning of fume extractors is an important consideration in kitchens. It is here that grease and fats accumulate in the ventilation hoods (canopies) and ducting. This has been the cause of fires due to the spontaneous ignition of this flammable material. Special cleaning procedures in line with the makers recommendations should be used to clean inside surfaces of these hoods and ducting, fan blades, condensation channels etc. Hood filters should also be cleaned or replaced in accordance with makers instructions. Automatic fire extinguishing installations and automatic shutters or lids on deep fat fryers should be cleaned daily. All units should be cleaned regularly. Chemicals Many of the chemicals used for cleaning equipment, utensils, working surfaces, floors etc., are hazardous to health. These include corrosive cleaners, detergents, sterilising agents. For instance, some cleaning chemicals contain chlorine while others contain acid. When mixed inadvertently they give off toxic chlorine gas. Therefore staff must be protected in so far as is reasonably practicable, from such exposures by adequate control measures. These controls include: Using automatic detergent dispensing equipment Using non-spill and unbreakable containers Transporting, transferring and storing substances in a safe manner Using smaller or diluted amounts Using manufacturers instructions for usage, protection etc. Providing staff with suitable PPE, for example rubber gloves, aprons, boots, chemical grade eye protection and respirators. Cleaning chemicals should never be transferred into other containers such as flour shakers, milks or soft drink bottles. This can lead to confusion and risk serious accidents. Cleaning chemicals should always be stored away from food or food preparation equipment and in clearly marked storage areas. Housekeeping In addition to cleaning, a good standard of housekeeping and tidiness must be maintained to prevent accidents from occurring. All gangways, aisles and passageways must be kept clean and clear of obstructions. All utensils and equipment should be left in good condition and put in their proper location after the work ceases. Equipment should be kept in good condition by routine inspection/maintenance and reporting any defects noticed in use. Routine housekeeping inspections should be carried out to highlight bad practices. Cold Rooms Employees should not be exposed to low temperatures for periods longer than necessary. Particular care is required, as hypothermia is an insidious hazard for vulnerable persons i.e. older employees, pregnant staff or others adversely affected by low temperatures. Working in cold store can slow down mental reactions and reduce manual dexterity, which increases the potential for accidents. Additional hazards may arise if the refrigerant escapes into the atmosphere. High concentrations of this substance in enclosed or non-ventilated areas lead to oxygen deficiency. Cold stores or chills require the following precautions: Suitable protective clothing should be worn when working in or frequently visiting cold rooms. It is particularly important to keep the hands, head and feet warm. Exits (clearly marked) should be capable of being opened from the inside and the opening mechanism kept in good working order. The escape route and the opening mechanism on the exit should be marked e.g. with emergency lighting or luminous signs clearly visible on the inside. Key operated locking mechanisms to cold room doors should be avoided. If absolutely necessary, they should be capable of being over-ridden by an emergency push button device on the inside of the door. Security bars should not be provided to the exterior of cold room doors. Doors and escape routes should not be obstructed from inside or outside the store. Checks must be made to ensure that opening mechanisms do not become inoperative due to icing up or lack of use. An alarm should be provided within the cold store to sound outside in occupied area in case of entrapment, or there should be an axe inside for breaking out. Checks should be made to ensure the cold store is unoccupied before locking up. Cold Rooms (contd.) Checks should be made to ensure persons are not left too long within the cold store. Chills and stores should be well lit. A minimum illumination level of 300 lux is recommended. The refrigerant plant should be regularly checked and maintained by competent engineers. FIRST AID The requirements for the provision of First Aid have been laid out in Section 10 in Document 1and Section 18.9 First Aid in Document 2 of this Safety Statement, however burns and scalds are very common in the catering industry and special mention should be given to it. Burns are caused by touching hot surfaces or picking up a hot dish or utensil. Scalds are caused by hot liquids, steam, hot oils or fat. The effects can be redness, swelling, blistering and often shock. Chemical burns are caused by some cleaning products. Trained First aiders must be available to deal speedily with these injuries. A notice showing what action to be taken if someone is burned or scalded must be permanently displayed in the kitchen. Figure 1 shows suitable wording of such a notice.  REPORTING ACCIDENTS AND OTHER INCIDENTS Refer to Section 10 in Document 1 for procedures in above. ELECTRICAL SAFETY Electrical safety and the requirements are already covered in Section 18.10 of this Safety Statement Work Manual. GAS SAFETY Natural gas is widely used as a source of direct heat for ovens, hobs, grillers, steam boilers etc. in the catering industry. The main hazards as outlined earlier include fire and possible explosion when unburned gas ignites. Carbon monoxide is an odourless, tasteless and poisonous gas, which may occur from faulty or badly maintained installations. Gas appliances should be installed in accordance with BS 6173 Installation of gas catering appliances Gas appliances should be installed, fitted and maintained by a competent person trained in accordance with the registered Gas Installers approved code of practice Gas appliances should be regularly serviced and maintained by a competent gas engineer. Staff should know where the mains gas shut off valve is located and be trained to turn it off in an emergency Only trained staff members should re-light the appliances or pilot lights after the gas is turned on. Ignition jets and pilot lights should be kept clean and be regularly serviced. Any faults with the appliance or integral ignition device should be reported for investigation. Manual ignition appliances should always be re-lit with a taper. Gas detection should be provided in any area where an open jet could lead to a build up of gas. Permanent ventilation should be provided at high level in areas where natural gas is used. Important: If gas smell is noticed or detected: do not use any naked lights do not switch on the lights or any electrical equipment that may ignite the gas check whether the gas is coming from the pilot or burner if so, turn off the burner if not, turn off the supply at meter or main valve open doors and windows to disperse gas report the leak immediately to supervisor do not turn gas back on until the fault has been traced and repaired by service engineer If the gas continues to escape after the supply has been turned off, contact the Bord Gais immediately. STEAM SAFETY Steam heated equipment includes steaming ovens, bulk boiling pans, bains-marie, hot cupboards, steam cupboards, water boilers and some beverage machines. The main hazards are explosion from over pressure, burns and scalds. The precautions required for steam appliances would be: Steam boilers should be fitted with safety valve, pressure gauge, glass water level gauge, low water level cut-off device, blow down valve and shut off valve. The boiler and fittings should be thoroughly examined every year by an inspection engineer usually employed by the insurance company. Steam boilers, water inlet valves, pipes and tanks should be regularly cleaned and scale removed. The steam trap must be regularly drained and maintained. A competent service engineer should carry out this work. The steam boiler should be situated so that the pressure gauge and water level gauge is easily seen. It should not be switched on if water level is low. Steam safety valves and blow down valves must be vented to a safe place. Equipment that is pressurised should not be opened until pressure is released. Staff should open the lids or doors of steam heated equipment carefully to avoid escaping steam. Gate/Ball valves to steam lances should be locked in the off-position using a proprietary lock-off system to prevent unauthorised use. KNIFES, CLEAVERS & HANDSAWS The food preparation departments use a wide range of knifes and edged tools for cutting, slicing and dicing. Many serious injuries have occurred with the use of many common hand tools to limbs because simple precautions had not been taken and observed or work was rushed. There is also the possibility of infection in wounds when cutting meat products. The key safety measures for the above tools are: Operators should be trained in the correct use and safety measures required for knives and hand tools. Suitable protective clothing must be worn at all times e.g. Aprons, gloves, gauntlets and forearm protectors. Select the correct knife for the job, ensure it is in good condition before use. Ensure all knives, cleavers and saw blades are sharp. They should also be kept clean before and after use. Ensure cutting blocks, tables and boards are firm, smooth and clean. When carrying knives hold the knifepoint in a scabbard/sheath in the downward position. When using a knife, use a firm grip, try to use even pressure for cutting, cut downwards and avoid cutting towards the body. Knives re-sharpened to very narrow blades should not be used, as they may snap during use. If a significant proportion of time is spent on cutting, particularly meat, a protective chain mail gauntlet should be worn on the non-knife hand (to protect the hand, wrist and arm). Knives should not be left lying about on worktops and tables. They should be stored in suitable racks or sheaths. A person should never try to catch a falling knife or walk around with a knife in their hand, unless it is covered. Chain mail aprons should be utilised to protect the body during meat de-boning operations (as the knife is generally pulled towards the body). De-boning knives should have a shaped plastic handle and protrusion at the blade/handle interface to prevent the fingers slipping onto the blade. PRINCIPLES OF SAFEGUARDING MACHINERY AND CATERING EQUIPMENT The basic principle of safeguarding machinery is that unless a danger point is safe by virtue of its position, the machinery must be fitted with an appropriate safeguard. This specific safeguard should eliminate or reduce danger before access to the danger point is possible. To apply the above principle, the following points should be taken into account: Dangerous parts should ideally be eliminated or effectively enclosed at the machine's design stage. If they cannot be eliminated, then suitable safeguards (e.g. guards, safety features and emergency controls) should be incorporated as part of the design. (This is a legal requirement under Ec law). Provision should be made to facilitate the fitting of alternative types of safeguards on machinery if it is known that the objects to be accommodated will vary in size and shape. Where an openable/re-moveable guard, cover etc. is used as a safeguard, it must be interlocked with the drive mechanism of the dangerous parts. NOTE: The latter would not apply to adjustable guards on machines such as band saws or crown guards to a woodworking circular saw). Maintenance operations set up/cleaning operations should therefore prevent the machine from operating. Lubrication points and routine maintenance facilities must be incorporated outside the danger area wherever practicable. Provision should be made for the machine to be turned off, energy controls locked off and tested to ensure it is at zero energy, and before guards are removed or maintenance work is undertaken. 18.29.4.7 principles of safeguarding machinery and catering equipment (Cont.) Suitable supplementary lighting should be provided at operating points. Any lighting fitting which is portable and easily adjustable should preferably be supplied from a low voltage supply. Every mechanism and control forming part of the safeguard should as far as practicable be of fail-safe design. All automatic and computer controlled machines must use fixed or interlocking safety devices to ensure all dangerous movements of the machine/tools are guarded. Work zone enclosures should be used where the speed and power of the machine may lead to risk of injury. All safeguards on all machinery should be of sound design and adequate strength and should conform to the latest IS EN Codes of Practice for the Safety of Machinery. Guards may be made of metal, laminated or toughened glass, suitable plastics or a combination of these as may be appropriate to the conditions. (The shatter resistant properties of materials may need to be considered where impact is a hazard). Whatever safeguard is selected, it should not itself present a hazard such as trapping or shear points, sharp edges or other sources likely to cause injury. Safe means of removing food debris (such as hook or rake) should be available for use when the machine has been turned off. Guards should also be used in parallel with local extraction ventilation (LEV), to enclose and control heat/odours generated or ejection of food particles/powder/dust. Where noise is excessive the guards may serve as noise control enclosures by lining them with sound absorbent materials. In running nips at rollers/pulleys and the ends of rotating rollers or spindles require to be guarded. On/Off controls and an emergency stop button should be provided at each machine at easily assessable locations (convenient to the operator). REQUIREMENTS FOR ALL CATERING EQUIPMENT USERS Staff training and usage Every operator should be trained competently and know the main hazards of the catering equipment prior to use, they should also know: how to start, stop and operate the machine safely how the safeguards and other controls work What to wear e.g. appropriate PPE and what not to wear e.g. loose garments, jewellery, ties, long hair etc. how to load and unload components safely and safe manual handling practices how to remove waste food debris and clean machine without safely good housekeeping procedures around dangerous machines Staff training and usage (contd.) Hazardous equipment should only be used with written departmental authorisation and when the user is confident that he/she has received and understood all the relevant instructions. Untrained staff should not be authorised to use band saws, slicers or other hazardous machinery. (Key operated switches may be essential in food halls used by students). Ensure all dangerous machinery and equipment is switched off and left in safe condition after work is finished. Users of food equipment should not allow themselves to be distracted by others and should concentrate on the task in hand. Likewise, never speak or distract someone working dangerous machinery. All machines should be sited away from congested areas where they can be operated and cleaned safely. Trainees must be under close supervision when using certain dangerous machinery. Food hygiene requirements and routes of cross contamination. Maintenance and cleaning personnel All maintenance and cleaning personnel should be trained to know the main hazards of the equipment; they should also know: How to use the permit to work system especially work on hazardous equipment. Know where the power isolation switch is located. Ensure power is switched off and isolated before inspection, cleaning, maintenance or repairs are carried out. How to display warning signs properly. How the safeguards and other controls work and safe procedures appropriate to the equipment. What to wear e.g. appropriate PPE and what not to wear e.g. loose garments, jewellery, ties, long hair etc. Maintenance and cleaning personnel (Cont.) How to remove waste food, debris safely. Safe manual handling practices during maintenance. Good housekeeping after maintenance or repairs around dangerous machines. That the instruction manuals must be consulted prior to any cleaning or maintenance carried out. CATERING EQUIPMENT ALL SLICERS (In addition to the relevant requirements given in Section 18.29.4.9) There are three main types of slicer: the gravity feed slicer, the horizontal feed slicer and the bacon slicer. Many serious accidents have occurred e.g. fingers or amputation from contact with running blade when feeding, adjusting or removing work pieces and when cleaning the machine. On power driven feed slicers there is a risk of entrapment between the carriage and the machine frame and on power driven bacon slicer it is possible for the operators hand to be pushed onto the blade. All slicers must conform to the guard requirements stated in Section 18.29.4.8 Principles Of Safeguarding Machinery And Catering Equipment 18.29.4.10.1 GRAVITY FEED SLICERS Gravity feed slicers have an inclined carriage and are used for slicing cooked meat and other foods. The carriage may be hand or power operated. Precautions and Controls: A suitable plastic or perforated carriage guard should be fitted at the operators side of the carriage to prevent accidental contact with the blade. A thumb guard should be provided at the operators side of the carriage to cover the blade at the end of each cut. On certain machines the blade has to be removed for cleaning. A blade carrier that prevents access to the sharp edge should be used to remove the blade easily. The carriage should have a last slice device or meat pusher. If the operator holds the material being sliced there is a danger of slipping onto the blade. Every new machine should be fitted with a no-volt release (NVR). This ensures that the machine can only be started from the start button. In particular, the NVR prevents the machines from being started unexpectedly when it is plugged in or the supply is switched on. Start buttons should be recessed or shrouded to prevent unintended operation. Start buttons should be protruding, easy to operate and within reach of the operator. The blade should be kept sharp, as a blunt blade requires more force, which increases the risk of slipping onto the blade. During blade sharpening all guards shall be in place. The slice thickness plate should be shaped to the edge of the blade to prevent injury at the cutting section. The slice thickness plate should be at zero except on machines with a detachable sharpener. Slippery, small or unevenly shaped food that cannot be held securely on the carriage should never be sliced. The carriage should always be pushed by the handle, never by the last slice device or the food. Only a trained person should clean the machine and the instruction manual should be consulted for the cleaning procedures. Before cleaning the machine must be unplugged or switched off at the isolator. The control switch must not be relied on. On some machines the blade has to be removed for cleaning and a blade carrier should be used to remove the blade safely. After cleaning, check that all guards are put back in place. Suitable warning notices should be posted beside the machine. HORIZONTAL FEED SLICERS Horizontals feed slicers have a horizontal carriage to carry the meat. The operator pushes this carriage towards the circular blade and slice thickness place. Precautions and Controls: The edge of the blade must be fitted with a guard, except at the cutting section. The guard may be permanently fixed to the machine frame flush with the blade edge or it may be removable for cleaning if it interlocks the power supply to the blade motor. The slice thickness plate should be shaped to the edge of the blade to prevent injury at the cutting section. The carriage should have a meat pusher which is large enough and shaped so as to prevent the operators hand slipping onto the blade. The meat pusher should have a handle. It should not be possible to swing the pusher clear of the carriage. During blade sharpening, all guards should be in place. The slice thickness plate should be at zero except on machines with a detachable sharpener. A thumb guard should be provided at the operators side of the carriage to cover the blade at the end of each cut. On certain machines the blade has to be removed for cleaning. A blade carrier that prevents access to the sharp edge should be used to remove the blade easily. Every new machine should be fitted with a no-volt release (NVR). This ensures that the machine can only be started from the start button. In particular, the NVR prevents the machines from being started unexpectedly when it is plugged in or the supply is switched on. Start buttons should be recessed or shrouded to prevent unintended operation. Start buttons should be protruding, easy to operate and within reach of the operator. The blade should be kept sharp, as a blunt blade requires more force, which increases the risk of slipping onto the blade. Before cleaning the machine must be unplugged or switched off at the isolator. The control switch must not be relied on. After cleaning, check that all guards are put back in place. Suitable warning notices should be posted beside the machine. BACON SLICERS The bacon slicer has a vertical circular blade and a horizontal carriage with clamps for holding the meat. The main danger is the exposed cutting edge of the blade but there is an additional hazard at the stacker, which has sharp hooks. Precautions and Controls: Hand operated machines should have a broad front guard beside the cutting section of the blade. The sharpener cover must always guard the blade edge. Power operated machines need a large plate guard to prevent the operators hand being pushed onto the blade if the machine unexpectedly starts. The guard used on the hand-operated machine is not enough. The plate, other guards and the sharpener should interlock the power supply to the blade motor. Modern machines can be modified to this standard. All guards interlock with the power supply to the blade motor. Every new machine should be fitted with a no-volt release (NVR). This ensures that the machine can only be started from the start button. In particular, the NVR prevents the machines from being started unexpectedly when it is plugged in or the supply is switched on. Warning notices have been provided on and beside the machine. Stop/Start buttons will be colour-coded for ease of recognition. If rashers become caught or do not move along the conveyor, the machine must be switched off at the isolator before attempting to remove the blockage. Before cleaning the machine, it must be unplugged or switched off at the isolator. The machines control switches should not be relied upon. Fixed parts of the machine shall be cleaned using appropriate brushes and cloths and a hot detergent solution. Care should be taken that no water enters the motor or electrical connections. Never reach around the edge of the blade when cleaning. TABLE TOP BANDSAWS These machines are used for cutting portions of meat and there is a serious risk of amputation at the blade. Precautions and Controls: (In addition to the relevant requirements given in Section 18.29.4.9) The machine must have a clearly visible and easily accessible, red, protruding emergency stop button. Every new machine must be fitted with a no-volt release (NVR). This is a device to ensure that the machine can be started only from the start button. In particular, the NVR prevents the machine from starting unexpectedly when it is plugged in or when the supply is switched on. New machines should already have an NVR. It may be possible to modify some existing machines if the opportunity arises, during major repair, for instance. Serious accidents can result if the operator is distracted, pushed or bumped. The machine should be sited where it can be used and cleaned safely, away from passageways, doorways, other working areas and other equipment. The floor surface surrounding the machine should be well drained, made of non-slip material and kept clean. The machine should not move or rock when used. It may need to be secured to the table or stand. Only the cutting area of the blade should be exposed. The top and bottom pulleys and the return section of the blade must be enclosed in a strong guard. The guard needs to be opened for cleaning so it should interlock the power supply to the motor. The blade should come to rest as soon as possible after the machine has been switched off or the guard door opened. A maximum stopping time of 4 seconds is strongly recommended. As much as possible of the cutting area of the blade must be guarded. The hinged meat pusher should be used, if the machine has one, or the adjustable blade guard must be set as low as possible. Blade guides and scrapers should be provided and maintained in good working order. If blade guides are worn or badly adjusted, the blade can twist unexpectedly. The correct blade tension should be applied. Slice thickness plates, sliding tables and last slice devices should be used whenever possible. Suitable warning notices should be posted on or beside the machine. Before cleaning, the machine should be unplugged or switched off at the isolator. The machines control switch should not be relied on and particular attention should be paid to cleaning the blade guides and scrapers, to keep the blade running true. After cleaning, it should be checked that all guards are put back in place, and the blade guides and scrapers are correctly set. Small portions (e.g. poultry, small pieces of meat) should never be cut so that the hands of the operator come too close to the blade. Chain mail or other gloves, loose or frayed clothing or jewellery that might catch on the blade teeth should not be worn. The blade should be kept sharp and correctly tensioned. The blade guides and scrapers should be set correctly when cleaning the machine. The machine should never be used if feeling unwell or drowsy. (Certain medicines etc. carry a warning that they may cause drowsiness). FREE-STANDING BANDSAWS Free-standing bandsaws are widely used in butcheries for primal cuts, portion cutting and cutting frozen blocks before mincing. There is a danger of amputation at the blade of even the smallest bandsaw. Precautions and Controls: (In addition to the relevant requirements given in Section 18.29.4.9) Serious accidents can result if the operator is distracted, pushed or bumped. The machine should be sited where it can be used and cleaned safely, away from passageways, doorways, other working areas and other equipment (see below for suggested layout). The floor surface surrounding the machine should be well drained and made of non-slip material and kept clean. The machine should not move or rock when used. It may need bolting to the floor. Only the cutting area of the blade should be exposed. The top and bottom pulleys and the return section of the blade must be enclosed in a strong guard. This guard should interlock the power supply to the motor. The blade should come to rest as soon as possible after the machine has been switched off or a guard door opened. A maximum stopping time of seven seconds is strongly recommended. The blade guard must be easily adjustable. It must be set as low as possible. Precautions and Controls (Cont.) : Blade guides and scrapers should be provided and maintained in good working order. If blade guides are worn or badly adjusted, the blade can twist unexpectedly. Any removable table should interlock the power supply to the motor. The correct blade tension should be applied [consult the instruction manual]. The machine must have a clearly visible and easily accessible protruding emergency stop button. Every new machine must be fitted with a no-volt release. Slice thickness plates, sliding tables and last slick devices should be used whenever possible. Suitable warning notices should be posted on or beside the machine. Before cleaning the machine, unplug it or switch it off at the isolator. Do not rely on the machines control switch. Pay particular attention to the blade guides and scrapers, to keep the blade running true. Always set the adjustable guard as low as possible. Never wear chain mail or other gloves, loose or frayed clothing or jewellery that might catch on the blade teeth. Never use the machine unless the guards and interlock switches are fitted and working properly. Never use the machine if you feel unwell or drowsy. (Certain medicines etc. carry a warning that they may cause drowsiness). BOWL CUTTERS Bowl cutters, otherwise known as bowl choppers, have a serious of blades on a horizontal drive shaft, running in a bowl that rotates to feed material to the blades. The potential dangers include cuts, loss of fingers and broken fingers. The main danger is contact with the blades, which run at high speed. Precautions and Controls: (In addition to the relevant requirements given in Section 18.29.4.9) The bowl cutter should be firmly fixed to the floor, a table or a stand. The cable must not be allowed to trail across the floor or tabletop. Power sockets must be positioned where water cannot be splashed on them. The plug and cable should be inspected to ensure that they are in sound condition and properly wired up. The bowl should be smooth and without projections so that it cannot catch anyone. The guard over the blades must enclose the rear half of the bowl. It should be interlocked with the power supply to the motor, and the blades should stop before it can be opened. A time-delay-interlocking device is usually needed unless a brake is fitted to the drive. A series of bars should be fitted to cover the quarter of the bowl where it runs towards the blades. These prevent access to the blades but allow the operator to load the bowl. The remaining quarter of the bowl is left open so that the machine can be unloaded. Alternatively, an interlocking guard may be used to enclose the open top of the bowl entirely. A non-return flap should be fitted to the blade guard where the bowl runs out from the blades. It should not be possible to push the flap back under the guard or lift it above the horizontal. The switch on the machine and on the socket must be in the off position before the plug is inserted. Hands should be dry before carrying out this operation. Instructions for operating the machine should be displayed in a clearly visible position on or near the bowl cutter. Before using the bowl chopper, it should be checked to see that all guards and protective devices are in place. Before starting to clean the machine, it should be unplugged or switched off at the isolator. The control switch on the machine or the blade cover interlock should not be relied on. After cleaning it should be checked that the machine is put back together properly. Care should be taken when cleaning the blades as lacerations can be caused even when they are not moving. The machine should not be used if the interlock between the guard and the motor is not working. Blades should be kept sharp at all times. The machine should always be kept properly lubricated and maintained. MINCERS If properly used or misused, especially while cleaning, serious injuries can be caused by even the smallest of mincers. The main risk is of fingers coming into contact with the cutters or worm drive when the machine is in motion. Precautions and Controls: (In addition to the relevant requirements given in Section 18.29.4.9) It must not be possible for the operator to touch the worm drive through the feed throat. Either the feed throat must be long and narrow (opening not more than 2.5 inches in diameter and the distance between the top of the opening and the worm of the machine to be less than 5 inches) and/or a restrictor plate must be securely fixed over the top of it. Any holes in the restrictor plate should be small enough to prevent anybody reaching the worm. Some old mincers have a feed tray, which can be easily lifted off to give access to the worm. Such machines should be modified. A delivery guard must be fitted if the operator can reach through the mincing plate to the blades. This is generally unlikely but some operators can reach through a 10mm mincing plate. Products should be fed to the machine using a suitable plunger/push stick, which should be designed so that it cannot touch the worm. The plunger should preferably be made of a synthetic material, which can be easily cleaned. The delivery guard should always be fitted if it might be possible to reach the cutter behind the mincing plate. The machine should never be overloaded and the food should always be cut to a convenient size. The machine should not be used if the restrictor plate is bent, loose or missing. The machine should never be run without the food tray being in the correct position. The power supply to the machine should be turned off and the plug withdrawn before commencing cleaning. The control switch should not be relied on. After cleaning it should be checked that the machine is reassembled properly for next use. The machine should be sited where it can be used and cleaned safely. Suitable warning notices should be posted beside the machine. MIXER/MINCERS This section deals with manually fed machines that mix and mince. Material is fed to the worm from a hopper. The mixing arms or paddles are normally located on a horizontally shaft in the feed hopper. In addition to the risks associated with mincing machines (in Section 18.29.4.14), the mixing paddles on mixer/mincers are dangerous, and fatal accidents have occurred. Precautions and Controls: (In addition to the relevant requirements given in Section 18.29.4.9) The operator needs access to the hopper for feeding and cleaning, but should not be able to touch the mixing paddles or the worm while they are moving. A hopper guard or lid should be provided to prevent access to the mixing paddles and worm. This should interlock the power supply to the motor. The worm and mixing paddle should top before the lid can be opened. The lid may have openings in it so that the operator can look into the hopper or add seasonings etc. The openings should not be large enough to allow a hand or finger to reach the paddles or worm. The operator must never push a stick or rigid object through the openings in the lid. A delivery guard should be fitted where the holes in the mincing plate exceed 10mm in diameter. This guard may be fixed or, alternatively, a hinged hood or cover could be fitted, interlocked with the power supply to the motor. The power supply to the machine should be turned off and the plug withdrawn before commencing cleaning. The control switch should not be relied on. After cleaning it should be checked that the machine is reassembled properly for next use. The machine should be sited where it can be used and cleaned safely. Suitable warning notices should be posted beside the machine. PATTY FORMING MACHINES Patty (hamburger) forming machines mould minced or ground products into portions. The mould is filled in one position and moves to another for the completed product to be ejected. Some moulds have a sliding action, others have a rotary motion. Most machines have a feed hopper but some are fed from mincers. Trapping in the meat feeder, mould and ejector as they move are the main hazards of these machines. Precautions and Controls: (In addition to the relevant requirements given in Section 18.29.4.9) The meat feeder must be guarded. If the machine has a feed hopper, it must have a feed hopper guard to prevent the operator touching the meat feeder. The guard may be securely fixed in position or hinged. If it is hinged, it should interlock the motor power supply. The guard may be a grid with suitably spaced bars. Never use your hands to free meat sticking to the side of the hopper, use a long handled scraper. Precautions and Controls (Cont.) : The machine must have a guard to prevent access to the traps between the mould and other parts of the machine. The guard should interlock the power supply to the motor. Machine drives should be enclosed in suitable guards. Some machines have a device that puts paper or plastic film onto the portions to prevent them sticking when stacked. This device has cutters and moving arms that must be guarded. All guards must be in position when the machine is running normally or slowly. The machine must not be cleaned while it is running unless all guards are in place. Remove the plug or switch off at the isolator before stripping the machine for cleaning. Do not rely on the machine controls. The power supply to the machine should be turned off and the plug withdrawn before commencing cleaning. The control switch should not be relied on. After cleaning it should be checked that the machine is reassembled properly for next use. The machine should be sited where it can be used and cleaned safely. Suitable warning notices should be posted beside the machine. MEAT TENDERISERS Meat tenderisers have a series of sharpened toothed cutters, which make a large number of cuts in the surface of a steak and can equally make a large number of cuts in the surface of a hand. Precautions and Controls: (In addition to the relevant requirements given in Section 18.29.4.9) The machine should not be used unless the guards are properly in place. Guards should be fitted at the feed chute to prevent access to the nip between the cutter. A guard must enclose the cutters and prevent accidental access to them. On reversible machines, both feed and delivery chutes should prevent access to the moving cutter. Any opening or removable guard should interlock with the power supply to the motor. The machine should never be overloaded by attempting to pass too big a piece of meat through it. The machine must not be used unless the guards are properly in place. Before cleaning the machine, it must be unplugged from the power supply. The on-off switch must not be relied upon. Care should be taken with sharp cutter while cleaning them. After cleaning the machine must be put back together properly and all guards must be in place. PLANETARY MIXERS This widely used mixer has a single beater, which moves around the stationary bowl so that the material at the side is thoroughly mixed. The beater may be a metal grid hook or a whisk. The machine may have other attachments such as vegetable slicers, graters or chippers connected to them. The attachments may have independent power units or power supplied by the mixer motor. The main risks are from: Trapping of hands, arms, clothing etc., between the beaters or hooks and the bowl. Hands can be bruised and even crushed in the trap between the beater and the bowl. The risk arises if the operator adds ingredients or scrapes down the bowl during mixing. The larger the machine the greater the risk. Some machines have gear or clutch levers, which can easily be inadvertently knocked into engagement. This is more likely on odd or poorly maintained machines with worn mechanisms. Most modern machines have electronic speed controls or gear box designs that do not have this risk. Precautions and Controls: (In addition to the relevant requirements given in Section 18.29.4.9) Ensure that the mixer is stable and securely fixed to the floor. It should be located in such a position as to allow the operator ease of movement around the mixer. The operating instructions should be placed on or near the mixer, while the manufacturers user guide should be made available in the workplace. Mixers should be switched off and isolated and the bowl lowered before scraping or adding ingredients or before cleaning. The mixer should always be properly assembled before use and the attachments correctly and safely fitted. The gear or clutch level should not be capable of being easily knocked into operating position. Precautions and Controls (Cont.) : Guards around the bowl are not commonly found in catering premises, although these are available and will fit around the bowl and spindle mechanism to prevent contact with moving parts. Such guards, where provided should be interlocked. Bowl extension rings should be used whenever possible to restrict access to the beater. When the machine is running: Never try to feel the mix. Never try to scrape down the bowl. Never reach into the bowl when adding ingredients. On larger machines a full mixing bowl can be very heavy. Castor-framed trolleys should be used to prevent strain injuries. Regular maintenance should be carried out preferably by the manufacturer or the manufacturers agent. Suitable warning notices should be posted beside the machine. Always unplug the machine or isolate its power before commencing cleaning. Where attachments are used only use the pressure plate to push material into the cutter. Material to be chipped, sliced or grated should be cut up into convenient sizes before feeding to the hopper. On some machines, the beater unit rotates when attachments are in use. For this reason, the beater paddle must be taken off and the empty bowl raised up on the carrier. FOOD PROCESSORS Food processors can be used for a number of different operations including slicing, grating, mixing and liquidizing. The cutters and mixing blades rotate at high speed and can cause severe injuries to the fingers. There is also the risk of ingredients being ejected from the bowl. Precautions and Controls: (In addition to the relevant requirements given in Section 18.29.4.9) Slicing, dicing, grating and chipping devices: The feed chutes and pusher devices should prevent access to the cutter when it is running. Pushers should be connected to the machine by a fixed linkage. Loose pushers tend to get lost. Machines are usually designed so that cutter plates can be changed quickly. There is a risk of injury if the cutter can be exposed when it is moving. The blade cover should interlock the power supply to the motor. A braked motor or a time-delay interlock may be needed to prevent access to the cutter before it has stopped. Access to the underside of the moving cutter must be prevented. This may be achieved by an elbow in the delivery chute or a smooth plate below the cutter plate, which throws the cut material into the delivery chute. Mixing and liquidising bowls: Mixing and liquidising bowls must be fitted with a lid to prevent material being ejected or fingers reaching to the moving mixing blades. The lid should interlock the supply to the drive motor. If a feed chute is fitted so that ingredients can be added during mixing, it should be designed to prevent fingers touching the blades. Many existing machines do not fully satisfy the above standards. If they are to continue in use, they should be maintained to at least their original new condition. It is strongly recommended that any suitable modifications available from any manufacturer should be obtained and used. Before you start to clean the machine, unplug it or switch it off at the isolator. Do not rely on machine controls or interlock devices. A machine with a broken bowl lid, feed chute or electrical interlock should never be used. The bowl should never be overfilled with hot ingredients. PIE AND TART MACHINES Mechanically powered pie and tart machines have moulds on to which flat pastry is positioned. A die comes down to push it into the mould. Some machines inject fillings in the pastry casing and crimp a pastry lid on top. Severe crushing and/or amputation injuries can occur at the trap between the die and mould or even at the measuring device or valve of the depositing mechanism. Precautions and Controls: (In addition to the relevant requirements given in Section 18.29.4.9) Hand operated machines: Heated dies should be clearly marked to show that they are hot and the electrical cables should be properly maintained. Powered operated machines: A hinged guard must be fitted to prevent access to the trap between the die and the mould when the machine is working. The guard should interlock the motor supply, and act as a trip device. It must be adjusted as close as possible to the top of the moulds. The gaps between the moulds under this guard should be filled by a false table or safety frame. A separate false table may be needed for each different set of moulds used on the machine. There must be a guard to prevent access to the die from the rear of the machine. The machine should stop immediately when an interlocking guard is opened or the stop button or trip device is operated. Heated dies should be clearly marked to show that they are hot. Suitable warning notices should be posted beside the machine. Before cleaning, remove the plug or switch off at the isolator. Do not rely on the control switch or guard interlocking switches. After cleaning check that the machine has been put back together. BREAD SLICERS Precautions and Controls: (In addition to the relevant requirements given in Section 18.29.4.9) A guard must be fitted so that the operator cannot touch the blades on the cutting side when they are moving. If the guard is opened to load the loaf it should electrically interlock the motor supply. A fixed tunnel guard may be used if there is a steep feed chute. If the pusher is released before the guard is closed, the motor should not start. The pusher plate should have a comb device to fit between the blades and push the cut slices through. The back (non-cutting) side of the blades should be blunt. There should be no gap at the sides of the cutting frame where a hand could be trapped between the pusher plate and the blades. The drive from the motor to the cutting frame should be enclosed by a guard. The machine framework may form part of the guard. The guard must prevent access to the drive from below the machine. The crumb tray should be designed so that it can be cleaned without the operator touching the blades or the drive. The plate supporting the loaf should be a close fit to the blades at the delivery side and should not be loose. The cutting blades should be checked regularly to ensure they are sharp. Before cleaning the machine, it should be unplugged or switched off at the isolator. The control switch on the machine should not be relied on. After cleaning it should be checked that all guards are put back in position. Bread slicers should be kept in good working order. ROTARY CHIP CUTTERS Rotary chip cutters have a rotating drum with a series of pockets. These pockets take potatoes and force them outwards against a fixed set of cutters. The cut chips then fall out via a delivery chute. The rotating drum and the fixed cutter create a trapping risk. Precautions and Controls: (In addition to the relevant requirements given in Section 18.29.4.9) Machines should have a feed chute so that potatoes are not loaded directly into the rotating drum. It may be on the top or side of the machine. The chute should have a device to interlock with the motor power supply. The delivery chute should be designed to prevent the cut chips adhering to it. Never use the machine without the feed chute in position. It should not be possible to reach beyond the cutters to the trap created by the moving drum and the fixed cutters. The cutters themselves may act as a barrier. The electrical supply cable and switches must be maintained in a sound condition. Any damage should be reported and repaired immediately. Never attempt to clean the machine when it is running. Always remove the plug or switch it off at the isolator before you start. After cleaning, check that the machine has been put back together properly. RECIPROCATING CHIP CUTTERS Reciprocating chip cutters have a series of fixed and sliding cutters, which cut peeled potatoes into chips. They have a feed hopper above the cutters and the chips generally fall into a container underneath. The shearing action of the cutters may cause series crushing and amputation injuries. Most accidents happen during cleaning or while clearing a blockage. Precautions and Controls: (In addition to relevant requirements given in Section 18.29.4.9) Effective guards must be provided to the feed hopper to prevent the operator reaching the cutters. The feed hopper should interlock the electrical supply to the drive motor to prevent the machine running if the hopper is not properly in place. The cutters should be kept sharp to minimise blockages. The delivery must be guarded to prevent access to the moving parts of the cutters. The electrical supply cable and switches must be maintained in a sound condition. Any damage should be reported and repaired immediately. Suitable warning notices should be posted beside the machine. Never run the machine with the feed hopper off even if you are only trying to pour water through the cutters. Always unplug the machine or switch it off at the isolator before cleaning. After cleaning, check that all guards are put back in place. OVENS & RANGES Ovens may be convential, forced air convection or combination types. The main dangers are from contact from hot surfaces, hot vapours or gas flashback and electric shock. Precautions and Controls: (In addition to the relevant requirements given in Section 18.29.4.9) Use suitable dry oven cloths or gloves when handling utensils in or out of the oven. Ensure adequate space in front of bottom hinged doors to allow operation to stand clear when opening doors. Handles of pens or pots should not project beyond the edge of oven tops or ranges. They should also be clear of heat emanating sources e.g. gas rings, hot plates. The makers handbook should be followed to ensure safe lighting procedure for gas appliances. (See 18.44.4.5 Gas Safety). Switches that turn off fans in forced air convection ovens when door opens should be checked regularly. Do not place heavy items of food on button hinged doors. Do not clear the oven until the power sources are turned off and the appliance is allowed to cool. Follow the makers instructions and use suitable personal protective equipment (PPE) when using caustic cleaning chemicals. STEAMING OVENS These ovens could be inject steam type, which uses steam from outside sources or ovens that generate their own steam by heating an open container of water under the cooking department. The main hazards are from scalds or contact with hot surfaces. Precautions and Controls (In addition to the relevant requirements given in Section 18.29.4.9) Do not turn on the steamer until you have checked that (a) the steam vent is open and clear of obstructions and (b) the water supply is on and there is sufficient water in the base of the oven. Ensure that the door seals have gaskets in good condition. The steamer oven should be positioned to allow staff to stand clear when the door is opened. Open doors carefully to prevent sudden escape of steam. Wear suitable heat resistant gloves for handling utensils. Only trained staff should clean the steamer in accordance with the makers manual. It should be cool with electrics, water supply or steam turned off. GRILLERS The most common grillers are griddles, grilles and salamanders, which may be heated by electricity or gas. The main dangers are from contact with the later, tray or hot food resulting in burns. The other hazard could arise if the shelf unit fell out causing injury to limbs. Precautions and Controls (In addition to the relevant requirements given in Section 18.29.4.9) They should not be placed over ranges and if wall mounted, well secured. Use oven gloves or oven clothes to handle hot trays. If positioned at eye level, ensure special precautions to protect eyes. The distance between the top of the grill and any overlying shelf or ceiling should be greater than 24 inches (60cm). Observe the safety precautions in Section 18.44.4.5 Gas Safety, if the gutter is gas heated in conformance with the makers recommendations. DEEP FAT FRYERS Deep fat fryers are used for cooking food quickly and efficiently and may be heated by gas or electricity. They range in size from small tabletop models to large multipan fixed units. The main hazards are: Burns from contact with hot cooking oil or fat. Burns can be caused if the hot oil or fat splashes when food or the basket is dropped in carelessly, or if it spits or boils over if there is excess water or moisture in the food. Fire from ignition of hot cooking oil or fat. Spilled or splashed oil or fat on the floor around a fryer. Precautions and Controls: (In addition to the relevant requirements given in Section 18.29.4.9) All fryers purchased should comply with BS5784 Safety of electrical commercial catering equipment - Part 2, Specification for deep fat fryers. All fryers should be equipped with thermostats for user temperature control. All fryers should be equipped with automatic cutouts (to operate at 2000C), so arranged as to cut off the heat source in the event of thermostat failure. Grease filters should be installed in the extract ducting in an accessible position as close to the fryer as possible. Extract ducting, grease traps and filters should be cleaned frequently in order to maintain them in efficient working order. All deep fat fryers should be equipped with lids or shutters capable of being closed immediately in the event of fire. The electricity supply switch and/or gas valve for the fryer should be clearly marked and positioned where it can be safely operated to turn off the heat source if the oil or fat catches fire. Before draining the fryer, first isolate it and allow the oil or fat to cool sufficiently before draining into a suitable container. Make sure that the inside surface of the container is dry before oil is run into it. Check that the drain valve is closed before re-filling. Do not use oil or fat at a higher temperature, or for a longer period, than the suppliers recommend. Do not mix oil and fats. Before switching on the heating element or light the gas check that the oil is filled to the oil level mark: when topping up to the recommended level, add the new oil or fat slowly. Do not top up from large containers, decant into smaller sized containers. DO NOT OVERFILL. Take care when shaking food in the basket not to let oil or fat drop onto the floor. To reduce spitting and boiling, food should be dry before immersion into hot oil or fat. The basket should not be overloaded and should be lowered gently into the oil; do not drop it in. Do not leave a working fryer unattended. Appropriate fire fighting equipment and a fire blanket should be available for use in the vicinity of the fryer. A notice should be prominently displayed giving details of the action staff should take if there is a fire. Before cleaning the fryer, ensure it is turned off, power isolated and the contents allowed to cool. MULTI-PURPOSE COOKING PANS (BRAT PANS) Brat pans are used for shallow frying, stewing, braising, boiling etc. They can be tilted to pour out the contents. As with all cooking equipment, the main hazards are burns or scalds. Precautions and Controls (In addition to the relevant requirements given in Section 18.29.4.9) Brat pans must never be used for deep fat frying, as it is extremely hazardous. The pan should have thermostatic controls to maintain temperature (temperature not to exceed 1900C). Pans should be designed so that they cannot tilt accidentally and must always be returned to the horizontal position after use. Power tilted pans should not exceed moving 10 degrees per minute and stop automatically at the maximum tilt position. Precautions and Controls (Cont.) : Hinged lids must be counter weighted into the raised position. The handle of the lid should be placed to prevent the users arm being exposed to the steam when the lid is opened. A lid drainage tap should be fitted to collect condensates. Suitable floor drainage should be provided beneath the pan, to reduce slipping hazards. The brat pan should be power isolated and allowed to cool before cleaning. BULK BOILING PANS & TILTING KETTLES. These are used for cooking soups, stocks, meat, vegetables etc. Some are fixed with draw off taps at the bottom or tilting from which the contents are poured. They may be directly heated by gas, electricity or steam, while others use indirect heating jackets using steam or water. The main hazards from these appliances are burns and scalds. Precautions and Controls: (In addition to the relevant requirements given in Section 18.29.4.9) Exercise carefully when opening lid to reduce exposure to steam by standing to one side. When boiling, only use sufficient heat to prevent the pan from boiling over. When simmering soups and stocks, reduce heat to minimise amount. Ensure drain/draw off tap is adequately secured to the pan. Suitable floor drainage should be provided to reduce slip hazards. The pan should be power isolated and allowed to cool before cleaning. MICROWAVE OVENS Microwave ovens do not pose a threat to health when properly used. Potential hazards would involve the leakage of microwave energy usually around the door into the oven. The seal around the door is designed to prevent such leakage and interlock switches are provided to ensure that the energy cannot be switched on unless the door is shut properly. Precautions and Controls: (In addition to the relevant requirements given in Section 18.29.4.9) Operating instructions should be placed on or near the microwave and a manufacturers user guide should be available for consultation. Microwaves should be regularly maintained and serviced in accordance with the manufacturers instructions by either the manufacturer or the manufacturers agent. The supervisor should have the manufacturers instructions. Ovens should be regularly inspected to ensure that there is no obvious damage to the hinges, doors, seals, or any other parts of the oven. The door alignment and locking mechanism should be checked regularly. If the door or the door surrounds show any sign of burning, then the oven should be taken out of service and the matter reported. Microwave ovens should comply with British Standard BS5175. (Specification for commercial electricity appliances using microwave energy for heating foodstuffs.) Ovens should not be operated empty. If for any reason, the oven must be operated without food, a small bowl of water should be used to simulate a normal load. (NOTE: Microwave ovens should not operate with the door open. If this is found to be so it must be reported to the supervisor immediately). Food that has a skin (such as potatoes) and canned food, should be pierced before being placed in the microwave, otherwise it will explode. Metal cooking vessels, ordinary aluminium foil, polythene bags, plastic wrapping or ordinary glass should not be used unless microwave approved. Care should be taken when thawing food in a microwave that the centre of the food is thoroughly thawed out before cooking. Regular checking of the door alignment and locking mechanism should be carried out. Care should be taken in the cleaning of ovens. Abrasive cleaners should not be used on the seals. WATER BOILERS/CAF SETS These provide hot water or steam for making hot drinks. They may be heated by gas, electricity or steam. Most units are fixed to servers although free standing beverage units may also be used. These are three types: bulk water boilers - basically a large kettle under no pressure; expansion boilers - provide boiling water at no pressure; pressure boilers - work at low pressure and provide boiling water and steam; The main hazards associated with boilers are burns and scalds. 18.29.4.30 (Cont.) Precautions and Controls (In addition to the relevant requirements given in Section 18.29.4.9) Pressure boilers should be fitted with the following safety devices: safety valve, pressure gauge, water level gauge; if electricity heated, a low water level cut-out device; if gas heated, a flame failure cut-out device. Pressure boilers and safety devices should be inspected by a competent person, at least once every twelve months. The unit should be positioned where it can be easily operated, on a fireproof base where safe flues can be installed. To minimise the risk of splashes from boiling water, particularly from pressure boilers, place the receiving vessel right up under the draw-off tap. Keep a drip tray under the draw-off tap at all times. Never overfill a boiler to avoid boil over. Before starting to clean any of this equipment it should be turned off at the gas tap or steam valve or, if electric, isolate and allow to cool. URNS Urns provide hot or boiling liquids such as water, milk, tea or coffee in limited quantities. They are fitted with taps near the bottom to draw off the contents. Portable urns and jacketed urns, which have separate containers, immersed in water for heating beverages are also available. They may be heated by electricity, gas or steam. The main hazards associated with their use are scalds and burns. Precautions and Controls (In addition to the relevant requirements given in Section 18.29.4.9) Portable urns should be positioned on a firm level surface where they cannot be accidentally knocked against or knocked over. Ensure the draw-off tap is kept clean, free from sediment and properly secured to the urn. Do not let the urn boil over. This may result in scalds or burns, electrical equipment damage or gas flames extinguished. Make sure the water level in the jacket of a jacketed urn is up to the correct level. Never let the urn boil dry. Never tilt an urn to draw off hot liquid from below the level of the tap. Place the receiving vessel as close as possible to the tap to minimise splashing. Keep a suitable drip tray in position under the tap. Before cleaning the urn, switch if off and, if it is electric, isolate from the supply. Allow cool before you tilt it to remove residual cleaning water. SAUSAGE FILLING MACHINES These machines are used to fill artificial or natural casings with sausage meat. This section deals with the smaller, cylinder type of machine, which consists of a vertical cylinder, containing the sausage meat, and an adjustable portioning piston, driven upwards by hydraulic pressure supplied by a pump within the lower casing of the machine. The cylinder has a close fitting lid. Meat is forced out of the cylinder via a discharge nozzle, into the sausage casings. Some machines create a shear trap between the internal piston and discharge port. Amputations have occurred on these machines, particularly during cleaning. Precautions and Controls (In addition to the relevant requirements given in Section 18.29.4.9) To prevent a trapping risk as the rising piston passes the discharge port, there should be a cut out groove on the piston head, aligned with the discharge nozzle. Machines should be examined to check the operation and to ensure no trapping point exists. The machine should not be operated unless it is properly assembled. 18.29.5 ARRANGEMENTS AND CONTROLS The details of the Arrangements and Controls in place and those required in the short, medium and long term, shall be set out by the Department in the forms provided in Document No.4 i.e. Departmental Safety Action Plan (D.S.A.P.). These Arrangements and Controls shall be reviewed and updated on a yearly basis. 18.29.6 RESPONSIBILITIES The following personnel are responsible in the Department/Office/Area for ensuring the implementation and ongoing compliance with the aforementioned arrangements and controls. AREA/LOCATIONPERSON RESPONSIBLE1.2.3.4.5.6.   DEPARTMENT SAFETY STATEMENT DOCUMENT NO. 2: Requirements for the Control of Hazards and Risks SECTION 18.29.0 - Food Halls, Food Preparation areas & Canteens Rev.1 PAGE   PAGE 24 of  NUMPAGES 24 AppSc\Doc2\Sect 18.29 DOCUMENT NO. 2: Requirements for the Control of Hazards and Risks SECTION 18.29.0 - Food Halls, Food Preparation areas & Canteens (Cont.) Rev.1 BURNS AND SCALDS - FIRST AID Immediately immerse the affected part in (or pour over) cold running water for at least 10 minutes or until the pain is relieved. Remove anything that may cause constriction if there is swelling e.g. rings, belts, shoes. Cover affected area with a dry sterile dressing. 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C. PatrickNora McElhinneym                           ! " # $ % & ' ( ) * + , - . / 0 1 2 3 4 5 6 7 8 9 : ; < = > ? @ A B C D E F G H I J K L M N O P Q R S T U V W X Y Z [ \ ] ^ _ ` a b c d e f g h i j k l  Oh+'0 0< ` l x ' 18.33 Workshops and MachineryA. C. Patrick Normal.dotmNora McElhinney2Microsoft Macintosh Word@F#@~q@LE@LE* ՜.+,0 px  '  18.33 Workshops and Machinery Title  !"#$%&'()*+,-./0123456789:;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXYZ[\]^_`abcdefghijklmnopqrstuvwxyz{|}~      !#$%&'()+,-./016Root Entry FpҙE8Data 1TablenWordDocumentySummaryInformation("DocumentSummaryInformation8*CompObj` F Microsoft Word 97-2004 DocumentNB6WWord.Document.8