US: Georgia chicken feed mill, contractors face $112,000 in OSHA fines over fatality

An investigation​​ by the US Department of Labor's Occupational Safety and Health Administration (OSHA) found that JCG Farms in Rockmart violated safety standards that could have prevented the tragedy.

Federal inspectors determined excessive accumulation of grain dust in the hammer mill area ignited and the explosion killed one worker and sent five others to area hospitals. The blast caused excessive damage to the building and closed the feed mill.

On July 22, OSHA issued citations to JCG Farms of Alabama LLC, doing business as Koch Farms of Collinsville, A to J Electrical Services and D. Sims Inc. for 23 safety and health violations.

"It is tragic that despite wide industry awareness of these hazards, that some employers remain unaware of the common hazards of combustible dust,"​ said Christi Griffin, OSHA's area director in the Atlanta-West Office. "This incident and this man's death were preventable. JCG Farms needs to take a proactive approach in their safety and health program to assess the workplace for hazards and correct them to ensure worker safety."​

JCG feed mill's parent company is Koch Foods Inc. which employs approximately 14,000 workers nationwide. Koch Foods is a leading poultry producer with headquarters in Chicago.

JCG Farms' feed mill is part of Koch Foods Eastern Region based in Collinsville, Alabama. JCG Farms contracts with A to J Electric and D.Sims to perform various work at the facility.

Neither Koch Foods nor JCG Farms responded to requests for comment.

Violations​

OSHA cited JCG for 15 serious and five other-than-serious safety and health violations.

Examination of the incident started after an explosion injured five and killed Justin Deems, 25, at the Rockmart, Georgia facility in February, said OSHA. It was determined that excessive build-up of dust led to the explosion.

OSHA alleged the employer did not provide a work place free from recognized hazards that could cause death or considerable physical harm to employees.

Moreover, safety signs warning of dangers caused by dust build up were not posted; spaces were not evaluated to see if they needed to be labeled confined spaces and employees were not alerted to the dangers of confined spaces, claimed the agency. The employer also did not have an established plan for emergencies.

“The employer exposed employees to fire and explosion hazards such as severe burns and/or death caused by conveyor covers being left off”​ said the agency. “This condition allows combustible dust to build-up on floors, machinery and walls.”​

OSHA also alleged that current employees had not been trained in general safety precautions or how to identify known hazards.

The staff was also not trained on safety practices that related to specific jobs like cleaning grinding equipment or housekeeping procedures; written housekeeping protocols had not been developed or implemented; and improper dust management methods were used while machinery was being operated, said OSHA.

The mill’s dust collection system had been inoperative for 22 months, added the agency.

Additionally, tag and lockout procedures were not used with machinery; employees were exposed to tripping hazards; not all electrical fittings were completely closed, covered or correctly installed; and employees were not adequately trained for some electrical work, noted OSHA.  

Contractors working in the feed mill also were not informed of safety rules or potential fire and explosion hazards, reported the agency.

OSHA also claimed the company did not use or develop a safety data sheet for the different chicken feeds made on site.   

Sanctions against contractors​

A to J Electrical Services was cited​ for one serious violation and fined $2,800 said OSHA.

The company was notified that it failed to inform contractors of safety rules for a grain handling facility including fire and explosion hazards in the area where work was being done, the agency said.

D. Sims was cited​ for two items including one serious violation and one other-than-serious item, said OSHA. The company faces a total fine of $2,800.

The violations included that current and new employees were not fully trained in general safety precautions or how to recognize and prevent hazards connected to dust or ignition sources, said the agency. And, information on use of respirators was not offered to employees.

“On or about February 7, 2016, and times prior, employees were exposed to fire and explosion hazards in that employees were not told of specific areas that were considered ‘high hazard’ and about common ignition sources for combustible dust other than smoking,”​ the agency said. “This was evident based on employer and employee statements regarding the use of steel sledge hammers provided by JCG Farms which were in fact spark producing tools.” ​

What’s next?​

The citations were issued July 22 and published on Monday, said OSHA. The feed mill and contractors were given 15 days from receiving the citation and notification of penalty to fix the issues mentioned and pay the fines.

Several of the items were reported as having been corrected during the inspection, said the agency.

Additionally, the organizations cited can contest the entire citation or individual items and penalties presented within it, the agency said.

They also have the option of requesting an informal conference regarding the citations issued, said the agency. “If conditions warrant, we can enter into an informal settlement agreement which amicably resolves this matter without litigation or contest,”​ it added.