Malthouse toasts a better approach to worker safety

Brewing on an industrial scale involves exposure to high levels of dust and particles, aggressive cleaning chemicals, up to 100% humidity levels and physically confined working conditions.

Constant heat and humidity may be essential to germination, but they are also ideal conditions for the development of bacteria, moulds and fungi. To meet hygiene and food safety conditions, cleaning is therefore a daily necessity.  Once a soaking vat or malting floor is empty, a cleaning team uses bleach to clean the room, beneath the malting floor and the grain conveyor systems, followed by rinsing with a high-pressure jet. These operations are particularly essential beneath the malting floor to prevent aeration holes becoming blocked since, without ventilation, the grain is asphyxiated.

At Malteurop’s largest malthouse, with its 12 malting floors and two soaking vats, these rigorous manual cleaning procedures are conscientiously performed every day. It takes between 4 and 8h to clean each room, depending on how clogged the vat is. Workers are exposed to the hazards of diluted bleach, with a high risk of projection during the high-pressure rinsing process, as well as posture-related constraints in the confined spaces. They must wear chemical protection gloves and an overall, on top of which they don a helmet and a harness with a ventilation belt.

Observation visit

To achieve the best personal protection for the cleaning staff, DuPont Personal Protection visited the Malteurop site to gain precise knowledge of the chemical products used and to observe the real conditions in which the overalls are used. Mélissa Chauvière, production manager at Malteurop, comments: "We wanted an item of clothing that is easy to put on and is sufficiently tear-resistant in the event of snagging; but the correct use of the overall also needs to be easily understood by the staff".

DuPont Protection Solutions recommended the Tychem 4000 S to meet Malteurop’s requirements. This category III overall is particularly suited to applications which require optimum protection against chemical substances without hampering the movements of the wearer, even in a confined space. Great care has been taken to perfect the shape and fit of the garment, particularly when moving. Worker safety is also enhanced by the white colour of the Tychem 4000 S garments, which provides contrast across a wide range of natural backgrounds to make the wearer more visible, even in poor light.

The overalls were tested by Malteurop staff working in various cleaning areas. Following the trials, the Tychem 4000 S overall was unanimously welcomed. Jamel Bahri, who has worked at Malteurop for six years, says: "I felt safer, the seams are better protected and it fits better at the neck. Together with the dual zip fastener and dual flap, it is really sealed, which re-assures us.”  

Other colleagues agreed, observing that they found the Tychem 4000 S easy to put on, lighter and more comfortable to wear than their previous protective workwear. The safety team was particularly impressed with the coverall’s protective sleeves that stay in place more effectively due to the elasticated thumb loop at the wrist.

DuPont also provided Malteurop with training, advice about garment sizing and the adoption of best practice. QHSE assistant, Véronique Coeffier, concludes: “The support we received from DuPont has been a key driver to introducing a global approach to safety and involving the teams. We are really satisfied with the progress that has been made.”