HAZARDS IN A FERMENTATION LABORATORY OR PLANT

Have anyone of you tried visiting a fermentation factory or plant? If you have you will know the experience....

Huge fermentors that stretch from the floor almost to the ceiling
High over head gantries
Humid and warm environment
Noisy with all the steam hissing sounds
Motors everywhere

Sometimes it looks as if these fermentation laboratories or plants are located in workshops, with tools and skids everywhere..

It is a dangerous and hazardous place to be and safety precautions are of the utmost. Accidents do easily happen here if no precautions are taken.

The type of hazards that might occur can be classified into the following areas:

1 Microbiological hazards
2 Physical hazards
3 Chemical hazards
4 Electrical hazards

MICROBIOLOGICAL HAZARDS
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In the fermentation industries or laboratories, we are dealing and always exposed to very high concentrations of microorganisms. If taken care and proper control these high concentration microorganisms are always contained in the bioreactor where they are purpose grown.

Depending on the type of fermentation process, the microorganisms used may or may not be pathogenic. Any danger of release of pathogenic microorganisms would be a real threat to the surroundings

The risk of mirobial hazards can occur at all stages of the fermentation activity right up from upstream, mid stream and down stream. Of course the most crucial stage will be the period the microorganisms are grown in the fermentor. There are billions and billions of microorganisms "swimming" in the fermentation broth!

Microorganisms can only escape due to poor handling procedures that is poor microbiological techniques. They can also be released by accidental discharge or poor containment of the microorganisms in the fermentor

In aerobic fermentors, air or oxygen is actively supplied into the broth of the fermentor for the use of the aerobic microorganisms. Most of the air will be released through the exhaust outlet to the environment. If the exhaust air is not sterilized or filtered, there is the danger that aerosols carrying the microorganisms from the fermentor will be released.

The fermentor is usually operated skightly under high pressure of about two bars. Any sudden release of the pressure through any of the valves risk releasing and spreading the microbes.

The presence of aerosols released from the pressured fermentor will exacerbate the problem of microbial dispersion and transmission. Not only will the aerosols be the " carrier" for the microbes but it will even protect the microbes from premature dessication and even provide nutrients for the microbes

Microbial containment should be of the highest order in managing pathogenic bacterial and viral fermentation

CHEMICAL HAZARDS
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There are a few possible chemical hazards that may arise in operating the fermentor or in the fermentation plant. Chemicals that may be used in the fermentation plant are from a few sources"

1 Calibration gases
2 Gases used in fermentation such as nitrogen, oxygen, hydrogen, carbon dioxide, NH3 gas
3 Solvents such as alcohols
4 Surfactants
5 Chemicals used as substrates
6 Acids and alkalies
7 Disinfectants

Some of these chemicals are toxic, flammable, corrosive and may be dangerous if not used properly

PHYSICAL HAZARDS
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Physical dangers that lurked in the fermentation laboratory or plant may include:
1 Heat
2 Pressure
3 Slips and falls
4 Knocks
5 Fire and burn hazards
6 Cuts and bruises

Dangers from high heat source occur in such activities as sterilizing the fermentors or from the use of autoclaves.
High pressure accidents too can occur by improper use of fermentors and autoclaves

Slippery fermentation plant floors could easily lead to slips and injuries. Cuts and bruises are common during handling of the fermentor

Equipments and tools left haphazardly could lead to unwanted accidents and falls

Improper use of flaming during aseptic procedures could lead to accidental burnings and personal injuries

ELECTRICAL HAZARDS
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Electrical accidents such as electric shocks is common in any fermentation laboratory. Short circuits are common. High voltage and high amps current are often used regularly in the fermentation operation

Fermentation operatives should be trained to identify all the possible danger points and steps taken should accidents happen. This will be discussed in future blogs