For those involved in any aspect of dairy production, there is a critical need for comprehensive workplace and worker safety measures tailored to the unique challenges of dairy.
By implementing stringent safety standards, the industry can protect its workforce, minimize costly workplace injuries and ultimately ensure the sustainability of dairy production.
Food safety expert Gary Wills, founder of the Food Safety Professionals Group and AMAS director of food and supply chain for BSI Group, said management commitment and effective training are key to a strong safety program.
“Holding a monthly town hall meeting and regularly incentivizing employees to call out issues and rewarding them for good catches is an effective way to promote a strong food safety culture,” he said. “Additionally, using guidance documents like PAS 320, and developing and sustaining a mature food safety culture can be highly beneficial.”
Culture of safety
Integrating food safety practices into the overall workplace culture in dairy processing requires a top-down approach, in which leadership and workers collaborate to ensure food safety is a shared responsibility. Dairy processors must prioritize food safety at every level by setting clear expectations, providing training and leading by example.
In facilities subject to regulatory requirements, such as those needing a food safety plan or hazard analysis critical control point (HACCP) plan, a structured approach is essential. This includes regular meetings, ongoing training, active participation in audits, and fostering open communication between leadership and staff.
“By involving all levels of the organization in these practices, dairy processors can embed food safety into the workplace culture, ensuring that everyone, from management to floor workers, is accountable for maintaining a safe and healthy environment, ultimately safeguarding the quality and safety of dairy products for consumers,” said Ray Chishti, EHS senior editor for J.J. Keller & Associates.
Photo: ultramansk - stock.adobe.comHaving a diverse workforce can be a real asset to dairy companies, but it also requires safety managers to ensure appropriate communication and continuous safety training.
“Companies that meet employees where they are tend to have more effective training programs and better outcomes,” said Danielle Quist, vice president, regulatory affairs and counsel, for the International Dairy Foods Association. “This includes easy-to-read and professionally translated policies and training in employees’ native languages.”
Furthermore, she said using various training methods can also help promote safety with a diverse workplace, such as descriptive pictures, videos and hands-on training to ensure that all employees understand and can ask questions about safety processes and policies.
“It is also important to have an understanding of cultural differences without stereotyping,” Quist said. “Companies that have a deep safety culture ensure that all employees, regardless of language and culture, feel comfortable speaking directly to supervisors and peers about safety procedures, risks and observations.”
Additionally, posting signage in all languages is extremely important.
“It is also essential to ensure that multilingual employees are present in the quality assurance department and in leadership positions, such as line leads within production, to facilitate questions and training,” Wills said. “Production and communication software should include automatic translation features when possible.”
Safety hazards and mitigation
More dairy companies are using leading indicators as proactive and preventative measures to identify and eliminate workplace hazards.
“Statistical data is still important, but leading indicators are key to understanding the effectiveness of company workplace safety activities and policies,” Quist said.
Francesca Vesce, food safety consultant for J.J. Keller & Associates, which provides safety and regulatory compliance solutions for the dairy industry, said intentional adulteration from ammonia and milk storage tanks stored in outside areas is one of the most critical food safety hazards in the dairy processing industry.
“Companies can best mitigate this risk by developing and implementing a strong food defense plan that incorporates monitoring and employee training,” she said. “Another critical food safety hazard in dairy processing is environmental pathogens in plant environment. Mitigation needs to involve a risk-based environmental monitoring program that seeks out niche areas, maintains the plant environment (floors, etc.) and equipment in good condition, and takes effective corrective actions before pathogens can spread in the facility.”
Bacteria risks
Among the biggest dairy bacterial risks of concern include Listeria, Staph, and Salmonella. Fortunately, heat treatments such as pasteurization can be used to reduce pathogens.
“One of the largest hazards is ensuring effective sanitation, meaning the equipment is properly cleaned and does not contribute to bacterial growth,” Wills said. “This is especially critical with cheese, as it contains active bacteria, and the addition of more bacteria can lead to both food safety and quality issues. Preventing downstream cross-contamination after pasteurization is key and can be achieved through effective GMPs and formulation control (more salt, lower water activity).”
In the case of ready-to-eat product, meaning no further kill step is involved, personal protective equipment (PPE) such as clean gloves and hair nets are crucial to prevent bacteria or other foreign materials from contaminating the product.
“Additionally, milk and milk derivatives are allergens, so ensuring to change PPE frequently to avoid any cross-contamination is important,” Wills said.
Furthermore, PPE should be treated as the last line of defense for employee safety, once engineering and administrative controls and work practices are proven insufficient for full protection.
Photo: Dusko - stock.adobe.com
Safety audits
Food safety audits, Wills explained, provide an unbiased evaluation of the business by an external party. Findings from these audits can help improve the environment, serving as an extra layer of protection to ensure compliance in the event of a regulatory inspection.
“Audit frequency should be based on the operation’s level of risk and frequent internal audits are extremely important,” he said. “For most large customers, an annual third party audit typically suffices unless the business scores poorly.”
Chishti noted regular safety audits and inspections are crucial for maintaining high food safety standards in the dairy processing industry.
“They ensure equipment functions properly, workers operate machinery safely and hazards are minimized,” he said. “Audits also validate food defense controls, support a positive safety culture and ensure compliance with regulatory agencies.”
For dairy processors, these efforts are essential in preventing contamination, ensuring the safety of dairy products and protecting consumers from foodborne illnesses.
“Facility audits should generally be conducted monthly, while equipment inspections follow manufacturer recommendations, often per shift,” Chishti said. “Additional audits for hygiene, pathogen control and occupational health hazards should be performed at appropriate intervals based on specific risks, ensuring that all safety aspects are consistently addressed in the dairy production process.”
Continued evolution
Wills thinks more rapid pathogen testing and more automatic/clean in-place technologies for enhanced sanitation and hygienic design will make things better for all. Emerging technologies also offer significant opportunities to enhance worker safety.
“Real-time sensors monitor key factors like temperature and equipment performance, enabling quick responses to potential issues and reducing contamination risks,” Chishti said. “Automation and robotics reduce physical strain on workers while ensuring consistent safety in tasks like material transport and sanitation.”
Additionally, artificial intelligence (AI) software can analyze data to identify hazards, while wearable devices track worker health metrics, such as body temperature and heart rate, with immediate alerts to health risks. Advanced software improves supply chain transparency, supporting compliance and reducing contamination.
“To implement these innovations, dairy processors must invest in infrastructure, provide training, collaborate with tech providers and regularly assess system performance to ensure they enhance both food and worker safety,” Chishti said.
