Foster Farms: OSHA inspections and violations

Incident on Aug 13, 2013: Employee's hand is caught in picker and is injured

At approximately 10:30 p.m. on August 13, 2013, Employee #1 placed a Gamco Picke r (Model Number D-16, Serial Number 37) machine into the automatic operation mod e. He was looking at the side of the Picker and observing the inner rotating pic king discs to ensure the picker components were operating correctly when he lost his balance. His right hand slipped off the top of the Picker and went inside t he machine. The hand was caught in between the rotating picking disc, causing a severe avulsion to his right middle finger. Emergency medical personnel were sum moned. They arrived and transported him by ambulance to a medical center, where he was evaluated and treated for his injuries. He was admitted to the medical ce nter as an inpatient and underwent surgical procedures and skin grafts, after wh ich he was hospitalized for five days.

Incident on Dec 22, 2011: Worker fractures wrist and forearm cleaning skinner machine

On December 22, 2011, Employee #1, a 20-year-old male sanitation worker with Fos ter Farms Inc., was cleaning the breast skinner machine. Employee #1 used a hose to spray the equipment. Employee #1 sawed a piece of skin on a sprocket and rea ched in to remove it. The sprocket grabbed Employee's glove. Employee #1 suffere d a fractured wrist and forearm which required surgery.

Incident on Sep 4, 2010: Employee suffers deep vein thrombosis

On September 4, 2010, Employee #1 was working at a conveyor that brought chicken s into the plant. He leaned on a bar that activated the conveyor. It took approx imately 5.5 lbs of force to move the bar. Employee #1 worked at that station for approximately two hours per day. Employee #1 was hospitalized for a deep vein t hrombosis that was not due to the work environment.

Incident on Nov 8, 2010: Employee's fingers are amputated by meat processing machine

At 1:30 a.m. on November 8, 2010, Employee #1, who was employed by a poultry sla ughtering and processing facility, was performing his normal work duties as a ma chine operator of a chicken leg processor. Employee #1 was rehanging a chicken p art in the machine, and his hand was pushed through the cutting section of the m achine. He sustained finger amputations and was taken to Community Regional Medi cal Center in Fresno for treatment. Employee #1 was hospitalized.

Incident on Dec 9, 2009: Employee is injured by box of waste chicken parts

Employee #1 was a sorter at a sorting table on a production line at a poultry pr ocessing plant in Livingston, CA. Employee #1 was standing at her assigned stati on, when a box of chicken waste parts hit her from behind, injuring her back and pushing her into the sorting table in front of her, which caused an abdominal c ontusion. The box was on a cart being pushed by a sanitation employee who was no t paying attention and ran into Employee #1. She was taken by ambulance to the n earest hospital in Turlock, CA, where she was evaluated, medically treated, and released the same day. Employee #1 was approximately 10 to 12 weeks pregnant at the time she sustained the back and abdominal injury. Employee #1 sustained a mi scarriage a couple of days after the injury and alleged the injury caused her mi scarriage. A medical review by Hazard Evaluation System and Information System w as performed to evaluate her allegation regarding the miscarriage. Investigation resulted in no citations being issued to the employer.

Incident on Dec 29, 2009: Chicken plant worker amputates finger on equipment

At approximately 8:30 a.m. on December 29, 2009, Employee #1, a worker at Foster Farms chicken processing plant, was trying to put the pin in the evisceration d rum on Line 2. He pinched his finger between the pin and the drum, and the small finger on his left hand was amputated. Employee #1 was taken to Industrial Medi cal but was not hospitalized.

Incident on Dec 24, 2009: Employee amputates finger in machinery

On December 24, 2009, Employee #1 was operating a package-wrapping machine when got his right hand became caught in the machinery. The machine amputated the tip of his right middle finger. He was transported to a medical center, where he re ceived treatment and was hospitalized.

Incident on Sep 25, 2009: Employee amputates thumb in centrifugal pump

At approximately 4:45 a.m. on September 25, 2009, an employee was sanitizing a t wo horsepower centrifugal pump. As the pump was operating, the employee disconne cted the 2 inch diameter stainless steel inlet coupling from the supply pipeline . The coupling was about a half inch away from the impeller. As the inside rubbe r gasket of the coupling became drawn into the pump cavity, the employee attempt ed to retrieve it with his right thumb. His thumb tip became engaged with the pu mp impellers and was amputated. The employee was taken to RK Davies in San Franc isco for further treatment. The employee was hospitalized and treated for thumb amputation.

Incident on Oct 25, 2009: Employee's finger is amputated by sprocket and chain

At approximately 10:25 a.m. on October 25, 2009, Employee #1, who was employed b y a poultry processing plant in Porterville, was performing his regular job duti es as a maintenance mechanic. Employee #1 was troubleshooting a noise coming fro m the drive chain of a mesh belt conveyor, as it was operating with the chain gu ard removed. He placed his tool bag near the assembly, walked over to engage the power control for the motor, and then came back to the sprocket and drive chain . As he came to the spot and was kneeling down to the chain, he stumbled over hi s tool bag. Employee #1 reached his right hand out towards the chain area, and t he sprocket caught his index fingertip. His fingertip was sheared off, as the sp rocket engaged the chain. Someone transported Employee #1 to Sierra View Distric t Hospital, where he was treated and released the same day. On November 5, 2009, Employee #1 had surgery to amputate his finger tip. Someone notified the DOSH F resno District Office about the incident on November 5, 2009.

Incident on Jan 3, 2010: Ammonia leak hospitalizes five workers

On January 3, 2010, a small amount of ammonia was released when a worker drove a forklift into the support frame of an entry door of a freezer. The entryway was equipped with an air curtain above the door. Five workers employed in this area of the distribution center began feeling eye, throat and lung irritation. All w ere transported to local hospitals where they were treated and released for expo sure to ammonia.

Incident on Jun 26, 2009: Employee slips, punctures abdomen

On June 26, 2009, Employee #1, a "cutter", was working on the rehang line at the Belgravia chicken processing facility in Fresno, CA and was working with a five in. blade. Employee #2, a "picker", attempted to pass by, and Employee #1 tried to avoid injuring his coworker. Employee #1 and #2 made contact. Employee # 1 s lipped. The blade entered Employee #1's abdomen, puncturing his liver. Surgical repair was needed as well as exploration for other organ perforations. He had be en working in the position for one year and received training, including safe wo rk procedures on how to minimize exposure to the blade. The employer's job safet y analysis identified the blade and slip hazards. A cutter would be provided a c hain glove with a plastic gauntlet for the opposite hand and slip-resistant rubb er boots. The cause of the accident was not determined. Violations of T8 CCR sta ndards were not identified. Since the incident, the employer now provides a chai n vest to the cutter and modified work procedures for pickers to make cutters aw are of their presence and actions.

Incident on May 9, 2009: Employee's leg is fractured by pallet jack

On May 9, 2009, Employee #1 was operating a pallet jack when it somehow swung to wards him. Employee #1 was pinned between a storage rack and the pallet jack. Hi s leg was fractured, and he was hospitalized. Employee #1 could not remember how the accident occurred or what he was doing when it occurred.

Incident on May 8, 2009: Employee's thumb tip is amputated by truck door

On May 8, 2009, Employee #1 was gluing molding around the door of his company tr uck/vehicle. He closed the truck door prior to getting his thumb out of the way, resulting in amputation of his left thumb tip. Employee #1 was hospitalized.

Incident on Feb 18, 2009: Employee suffers concussion when struck by falling pole

On February 18, 2009, an employee was struck on the head by a metal "Hook" retri eval pole falling from an overhead conveyor. The metal "Hook" pole was left by a coworker who did not remove it after he was finished using it. The employee a s uffered concussion but was not hospitalized.

Incident on Jan 26, 2007: Employee amputates index finger between tub and wall

On January 26, 2007, Employee #1 was working as a laborer at a poultry slaughter ing and processing facility. He was moving a stainless steel tub, when he pinche d the index finger on his right hand between the tub and the bump guard on a bac k guard wall. He sustained an amputation, but he was not hospitalized. The bump guard has since been lowered, and the tub corners have been rounded.

Incident on Apr 6, 2007: Employee is injured when struck by falling rack

On April 6, 2007, Employee #1 was moving a rack of hot dogs. The hook that holds the rack snapped off and the rack fell on Employee #1, striking him in the head . He was not hospitalized for his injury.

Incident on Feb 9, 2006: Employee is injured during conveyor cleaning

On February 9, 2006, Employee #1 was cleaning the conveyor, which was neither lo cked out nor tagged out. While Employee #1 was placing a lid on the conveyor bel t, a remote operator turned on the conveyor and the corner, of the lid held by E mployee #1 became hooked on the conveyor belt. He was pushed violently against a concrete wall by the lid attached to the conveyor. Employee #1 sustained a seri ous injury to the groin area and had surgery. He was hospitalized.

Incident on Mar 22, 2006 (fatal): Employee is killed in silo engulfment

At approximately 3:20 p.m. on March 22, 2006, Employee #1, a supervisor for the farm, was performing a clean out of corn feed silo number 111. He entered the si lo to place drainage grates over the Number 1, 2, and 3 augers, when several ton s of corn broke loose from the silo walls and engulfed him, resulting in suffoca tion and death.

Incident on Dec 28, 2004: Employee's fingers are amputated by chain

At approximately 1:30 on December 28, 2004, Employee #1 was adjusting a chain on Birght Coop Chicken Loader Number 204. The chain was located under a panel at t he end of the conveyer where the chickens were placed into storage units for tra nsport. Employee #1 stated that the loader operation key was in the off position and the device was idling while he was performing the adjustments. The chain co uld be activated by a button at the control panel or by a trip sensor, which all owed the chain to move one cycle. Employee #1's hand was under the chain making minor adjustments when the chain activated, amputating four of his fingers. Empl oyee #1 was hospitalized and treated for his injuries.

Incident on Aug 23, 2004: Employee's finger is amputated when pulled into running fan

On August 23, 2004, Employee #1, a maintenance mechanic, had been troubleshootin g a problem with a 36-in. exhaust fan in a chicken house. He unplugged the fans electrical cord from the wall next to the fan unit. When finished, he plugged th e cord back into the wall. Since the fan is on auto-start according to the contr oller, it did not start up. The employee proceeded to wipe off the dust that acc umulated on the fan motor when the fan did auto-start. The exhaust air grabbed t he rag he was using and pulled it and his hand into the fan blade. Employee #1 w as hospitalized with an amputated finger.

Incident on Dec 6, 2003: Employee amputates finger while operating pallet jack

Employee #1, a sanitation worker, was operating a pallet jack at a chicken proce ssing plant. The pallet jack went into reverse causing his fingers to become jam med between the pallet jack and an electrical plug on the wall. His right ring f inger was amputated at the first joint and he was hospitalized. The employee was not certified to operate an industrial truck.

Incident on Sep 24, 2003: Fall

This is a non-reportable injury, this was determined after the investigation.

Incident on Oct 7, 2002: Employee's hand caught in machine

At approximately 7:10 p.m. on October 7, 2002, Employee #1 of Foster Farms was c leaning the auto loader leg processor when his hand was caught and crushed in th e moving parts of the machine. Employee #1 sustained lacerations to his right ha nd and was hospitalized at California Pacific Medical Center.

Incident on Dec 14, 2001: Employee injured when finger caught in machine

At approximately 7:15 a.m. on December 14, 2001, Employee #1 was standing betwee n two taping machines. As the employee was aligning the rails on the indexer of one of the machines, his right hand slipped down into the sprocket and chain dri ve mechanism, resulting in the amputation of the tip of his right ring finger. T he employee was wearing gloves at the time of the accident. The chain guard on t he machine was damaged and ineffective, creating an opening and exposing the spr ockets to contact by the employee.

Incident on Nov 7, 2001: Employee's finger amputated in automatic feeder machine

On November 7, 2001, Employee #1, a member of the brooder crew, was repairing on e of the automatic feeder machines in Brooder Barn Number 8 of Foster Farms broo der facility in Riverdale, CA. The machine had not been deenergized. It was only turned off at the local switch. Employee #1 was using the belt and pulley to ro ll the gears to install a sheer pin when another employee attempted to start ano ther feeder and turned on the switch to the one being worked on. Employee #1's h and was pulled into the belt and pulley and it severed the left index finger. Em ployee #1 was taken to Hanford Community Hospital for emergency treatment.

Incident on Aug 1, 2000 (fatal): Employee killed when run over by front end loader

Employee #1 was a truck driver at a fertilizer plant owned by Foster Farms. At t he time of the accident, he and a coworker were at a chicken ranch in Atwater (C A). They had finished loading their trucks and were almost done servicing the fr ont-end loader when the coworker drove the loader forward, running over Employee #1. He sustained multiple crushing injuries and was pronounced dead at the scen e. The coworker did not see Employee #1 before striking him.

Incident on Oct 18, 1999: Employee injured when fingers caught in chain sprocket drive

On October 18, 1999, Employee #1 received an amputation injury to the index fing er and middle finger on his right hand when it was caught in a chain and sprocke t drive that restarted as Employee #1 attempted to clean off the build-up of glu e on the box machine at this poultry processing facility. Employee #1 was hospit alized for treatment.

Incident on Jul 22, 1999: Employee's fingertip amputated in stretch wrap machine

Employee #1 was running an Ossid 500 stretch wrap machine when the product being run through became hung up in the transition area. He called maintenance, which adjusted the machine and turned it back to the production crew. The problem kep t occurring so Employee #1 began using his left hand to push the product through the machine. He was pushing a package past the guard when the cutting arm swung down, amputating the tip of his middle finger.

Incident on May 24, 1999: Employee injured when thumb caught by conveyor

On May 24, 1999, Employee #1 was loading a conveyor with Styrofoam trays for pac kaging chicken. He reached under the guard for the conveyor's chain and sprocket s drive to unblock a cart loaded with Styrofoam trays. The bottom of the 15-in. by 9-in. by 18-in.-high guard was open allowing Employee #1's left thumb to be c aught by the machine and amputated. Employee #1 was taken to the hospital.

Incident on May 24, 1999: Employees injured from chemical exposure

At approximately 1:00 a.m. on May 24, 1999, various employees at the brown meat deboning tables in a production and packaging area complained to maintenance per sonnel about an odor in a drain channel adjacent to the deboning tables. The mai ntenance person, who was not authorized to mix chemicals, procured one gallon of hypochlorite solution and mixed it in a 5-gallon bucket of water and poured the solution down the drain channel. There was a release of chlorine gas or hypochl orite vapor which caused respiratory irritation to the employees adjacent to the drain channel. An emergency shut down was started and 11 employees were taken t o the hospital. Two employees were given a couple of days off and the other empl oyees returned to work. After interviewing the shop steward and personnel on the line and reviewing the Fresno City Police report it was evident that the employ ee who mixed the chemicals had violate company policy.

Incident on Jun 24, 1998: Employee injured when fingertip caught in machinery

On June 24, 1998, Employee #1 was the machine attendant on the wrapping machine in the packaging department of a chicken plant. The line consisted of long trays of chicken parts being wrapped with stretch wrap film. Employee #1 attempted to remove some stretch wrap film that had become caught in the gripper chain area. Employee #1 did not shut down the machine prior to pulling/repositioning the fi lm wrap as required by company policy. As a result, Employee #1 lost the fingert ip of the middle finger of his left hand. No hospitalization was required at the time of the incident.

Incident on Apr 21, 1998: Employee injured in fall from tank truck ladder

Employee #1, a tank truck driver, was assigned to pick up beef fat at a customer 's facility. He pulled into the loading area and climbed the ladder on the side of the tank trailer to open the hatch. When he pulled down the loading spout he found it did not line up, so one of the customer's workers jumped in the truck a nd moved it, but in the wrong direction. Employee #1 lost his balance and fell a pproximately 8 ft 8 in. to the ground. He fractured his right hip and injured hi s lower back.

Incident on Feb 21, 1998 (fatal): Employee killed when arm got caught in auger

At approximately 3:20 p.m. on February 21, 1998, Employee #1 of Foster Farms stu ck his hand into a vertical auger to clean off debris. While his hand was in the auger, the equipment was inadvertently started. The equipment had not been de-e nergized and locked out. Employee #1's left arm was crushed, resulting in nerve damage. Employee #1 died as a result of his injuries.

Incident on Nov 15, 1996: Employee's fingertips amputated in packaging machine

On November 15, 1996, Employee #1, an experienced production worker, was changin g the wrapping film on a Pioneer packaging machine for boneless turkey breasts. The normal procedure was to stop and lock out the unit, and to then attach the n ew film to a remnant of the old film roll. Employee #1 attempted to feed the new film by hand while a coworker jogged the packaging machine. Employee #1's right index and middle fingers became caught between a vertical sheet metal panel and the rising conveyor pocket. The tips of both fingers were amputated, including some bone loss. The employer was cited for a general violation of T8CCR 3314.

Incident on Dec 12, 1996: Employee injured in fall from ladder on truck

Employee #1 was standing on a ladder on a truck, removing a hose used to pump ou t material from the spill catch outer tank. The hose became hung up, so he gave it a strong pull. The hose released, and Employee #1 lost his balance. He fell 5 to 6 ft, landing on his head. He was taken to the hospital.

Incident on Jun 27, 1996: Employee's ankle fractured between pallets in moving truck

On June 27, 1996, Employee #1 was locked inside a van trailer by two coworkers i n an incident of horseplay. The truck driver was then signaled to pull forward. Employee #1 was trapped between sliding pallets when the truck moved, and he suf fered a serious ankle fracture. No management personnel were present nor did the y have reason to believe that such an incident would occur. No violations were f ound.

Incident on May 18, 1995: Employee's finger's partly amputated by quill puller machine

At 2:00 a.m. on May 18, 1995, Employee #1 was cleaning at a poultry processing f acility. He was attempting to pull turkey feathers out of a quill puller machine and received a partial amputation of the right thumb and tip of the right index finger. It was not determined whether the machine was on at the time of the acc ident or if someone inadvertently turned it on. The machine is comprised of two in-running 3 in. diameter, 2 ft long rolls with a 1 1/4 in. slotted opening 51 i n. above the floor. The employer has an effective safety program and energy cont rol program.

Incident on Aug 20, 1995: Employee's leg injured by falling storage rack

Employee #1 was using an electric pallet jack to move a rack that was partially filled with egg trays. The rack began to tip, and Employee #1 slipped and fell w hile attempting to prevent the rack from falling. The rack fell on his right leg . Employee #1 required hospitalization.

Incident on May 24, 1995: Employee's fingers amputated in auger

Employee #1, of Foster Farms Inc., was washing down equipment with a hose when h e saw a piece of chicken skin stuck to the side of a hopper that collects scraps . He decided to step over a section of machinery to get to the hopper. Without t hinking, he reached down to push the scrap skin into the hopper. His fingers cam e in contact with the auger and two fingers on his right hand were amputated to the first joint.

Incident on May 23, 1995: Employees exposed to chlorine gas from water chiller

Employees of Foster Farms noticed a chlorine odor in the water chiller area and evacuated the plant. Employees working near the 20 ft by 50 ft by 3 ft water chi ller were exposed to chlorine gas in an unknown concentration. A feed valve of t he chlorine system malfunctioned, releasing a higher than normal amount of chlor ine gas into the chilled water. Water concentration levels went from a 25-to-28 ppm range to 35 ppm, according to the plant engineer. No employees were admitted to the hospital, but all were given the option to undergo a medical exam. Nine of the plant's 300 employees were taken to emergency rooms. They were released.

Incident on Jan 31, 1995: Employee scalded by hot water from process boiler

On January 31, 1995, Employee #1 was checking a process boiler that had been shu t down the previous day. He had been instructed to determine whether the boiler' s pressure and temperature were low enough to proceed with opening of the top in spection hatch. Employee #1 proceeded to the top of the boiler, completely relea sed the strong back bolts, and pried open the inspection hatch. He apparently ma de no attempt to relieve the boiler's residual pressure, or to make sure that th e water level was below the hatch, as per written procedure. He sustained seriou s scalding injuries to his face, arms, back, and legs, and was hospitalized unti l February 17, 1995. .

Incident on Sep 16, 1994: Employee's arm struck by rotating shaft

Employee #1, of Foster Farm, was cleaning a piece of equipment that was energize d and running. When he attempted to clean an area next to a rotating shaft, his arm became caught by the shaft and was broken in two places.

Incident on Mar 3, 1992: Employee's finger crushed between two racks, later amputated

Employee #1, of Foster Farms, was positioning metal racks containing turkey prod ucts. Each rack is equipped with four wheels, two stationary and two swivel. A h andle on the swivel end is used to maneuver the cart. The cart fully loaded, as it was the day of the accident, weighs 1,500 lb. Employee #1 was attempting to p osition the cart between two other carts. Rather than having all his fingers ins ide the handle, Employee #1 had two fingers of each hand outside the handle. As he positioned the cart, he smashed the little finger of his right hand between t he cart that he was positioning and a stationary cart. His finger was so severel y smashed that his doctor decided to amputate it.

Incident on Mar 14, 1992: Employee's fingers damaged by drill cord

Employee #1, of Foster Farms, was using a 0.5-in., low-speed-high-torque drill t o ream out calcium deposits from the tubes in a heat-exchanger unit. A drill bit hung up in one of the tubes, and the drill was pulled from his hand. The drill' s cord wrapped around Employee #1's left hand and severely injured his left inde x and ring fingers. The drill was not equipped with a deadman switch.

Incident on Jan 14, 1992: Employee's finger amputated in gizzard machine

At approximately 7:00 p.m. on January 14, 1992, Employee #1, an experienced line worker for Foster Farms, noticed that the M-60 gizzard machine on line A-2 was plugged with chicken parts. Although she knew the proper disconnecting procedure , she circumvented it by lifting the guard and reaching into the machine. The do or interlock, which had been installed as an additional safety measure, was not adjusted to stop the machine, and the machine amputated one of Employee #1's fin gers. Employee #1 had recently been promoted to trainer and was on a promotion p ath to assistant foreman.

Incident on Jul 10, 1990: Employee's arm fractured in moving conveyor

Employee #1, of Foster Turkey Products, returned from her regular afternoon brea k to the opposite side of the turkey boning line (a regular practice designed to reduce repetitive trauma exposure). She had left her mesh glove and arm guard h anging on a sharpening steel attached to the turkey shackle conveyor frame. She reached through the conveyor frame to retrieve the glove and arm guard. The movi ng frame conveyor shackle trapped her arm against the conveyor frame, fracturing the right ulna. Employee #1 said she did not realize that reaching through the conveyor could cause injury, and did not recall a work rule or warning not to re ach through the running conveyor. She also did not recall receiving any training on the subject.