Diacetyl Exposures in the Flavor Manufacturing Industry

Abstract

Recently, worker exposures to diacetyl, a chemical used in the production of butter popcorn, has been linked to bronchiolitis obliterans, a severe lung disease. This chemical is also used in the flavor industry to confer a buttery flavor to many food products, with more than 228,000 pounds used in 2005. Diacetyl exposures were monitored at 16 small-to medium-sized flavor facilities to determine potential diacetyl exposures. A total of 181 diacetyl samples (both personal and area samples) were obtained, and a number of real-time samples were collected using an IR spectrometer. Samples were obtained during liquid and powder compounding operations at the facilities as well as during laboratory and QC operations. The personal and area samples ranged from non-detectable (<0.02 ppm) to as high as 60 ppm. Ninety-two (51%) of the samples were below the limit of detection, and the mean diacetyl concentration for all processes was 1.80 ppm. Mean diacetyl levels during powder operations were generally higher (4.24 ppm) than mean diacetyl levels during liquid operations (2.02 ppm). Maximum real-time diacetyl exposures during powder operations could reach as high as 525 ppm. These results are similar to exposures measured by NIOSH in popcorn facilities where lung disease was found; however, the duration of use and frequency of use may be significantly lower.

Speciation of volatile organic compounds from poultry production

“…Areas with the highest concentration were associated with active bird populations and the types of compounds detected in those areas (Table 1) were similar to the types of compounds measured in popcorn flavoring plants (Hubbs et al, 2002). The average air concentration in the poultry facility where birds were located, 1615 mg m À3 , was well below levels detected at popcorn flavor facilities with mean average concentrations of 6317 mg m À3 (Martyny et al, 2008, this assumes temperatures of 25 C at 1 atm for conversion purposes of ppmv to mg m À3 ). The concentration of acetic acid was also concerning since this compound was also found as part of suite of compounds associated with popcorn flavor facilities (Hubbs et al, 2002).…”

Popcorn Flavoring Effects on Reactivity of Rat Airways in Vivo and in Vitro

“…Sahakian et al (2008) demonstrated that butter flavoring-exposed workers have an increased risk of occupational asthma and exacerbated asthma symptoms. The flavorings in popcorn also find use in other foods, including caramel, butterscotch, and vanilla flavors and muffin and cake mixes (Day et al, 2011;Harber et al, 2006;Martyny et al, 2008). Employees in a cookie factory developed bronchiolitis obliterans after artificial butter flavoring exposure while preparing the cookie dough (Cavalcanti Zdo et al, 2012).…”

An evaluation of respiratory health at a flavoring manufacturing facility - Kentucky.

“…Prior evaluations at other flavoring manufacturing facilities demonstrated high diacetyl exposures and lack of effective engineering controls and respiratory protection programs [NIOSH 2007;NIOSH 2008;Martyny et al 2008]. At 16 flavoring manufacturing facilities evaluated by an academic group, diacetyl concentrations in air were as high as 60 ppm, with an average of 1.8 ppm [Martyny et al 2008].…”

“…At 16 flavoring manufacturing facilities evaluated by an academic group, diacetyl concentrations in air were as high as 60 ppm, with an average of 1.8 ppm [Martyny et al 2008]. At a flavoring manufacturing facility evaluated by NIOSH, the company provided air sampling results that documented diacetyl exposures as high as 10 ppm [NIOSH 2011b].…”