Safe Handling of Barrel Aged Beers

Presented by Andrew Dagnan

MBAA Rocky Mountain District Meeting

February 23, 2017

Agenda

• Barrel Hazards Overview

• Safe Barrel Handling

• Safe Barrel Storage

• Additional Quick Tips

– Chemical safety, PPE, general safety tips

This won’t cover every hazard. If this presentation is

missing something, let’s discuss.

DISCLAIMER• This is a basic overview of hazards related to barrel aging beers and methods

to reduce risk and/or to ensure regulatory compliance.

• While every effort has been made to assure the information provided herein is complete and accurate, it is not intended to take the place of published rules, statutes, regulations or your responsibility concerning the use of proper procedures. The contents of these tools may not be relied upon as a substitute for your responsibility to incorporate the most current text or information.

• The Master Brewer’s Association of the Americas (MBAA) does not assume any responsibility for omissions, errors, misprinting or ambiguity contained within this publication and shall not be held liable in any degree for any loss, or injury, caused by such omissions, errors, misprinting, or ambiguity in presentation.

• If legal advice or other expert assistance is required, the services of a competent professional person should be sought.

• Sources:– Dagnan, Andrew. “Barrel Aging Beers: Handling and Storage Safety.” MBAA District

NW Fall Meeting. Hood River, Oregon. November 14, 2014

– Pictures: sources are listed below the picture

Hazards Overview

• Barrels are HEAVY!

– Up to 100 lb. when empty

– Up to 600 lb. when full

• Barrel stacks can be unstable

• Ergonomics – moving/lifting barrels

• Barrel washing – hot water and chemical usage

• Pressure – pressure can build up during fermentation and from filling/emptying

Safely Handling Barrels

• Use a powered industrial truck (e.g., forklift or powered pallet jack) to move the barrels

BEST Method

Source: www.inboundlogistics.com/

Safely Handling Barrels

• Carry on your shoulder

WORST Method

Source: www.kegconditioning.com

• Use a powered industrial truck (e.g., forklift or powered pallet jack) to move the barrels

BEST Method

Powered Industrial Tucks – DOs• Written program & training per OSHA requirements

• Daily inspections– Each shift if a 24-hour facility

• Maintain trucks per manufacturers’ requirements

• Limit access to PIT areas

• Wear high-visibility vests in PIT areas

• Follow safe operation procedures

– Wear seat belt, lower load before moving, do not speed, etc.

Source: www.worldofstock.com

Powered Industrial Tucks – DON’Ts• Don’t load a PIT over its rated capacity

• Don’t allow anyone on a PIT, other than the operator

• Don’t use if it has failed an inspection

• Don’t drink and drive

• Don’t catch falling barrels (or kegs)

Source: www.giphy.comSource: Family Guy

Moving Barrels with a Forklift

• Move less than 4 barrels at a time

– Ex: Stack of 2, 2-barrel racks

• Can pick up racks from front or side

• If picking up from the side:

– Use fork extensions

– Set the rack as far back as possible to minimize tilting/shifting

– Tilt the forks backwards

Source: www.winebusiness.com

Manual Material Handlers

Source: www.reighleyresources.com Source: www.vestilmfg.com

Pallet Jack Portable Lifter

Manual Handlers – Safe Practices

• Use manual material handlers with extreme

caution!

– Use only if a powered industrial truck can’t be used

• Ensure equipment is rated to handle the weight

– Full barrel = 600 lb.

• Use only with at least 2 people to help push, pull,

and/or steer

• Wear steel-toed footwear

Moving 1 Barrel – Forklift Attachments

Source: Cascade Corporation Source: RGP Industries Source: Deschutes Brewery

Moving 1 Barrel – Rack Adapter

Source: www.carolinawinesupply.com Source: www.carolinawinesupply.com

Never move 1 barrel on a 2-barrel rack without an adapter!

Storage Safety

• Have trained forklift driver to properly center

racks evenly

• Place racks onto barrels, leaving ≥ 1 in. from

edge

– Helps prevent racks from sliding off barrels

• Use caution when stacking different sized

barrels

• Never climb barrel racks

Storage Safety

• Stack barrels as low as

possible (< 4-5 tiers high)

– Don’t overload the bottom racks

• Wrap the top layers, if stacking

empties on pallets

Source: www.whiskeytangoglobetrot.com

Source: Breckenridge Brewery

Rack Safety – General Tips

• Inspect racks for rust, bends, cracks, or other

damage prior to use

• Use caution when purchasing refurbished racks

– Could be rusted on the inside

• Replace racks per manufacturers’ recommendations

– Ex: Western Square recommends 6 years; RGB

recommends 15 years

• Immediately remove any damaged racks from

service

Pressure Safety

• Barrel heads have been blown-off while emptying under pressure and steam cleaning

– Example: Racking wand can clog with fruit, increasing pressure in the barrel

• Ensure you have a PRV

– Inspect PRV’s regularly

• If possible, don’t tighten into bunghole to allow pressure to escape

• Maintain a low pressure when emptying

– Rack-it-Teer: PRV set to 13 PSI

– Bulldog: Recommends under 15 PSI

Source: Breckenridge Brewery

Seismic Hazard

• 6.0 earthquake near

Napa, CA on 8/24/14

• $80M+ in damages and

lost product

• Could damage or losses

have been prevented?

– Better racks

– Better

practices/procedures

– Insurance

Source: www.kqed.org/

Seismic Risks in the US

Seismic Risk Controls Examples

Source: www.barrelsafe.comSource: www.barrel-racks.com

Source: www. barrelsandracks.com

Rack on Rack System Top Cap

4 Barrel Racks

Additional Quick Tips

Barrel Turner

Chemical Hazards

Hazard Controls

General Safety Tips

Barrel Turner

• Used to turn full barrels upside down when

cleaning and/or swelling barrels

Source: www.thevintnervault.com

Source: King Estate Winery

Chemical Hazards

• If using chemicals, follow supplier

recommended safe practices, controls, and PPE

• Chemicals potentially used:

– Sodium Metabisulfite – Slightly acidic, irritant

– Sulfur Dioxide (SO2) – Irritant, can be toxic if inhaled

– Ozone – Strong odor, irritant, highly reactive

Hazard Controls• Eliminate hazards before

controlling

• Example:

– Only move barrels when required

– Place barrels on rack and fill/empty in place

– Move barrels with a forklift

– Procedures/training for using forklift

– PPE: steel-toed boots, safety glasses, high-visibility vest, etc.

Elimination / SubstitutionElimination / Substitution

Engineering Control

Engineering Control

Administrative Control

Administrative Control

PPE

Effe

ctive

ne

ss

Typical Minimal PPE for Handling

Barrels

Safety glasses Cut-Resistant

Gloves

Safety shoes

(e.g., steel toed

boots)

Additional Resources

• MBAA Brewery Safety Committee

– Written safety programs

– Toolbox talks

– Q&A section

– Ask questions on MBAA forums

Additional Resources (cont.)

• Brewer’s Association Safety

• Contact your insurance carrier

• Contact your vendors

• Brewing Engineering and Plant Operations,

MBAA Practical Handbook for the Specialty

Brewer, Volume 3

Summary

• Use caution when using, moving, and storing

barrels

• Have program and documented training for

forklift use

• Properly store barrels at the lowest heights

possible

• Inspect your racks for damage

• Watch pressure when filling, emptying, and

cleaning

THANK YOU!

Andrew Dagnan

Environmental and Safety Manager

Breckenridge Brewery

Andrew.Dagnan@breckenridgebrewery.com

Cell: 865-742-9792