Creating a safe workspace is more than just a legal obligation—it’s a commitment to protecting the wellbeing of every employee in food manufacturing facilities. When safety measures are overlooked, the consequences can be severe, not only in terms of OSHA fines of up to $15,000 but also through costly lawsuits and damage to the facility’s reputation. Installing essential equipment like safety showers and eyewash stations is about more than compliance, it promotes swift and potentially life-saving action in hazardous moments.
In this blog, we’ll explore the regulations surrounding emergency equipment and the diverse safety shower configurations designed to keep food plants running safely and efficiently.
Code Requirements for Safety Showers and Eyewashes
OSHA regulations apply to all employers in the US and provide the requirements for safety showers and eyewashes. Safety showers and eyewashes are necessary in any facility where employees may encounter corrosive materials. Some requirements for safety showers and eyewashes include:
- Tepid water (60–100°F) must be supplied
- Emergency equipment to be accessible within 10 seconds or 55 feet of the hazard (whichever is shorter) and there must be a clear route to travel
- Thermostatic mixing valve (TMV) requirements including scald protection and cold-water bypass in case of failure
- Potable water must be supplied, and the fixture shall be lead-free and NSF 61 certified
Your state and local codes may have additional requirements, so be sure to reference those when installing safety showers and eyewashes.
Piping Configuration Options
Three of the most common methods of providing tepid potable water to emergency equipment are:
- Hot and cold-water supply to each fixture with point-of-use thermostatic mixing valve (TMV)
- Tepid water supply using a single master TMV
- Cold water supply to point-of-use tankless electric water heaters
Below is a layout of scenarios to show when these different methods might be used. For all three scenarios we’ll supply ten safety shower and eyewash stations in a process area and assume the fixtures are spaced 55’ apart. Please reference the image to see example flow diagrams for each method and access the cost breakdown.
Scenario A: Greenfield Facility
If you are designing a new facility, consider providing hot and cold loops to each emergency fixture. The hot and cold piping systems are likely already a design requirement for bathrooms, handwash sinks, and other fixtures. These systems can also be used to supply emergency equipment, eliminating an additional dedicated system for emergency fixtures and allowing for future flexibility.
Scenario B: Existing Facility
An owner wants to convert an existing space to support a new function that will require emergency fixtures. A single-tempered water loop will fit this need; with one piping loop and one master TMV, it has fewer devices and less equipment to maintain and, therefore, fewer fail points.
Scenario C: Emergency Fixture in Remote Location
A shower is required in a remote location. Routing multiple pipe loops out to the fixture is inconvenient due to the long pipe runs. Instead, you can install local tankless water heaters. A single cold-water pipe and either electric or natural gas can be supplied to the water heater. Local tankless water heaters can potentially put a strain on the electrical or natural gas system. To lessen this strain, manufacturers offer tankless water heaters specifically for supplying emergency fixtures that include scald protection and additional controls.
Other Considerations
There are some general things to consider for all three piping options. Emergency fixture design is largely governed by where it will be located. For example, fixtures in process spaces should be resistant to cleaning chemicals and other fluids. If isolation valves are installed, they must be protected from shutoff, typically by locking the valve open or removing the actuating handle. Emergency equipment must be actuated weekly to verify operation and flush the piping of any debris or impurities. Outdoor installations with cold climates subject to freezing require insulation and heat tracing, and outdoor installations with hot climates require scald-proof valves or recirculation to prevent scalding from the sun.
Smart facility design
Emergency showers and eyewash stations are part of a holistic safety strategy. Prioritizing hazard elimination through smart facility design and safe work practices should always come first. Once those foundations are in place, installing the right emergency systems gives your employees access to immediate protection when accidents happen.
Partnering with an experienced design firm like Mead & Hunt can help you navigate the complexities of regulations and configurations, meet compliance requirements, select the best equipment, and create a safer, more secure environment for everyone in your food manufacturing facility.
