Machine operators are generally aware of the moving dangers and hazards around their equipment.  Though, few are aware of the microscopic hazardous conditions floating in the air they breathe, originating from machining fluids.  Case in point, let’s rewind to 1981 where nearly 40% of workers in a major machining facility developed severe flu symptoms caused by microbial organisms thriving in the coolants and parts washers.  This pathogen was distributed fom one department throughout the entire facility via airborne fluid mist.  We now call this illness Hypersensitivity Pneumonitis.  Related to Legionaire’s Disease, over eight outbreaks have been recorded between 1992 and 1997.

What is HP or Hypersensitivity Pneumonitis?

Sometimes called "Machine Operator’s Lung", hypersensitivity pneumonitis is an alergic reaction; it is not an infection and is not contagious, yet will worsen as exposure continous.  What causes HP is microbial organisms or materials found in water based machine coolants or fluids.  The chemicals and microbes get into and affect the air sacs in the deepest part of the lung.  Symptoms include chills, fever, shortness of breathe and deep cough.  Symptoms are similar to a cold or pneumonia but may only occure while exposed to coolant mist.

What Should Someone Do If They Suspect They Have HP?

See a doctor… preferably one who is board certified in occupational or pulmonary medicine.  It may be helpful to bring along an MSDS sheet for the chemicals used in the machines.  If the doctor is not certified in occupational medicine or pulmonary medicine, he or she may not be familiar with HP and can mistake the symptoms (fever, chills, cough, shortness of breath, weakness, headache, and muscle pain) for pneumonia, flu or sinus problems.  If exposure continues without proper treatment, the illness can lead to permanent lungt scarring and impairment.

Aren’t Workers Faking It If They Suddenly Become Sick After Working at the Same Place for Years?

It is a chance that should not be taken.  Several unknown factors can lead to a sudden outbreak of Hypersensitivity Pneumonitis in your facility.  A subtle change in the work procedure, using a different chemical, changing the product cycle time, failure of air corrections equipment, or merely time to change media filters or wash electrostatic collection cells.  Using biocides to kill existing bacteria can allow different species to invade.  Even with no perceptible change, workers can become physically sensitized to coolant or biocides with no warning.  They may be exposed to the same chemical every day, then suddenly experience a severe reaction.  Once sensitized, even the smallest exposure can bring on shortness of breath, wheezing, asthma, skin irritation, itching hives, airway constriction, coma and even death.

Why Not Use Biocides to Protect Workers?

Biocides can kill bacteria but will also harm workers.  The most common biocides us formaldehyde, which is an irritant as well as carcinogen.  Other biocides are highly toxic when absorbed through skin and corrosive.  Designed to prevent bacteria from living in coolant, biocides can cause worse respiratory problems than the ones they are trying to solve.  Other ways of controlling bacteria include, keeping machines clean, preventing coolant puddles and accumulation on floors and surfaces, removing machine chips, sludge and dirt where bacteria lives and breeds.

Bacteria has and always will be everywhere.  The key is not to inhale it.  Controlling the coolant mist is a much easier solution than killing bacteria.  Use splash guards, hoods and enclosures along with oil mist eliminators to contain the mist, spray and splashing while ventilating exhaust air.

Oil Mist Collection Solves Most Commonly Recognized Occupational Disease

According to national statistics, a skin disease called contact dermatitis is the single most recognized occupation disease.  Dermatitis looks like a skin rash and is caused by cutting fluids.  Outbreaks involve dry cracked scaly skin, pimples on the arms and hands and raw sores.  Symptoms vary between differenent cooling systems.  Generally, detergents in the oil or coolant can remove natural skin oil and cause dryness and cracks that allow infections.  Anti-corrosion, germacidal and other additives in the fluids irritate and sensitize the skin.  Particles and metal shavings in the fluids scratch or cut the skin allowing bacteria to infect.

Using effective oil mist collectors and good cleaning procedures will help limit worker exposure to harmful metalworking fluids.  Be ready for the next OSHA regulations.  Unions are constantly working to make more stringent occupational health and safety regulations.  In 1993, teh UAW petitioned OSHA to cut Permissible Exposure Limit of machining fluids from 5 mg/m3 to 0.5 mg/m3.  According to the New York Committee for Occupational Safety and Health (NYCOSH), "the UAW believes that an exposure limit that’s 1/10 of the currentlegal limit is achievable and would substantially cut the risk ofoccupational cancer and respiratory problems."