For families to enjoy pristine milk and other dairy products, strict processing guidelines must be followed throughout the entire manufacturing process. Those tasked with pasteurizing and turning raw milk into delicious cheese are required to wear dairy processing protective clothing to protect themselves and others. Wearing proper personal protective equipment (PPE) also helps prevent unwelcome contaminants from tainting dairy foods in processing plants. 

How Large is the Dairy Processing Industry?

The U.S. dairy farm industry employs more than 160,000 people to process products from nearly 10 million milk cows. The number has remained relatively static over the last 25 years, despite the U.S. population increasing by almost 50 million in the 21st Century.

The revenue generated from U.S. dairy products is expected to exceed $45.5 billion by the end of 2024. It has increased from $40.5 billion over the last five years, hitting a high of $57.3 billion in 2022. Family farmers associated with the Dairy Farmers of America accounted for $24.5 billion in 2022, an increase of more than 25 percent from the previous year.

The challenge for industry leaders has reportedly been onboarding qualified people at every level and ensuring that U.S. dairy products remain pure. The latter requires stringent collection and production steps, as well as training new hires in how to properly use dairy processing protective clothing and equipment.

What Do Dairy Processing Industry Occupations Involve?

People who work in dairy processing plants are part of a larger food supply chain. The production cycle begins on farms where cows are fed, watered, sheltered, and milked 2-3 times daily. During the milking process, for example, dairy processing safety clothing such as splash-resistant aprons and gloves are typically mandated.

Once raw milk is transported in sterile vats by semi-trucks, it must be integrated into a sanitizing system that moves it through a variety of processing pathways. One of the largest outputs is the milk families use for breakfast cereals and beverages. However, products such as cheese, ice cream, yogurt, butter, and creams also require stringent processing from people in occupations such as the following.

  • Production Line Workers & Supervisors
  • Batch Makers & Chemical Technicians
  • Occupational Health & Safety Specialists
  • Pest Control Specialists
  • Commercial Motor Vehicle & Forklift Operators
  • Manufacturing Plant Cleanup Crews
  • Food Preparation Workers

People who directly convert raw milk into desirable products must follow dairy processing safety protocols to prevent contamination. But, to a large degree, extensive PPE for dairy processing must be adorned by those in charge of cleaning and sanitizing vats, cookers, and lines that transfer milk through a plant. The pasteurization process highlights the number of incremental steps required to prepare milk for human consumption.

How Does Milk Pasteurization Work?

The purpose of milk pasteurization is to eliminate any harmful bacteria that could result in a food-borne illness. Common diseases from drinking contaminated milk include listeriosis, typhoid fever, tuberculosis, diphtheria, and brucellosis. The U.S. Food and Drug Administration (FDA) warns that drinking unpasteurized milk also puts people at risk of illnesses such as salmonella, E. coli, and general “food poisoning.”

The FDA warning should also be taken seriously by dairy processing employees who encounter raw milk that can splatter. Below are pasteurization steps that always require PPE for dairy processing.

  • Chilling: Raw milk must be promptly chilled to ensure it does not spoil or allow bacteria to grow.
  • Pre-Heating: Raw milk is initially brought to approximately 105 degrees Fahrenheit.
  • Clarification: This step is designed to remove solid particles from the warm milk. It may involve running the liquid through metallic filters. Many modern dairy processing plants employ spinners that rely on centrifugal force to separate solid matter. Separators are also used to “skim” the cream and use it for other dairy products.
  • Standardization: During this phase, the cream or “butterfat” may be re-integrated into the pure milk liquid. Managing the amount of cream put into a given grade allows plants to create standard grocery store options such as low-fat, skim, 1 percent, 2 percent, and whole milk.
  • Homogenization: Homogenization essentially breaks down fat globules that make milk inconsistent. The goal is to produce smooth, drinkable milk products. 
  • Heating: The semi-refined milk is then raised to 160 degrees. Although this temperature is below the boiling point, it effectively kills harmful bacteria.
  • Chilling: Now pasteurized, the milk is transferred to a cooling container. The temperature used to store the pasteurized milk is approximately 39 degrees.

Pasteurization is not necessarily restricted to dairy processing facilities. Plants that produce soups, stews, canned goods, baby formula, pasta sauces, beer, condiments, and even toothpaste follow similar pasteurization steps. That’s largely because pasteurization prevents contamination and extends the shelf life of wide-reaching products.

 

While pasteurization provides enhanced protection against food-related health threats, dairy processing plant workers are confronted with a variety of workplace hazards.

Common Dairy Processing Hazards

Processing raw milk into dairy products goes much further than pasteurization. As the diversity of plant occupations indicates, workers are required to perform peripheral tasks that also expose them to health risks. These rank among the common dairy processing hazards that require PPE and dairy processing protective clothing.

Wastewater Contaminants

Wastewater from dairy facilities can have a negative impact on the environment. It may contain high levels of salt (nitrates), as well as detergents, chlorine compounds, and bacteria. Employees who oversee wastewater processes such as collection, transfers, and cleanup are routinely put in harm’s way.

Solid Waste Risks

The solid organic waste workers encounter due to spillage, clogged filters, and separation expose them to elements that are not necessarily pasteurized. And when milk and byproducts are exposed to warm internal plant temperatures, the risk of illness increases.

Exhaust Gases

Emissions are a common problem at dairy and other food processing plants. In addition to unhealthy carbon emissions, facilities use natural gas and diesel for power. Combustible liquids typically produce flammable gases that pose a health risk when inhaled or ignited. 

Airborne Particles & Biological Hazards

Moving machinery and foot traffic in processing plants tend to kick up dust. The risk of inhaling airborne particles is compounded by equipment exhaust. The issue of workers unknowingly breathing in significant lung and health dangers is compounded by the presence of biological and microbiological elements.

It’s also not uncommon for airborne particles to cause skin irritations. That’s generally why dairy processing PPE, such as breathable masks, eye protection, and coveralls, are mandated in dairy processing facilities.

Food Cleanliness Regulations for Dairy Processing Plants

The FDA enforces General Provisions of Title 21 of the Code of Federal Regulations to ensure “good manufacturing practice” (GMP) standards. To maintain FDA compliance, operations must adhere to the following guidelines.

  • Break Rooms: The consumption of food, beverages, gum chewing, and tobacco products must be confined to break rooms and designated areas. 
  • Hand Sanitization: The FDA, in agreement with the Centers for Disease Control and Prevention (CDC), requires handwashing at the beginning of each shift and before returning to a workstation after breaks.
  • Hair Coverings: Workers are required to don hair nets unless they are wearing dairy processing protective clothing that covers their heads. Beards must also be covered inside a dairy facility.

Like other food processing plants, dairy operations must adhere to strict workplace safety guidelines. The Occupational Safety and Health Administration (OSHA) expands the need for worker protection beyond food-related dangers, requiring PPE for numerous dairy processing jobs.

Required Dairy Processing Protective Clothing

Workplace safety practices in dairy and other food processing environments encompass wide-reaching dangers. These include electricians, machine repair technicians, equipment operators, as well as production specialists.

Each position calls for suitable PPE and disposable clothing to insulate people from imminent dangers. These are types of dairy processing protective clothing companies that would be well-served to stockpile.

  • Splash-Resistant Coveralls
  • Goggles and Face Shields
  • Breathable Masks
  • Gloves
  • Non-slip footwear and/or shoe and boot covers
  • Splash-Resistant Aprons

The best PPE and disposable clothing products can be easily accessorized, allowing dairy processing plant workers to upgrade their protection when necessary. International Enviroguard manufactures and distributes disposable protective clothing for the dairy and agricultural sectors.