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Bulk Loading Solutions for Food, Beverage, or Pharmaceutical Applications

From fall protection at loading docks to crossovers inside processing plants, we have the safety systems you need to keep your food and beverage business running smoothly. Not only are we North America’s #1 distributor of OPW and Emco Wheaton Loading Arms, but we’ve supplied safety solutions that support everything from liquid chocolate, to dairy facilities, and water bottling plants.

Recent events have led to consumer behavior changes, and with them come opportunities to serve new markets, or serve existing markets in a better way. For instance, beverage manufacturers, specifically alcohol, have been in a booming market that is anticipated to have incredible staying power. The Ready to Drink (RTD) category might be one of the biggest booms in the market generally. Once traditionally focused on a younger audience, the RTD market has been increasing market share like a rocket. From hard seltzers (including new products that are emerging featuring both very low and very high ABV offerings) to craft spirit-branded products, to answer Alan Shepard’s “light this candle”, the candle has been lit and this segment is taking off.

It isn’t just beverages that have seen massive growth. Look at some of the major food corporations who are being asked to produce more and more products not just for our consumption, but whose products are feedstock for an emerging market where the supply simply can’t meet the demand. Soybean oil, for instance, is not going to be able to keep up to demand once renewable diesel becomes more mainstream.

The best way to make sure that you can keep operating during these growth times is to make sure that you keep your greatest asset safe. Safety equals security equals productivity. Give your employees the best equipment to make sure they can give you their best efforts.

Take 10 minutes and learn tips that will help you maximize the safety of your food and beverage manufacturing operations.

Safe food and beverage manufacturing practices are crucial not only to your organization’s bottom line but also to the people who consume your products and the workers who produce them.

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Pharmaceutical Market Specialist

“As subject matter expert, I’ll leverage my years of experience as your personal consultant throughout the project to ensure you get a world-class solution.”

Brian Dieffenderfer

Marine, Food & Pharmaceutical Loading Market Specialist

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Typical Applications Quote or discuss your installation. Start by selecting loading application "" indicates required fields What vehicles are you loading? Top or Bottom Loading/Unloading? Top Bottom How many loading spots? Your information First Name Last Name* Phone* Email* Preferred contact method* Phone Email Company Industry* Zip/Postal Code* Country Message* Do you have project or reference files? Receive Email Updates Max. file size: 128 MB. Product Brochures Download PDF Please mail a brochure What product: ErectaStep SafeRack Address* Address 2 City* State/Province/Region* Hidden Hidden Fields Email This field is for validation purposes and should be left unchanged. Δ Download Sample Project Files Below are some of the loading and unloading solutions for illustrative purposes only. Our experts will work with you and your team for a custom solution to suit your needs.
Food or Pharmaceutical Loading Arms
	Product can be splash loaded into railcars and tank trucks via loading arms or chemical hoses. The current best loading practice is to use a 3″ carbon steel or stainless steel arm for tank trucks with PTFE or ChemRaz seals. Vapor recovery is optional and is used in conjunction with a splash plate, vapor cone, or inflatable hatch seal. Railcar loading will use a similar setup as trucks but with a 4” arm as higher flow rates must be obtained to load the higher capacity vehicles at an acceptable rate. The loading arms layout will ensure that it is self-draining after use as to completely evacuate product when the arm is stored to reduce product leakage which could injure passer-bys and corrode platform, support, and process piping located on the rack. Safety options such as high-level sensors/probes can be added to the arm to switch off loading should the level hit a predetermined height in the vehicles. Example of gravity fed top loading arm: UNLOADING ARMS These are generally 4”, carbon steel, ANSI 150Lb rated loading arms, that will be fitted with quick-couplings and an emergency break-away unit. The arm itself will be fitted to a support standpost, and will be self-draining in design. We would also recommend that the arm be fitted with a parking latch and parking sensor to ensure that the arm is stored in a safe place when not in operation. Example of a gravity fed bottom unloading arm
Food or Pharmaceutical Gangways and Safety Cages
	Since rail cars have off-set crash boxes SafeRack recommends a wider telescoping access gangway (48″-60″ is preferable) as it helps improve access and egress to and from the railcar. In addition, a wider gangway will reduce the risk of the operator’s PPE getting caught, torn or damaged, and will improve productivity and safety. Powered gangway solutions are also an option, with both hydraulic and pneumatic solutions being commonly used. Each gangway will be fitted with a two-rail safety cage for the railcar crash box. This will be a centered 7’6”x 6’ safety cage to sit directly over the cashbox; and will provide a safe, secure work environment for your operator when accessing hatches on railcars. For tank truck applications (loading or unloading) SafeRack’s standard 24” wide Self-Adjusting (SAS) gangway with a deeper 4’x6’x4-rail safety cage would be the preferred solution. GX SELF-ADJUSTING STAIR (SAS) GANGWAY SafeRack’s NEW GX SAS gangways use Retractalok power-assist technology allowing operators to raise or lower effortlessly, light as a feather to lift, solid as a rock. Tested in the most critical applications, this revolutionary new self-adjusting gangway ramp outperforms all others. Available in multiple lengths and widths. GX FLAT RAMP ACCESS (FRT) GANGWAY SafeRack’s NEW GX-FRT is a flat ramp access gangway model popular with railcars. It features a slip-resistant walk surface and, with the use of the telescoping extension, eliminates gaps on narrow railcars.
Food or Pharmaceutical Eye Wash/Drench Showers
	ANSI guidelines state that an Eye Wash/Drench Showers need to be located 10 seconds or 55′ (16.8m) from contaminants or hazardous materials. Eyewash stations need to be on the same horizontal plane with no obstructions. Therefore, we would propose the installation of a standard combination Drench Shower/Eyewash Unit, which will save limited space and fit easily into any work environment. This is a fundamental safety requirement for any loading or unloading station.
Food or Pharmaceutical Spill Containment
	Spill containment pans will be provided at the point of loading operations and is an essential piece of equipment in overall site safety and environmental protection. SafeRack recommends a minimum 20’ long galvanized, polyethylene or composite track pan to mitigate spills. Railcar spill containment and track pans
Food or Pharmaceutical Grounding
	Many food or pharma products are not flammable, industry best practice includes the grounding of all vessels before starting the (un)loading process. Vehicle grounding and bonding — ensure true grounding before product flow is permitted Explosion-proof enclosures — meet or exceed UL, CSA, and Ex requirements
Food or Pharmaceutical Safety Gates
	Safety Gates will be installed at the top of the stairs and any other openings to ensure operator safety at all times. YellowGate Safety Gates SafeRack’s line of industrial safety gates is the most flexible product on the market with the ability to span openings between 16” and 36” and is field adjustable with nothing more than a wrench. We also have guardrails, metal handrails, and full-fledged fall protection solutions with customizable options to fit your needs.
Food or Pharmaceutical Options
	Lighting – Lighting both over and under the platform will be provided. For overcast days or second shift, lighting is essential for improved safety and improved productivity. Platform & Canopies – Full platform canopies reduce exposure to the elements and improve the safe and productive loading operation from the operator’s perspective. Operator Shelter – Depending on your site requirements, consideration should be given to the requirement of an operator or guard building on the loading platform. This can be customized to meet specific site requirements. Wheel Chocks – Railcar Wheel Chocks provide fast blocking of all types of railcars and meet OSHA regulations to safely prevent railroad cars from moving during loading or unloading operations. This is a requirement by the Department of Homeland Security.
Personal Protective Equipment PPE Requirements
Eye/Face Protection: Wear chemical safety goggles. A face shield (with safety goggles) may also be necessary. Skin Protection: Wear chemical protective clothing e.g. gloves, aprons, boots. Wear a chemical protective, full-body encapsulating suit.
Use a local exhaust ventilation and enclosure, if necessary, to control the amount in the air. Consider using a corrosion-resistant exhaust ventilation system separate from other ventilation systems. It may be necessary to use stringent control measures such as process enclosure to prevent product release into the workplace. Use backup controls (e.g. double mechanical pump seals) to prevent the release of this material due to equipment failure.
* For illustrative purposes only. Our experts will work with you and your team for a custom solution to suit your needs

10 Minute Tips: Food and Beverage Manufacturing Safety Reminders

Safe food and beverage manufacturing practices are crucial not only to your organization’s bottom line but also to the people who consume your products and the workers who produce them.

In order to achieve and maintain safety standards in the food manufacturing industry, your organization needs to be committed to current sanitation and security guidelines, proper equipment use and maintenance, and thorough employee training. Not only do all employees, supervisors, and managers need to follow appropriate safety measures, but all of your subcontractors and suppliers need to be up to speed with your standards, as well.

Failing to maintain safety standards can lead to costly recalls, as well as put workers and consumers at risk.

Here are the four main areas of concern regarding food manufacturing safety:

Sanitation

According to the Food and Drug Administration (FDA), poor plant sanitation is one of the biggest factors contributing to food contamination. Food products can become contaminated at any time before, during, or after processing.

Sanitation procedures — including equipment disassembly procedures and methods used — must be documented, as well as the time required, types and amounts of chemicals used, and water temperatures.

All aisles and working spaces should be unobstructed and wide enough to allow employees to perform their jobs and protect against contamination. During processing, employees must use the proper protective products (like gloves, hairnets, and face masks) to prevent contaminating work areas and food, as well as to protect themselves from any bacteria or other pathogens they may come into contact with. There should be adequate drainage of all outside areas that may contribute to contamination, as well as proper spill containment solutions in place to decrease the chances of a spill and mitigate the damage after one.

Equipment Access and Use

Not only must all employees understand and follow equipment guidelines, but no workers should be allowed to operate any machinery without being properly trained on how to use it. Take, for instance, handling hot chocolate to make chocolate-covered treats. Our solution allows temperature control and visual acuity of the hot chocolate via temperature sensors — at the elbows and swivel joints — hard-wired to a Programmable Logic Control (PLC) system. These sensors are then linked to the plant automation system. Truly, we offer a holistic approach that treats the product like liquid gold.

In addition to wearing appropriate safety gear, employees should also avoid wearing any clothing or jewelry that could get caught in machinery. Such incidents can damage equipment, cause workers to become entrapped, and/or result in loose items entering and contaminating food during processing. With this in mind, it is imperative that machine guards are in place during operation and that employees know where to find and activate emergency shut-off switches in the event of an emergency.

Of course, providing workers with safe access to, from, and around the equipment is just as important as them using equipment safely. Not only should aisles and workspace be clear, but proper slip, trip, and fall prevention measures (including warning signs and hazard notifications) should also be in place.

Ergonomically designed gangways and loading racks boost employee and productivity during bulk loading, while crossovers allow workers safe and clear access over conveyor lines, as well as to and from other equipment.

Michael Angelo Winery needed access to stainless steel barrels and fermentation tanks that would keep employees safe without compromising their gorgeous new facility. ErectaStep proposed aluminum stair and work platforms as a customized solution that met the client’s budget and retained the sleek and stylish design they required.

Maintenance

Improper maintenance can lead to damaged equipment, compromised products, and injured or ill employees.

Broken seals can allow unwanted chemicals to seep into your products. Forklifts and other vehicles can expose and damage wires and cables, creating trip hazards. Dull blades can slip and cause jams. Worn-out belts can snap, contaminating food and harming employees.

Preventing these and other maintenance issues will protect both your manufacturing process and your employees.

In addition to keeping equipment clean during use, regular maintenance procedures — like making sure no cable or wires are frayed, or that all chemicals are labeled and used properly — must be followed.

Note: Only qualified personnel should be allowed to service or maintain equipment.

Custom metal stairs in a tight area at a pharmaceutical facility

Pharmaceutical facility access ladder — Replacing an access ladder at a pharmaceutical facility with ErectaStep metal stairs.

metal stairs pharmaceutical facility — Completed metal stair installation.

This ErectaStep installation at a large pharmaceutical company replaces an access ladder and uses mostly in-stock components with some customized parts to fit the tight area. This installation took just one day to install and didn’t require custom equipment or tools to install. No welding was needed either. View more on this project

ErectaStep Catwalk installation at Saint Paul Mountain Vineyards

With 10,000 square feet of space to work with and more than a dozen fermentation tanks to install, a thoughtful access plan would be crucial to the success of the operation. No less significant was a high-end, refined design that would enhance the look of the facility. Unlike projects in the manufacturing and industrial sector, this installation needed a certain aesthetic that would appeal to wine enthusiasts visiting the property. Special events, wine tastings, and tours are routine for St. Paul Mountain Vineyard, so looks topped the priority list.

High-quality, corrosion-resistant components were essential and flexibility in design was a non-starter. Our ErectaStep sales rep was ready with a customized design that could easily be reconfigured as production grew. Owner Allen Ward knew that most facilities have tanks that can’t easily be moved so a versatile catwalk access system was just the solution he was looking for. The pristine look of the winery was matched by a unique, upscale powder coating on the platforms, treads, and towers to match the clean, simple aesthetic of the facility. Lightweight, all-aluminum platforms complete the look while making installation a smooth, easy process.

Food Security

Food products aren’t always contaminated as a result of poor sanitation or an accident. Sometimes, they are tampered with by bad actors via chemical, biological, or radioactive means.

Proper measures must be taken to maintain the integrity of your food chain.

While there are no guarantees when it comes to safety or preventing incidents, you can decrease the likelihood of tampering by employing various safety measures, including fencing, security cameras and teams, metal detectors, open floor plans, and controlled entrances to your facilities

Is your plant or facility compliant with ANSI, OSHA, and local safety codes? We can help!

EMERGENCY EYEWASHES / SHOWER EQUIPMENT AND THE ANSI/ISEA Z358.1 – 2014 STANDARD

Following eye contact, you must start washing with water immediately to prevent permanent damage. In the event of skin contact, you must start washing with water immediately to prevent slow-healing chemical burns.

Are you aware that ANSI guidelines state that Eye Wash/Drench Showers need to be located 10 seconds or 55′ from contaminates or hazardous materials and located on the same horizontal plane, with no obstructions? If bottom loading/unloading, an additional shower should be located at grade as well. SafeRack provides the above equipment plus much more needed to keep employees safe and expedite bulk chemical loading and unloading.

OSHA Regulation Experts – Does your existing chemical safety equipment or chemical loading systems meet OSHA’s latest requirements? SafeRack’s professional technical sales consultants are available to meet with your team to make recommendations to keep your facility in front of OSHA’s ever-changing country and region-specific standards and regulations, including lifeline and trolley beam fall arrest systems, metal stairs, and access platforms.