Burrito Plant Death Calls for Safety Shift, Experts Say
Three workplace safety experts from different disciplines highlight the importance of precautions, training, and culture in food manufacturing operations following a 19-year-old burrito factory employee’s death during equipment cleaning.
On July 13, a 19-year-old man died while cleaning an industrial food processor at Tina’s Burritos factory in Vernon, Calif., according to reports from ABC 7. Vernon Police told ABC 7 the tragic incident occurred when the processor unexpectedly activated while the man cleaned. It is unclear what caused the machine to turn on or what precautions the facility had in place to prevent such accidents, but manufacturers can learn from the incident and gain insight that may prevent future tragedies.
Curtis Chambers, a Certified Safety Professional (CSP) who possesses a Master of Science in Occupational Health & Safety and serves as President of OSHA Training Services, says incidents like the burrito factory one happen more often than they should.
“As a board-certified safety professional with 35-plus years of experience in occupational safety and health experience, I have seen similar accidents occur way too frequently. And it usually comes down to two things: either the employer did not implement adequate lockout/tagout (LOTO) procedures to be followed during equipment maintenance and servicing (including cleaning), or the procedures were in place, but one or more employees were not adequately trained,” Chambers shares with ProFood World.
Chambers says it is important that employees performing cleaning should be authorized to do so, however, “in many cases, someone who just operates or cleans around machinery and is not authorized to perform service or maintenance on the equipment takes it upon themself to put themself in a dangerous position to try and take care of a problem, sometimes because they do not know any better.”
It is unclear whether the burrito factory employee was a designated cleaner for the processor, but Chambers stresses that adequate training helps prevent accidents. The cause of the incident will be unknown until OSHA releases its report on the matter, Chambers says.
If OSHA finds certain safety violations, the burrito company, or any food manufacturing facility an incident like this occurs in, may face significant financial penalties. OSHA may impose up to $16,550 for what it considers “serious” violations, according to the agency’s website. The same amount can apply if a company has a “failure to abate,” or failure to correct a previously cited safety violation. “Willful or repeated” violations can cost up to $165,514 per violation.
Moreover, a company may have to provide additional financial compensation to a victim’s family or other employees, pending lawsuits.
As seen, safety breakdowns in food processing operations can have a costly impact are only part of the reason why preventative systems are important.
Experts agree that proactive safety culture is key
Commitment to a stronger safety culture is needed to further prevent accidents, says one expert.PMMI Business Intelligence: 2024 Technology & Workforce: Using Smart Technologies to Bridge the Skills Gap
Like Chambers, Career Nomad CEO Patrice Williams-Lindo, a seasoned management consultant executive with experience advising Fortune 100 companies in workforce transformation, safety culture, and operational risk, believes a systems failure likely contributed to the tragedy.
“Preventing workplace accidents in food manufacturing begins long before anyone clocks in. It requires a proactive safety culture, not a reactive one—where lockout/tagout procedures are non-negotiable, training is routine and scenario-based, and supervisors are empowered to halt production when lives are at risk,” Williams-Lindo says.
Williams-Lindo stresses that adherence to safety procedures should take precedence over the urge to cut corners to meet quotas, especially during overnight or under-supervised shifts. ABC7 reported the burrito factory incident occurred around 9:30 p.m., which may have been the early parts of an overnight shift or the later parts of a second shift. Neglecting to follow preventive procedures can dangerously signal “that efficiency above all things is the order of the day,” Williams-Lindo warns.
As Chambers questioned if the young employee was authorized to clean the processor, Williams-Lindo concurred, asking if the worker was specifically trained to clean without assistance from someone else.
For additional precautions, Williams-Lindo says automated cleaning systems, particularly Clean-In-Place (CIP) systems that allow internal cleaning without disassembly or human contact, can reduce exposure risk, yet “automation alone doesn’t solve for lax enforcement or insufficient oversight. Tech is only as safe as the policies around it. In addition to regular checks, it is critical that policies are being followed and updated regularly.”
Williams-Lindo’s broader message touches on the fact that compliance does not necessarily mean safety. Incorporating a stronger culture and empowerment amongst workers is key.
“Many food manufacturers pass audits but fail to embed safety into their culture. And yes, this is a culture shift, one that requires end-to-end involvement from all parts of the organization. We need a transformation from chasing efficiency at all costs, to protecting workers at all levels, especially young, inexperienced, undertrained, or non-unionized employees who may not feel empowered to say, ‘this feels unsafe.’ This is where workplace safety is rooted in psychological safety and vice versa,” Williams-Lindo states.
Safety culture shifts may sometimes occur through legal action, and Will Pemberton, Owner and Personal Injury Attorney at Pemberton Personal Injury Law Firm, offers his perspective on the employee tragedy.
“The sudden and tragic demise of any person performing their job duties is something that should be completely preventable. It is up to each industry to find ways to protect its employees through greater education and safety measures. Failing to do so can be viewed as negligent behavior, which may see legal filings soon follow,” Pemberton shares.
As previously mentioned, legal filings may be sought by a victim's family, regulatory agencies like OSHA, or other connected third-parties such as company employees.
Like Chambers and Williams-Lindo, Pemberton believes that proactive planning is essential in preventing such fatal incidents.
“The tragic death of the burrito factory worker will likely haunt the remaining employees for the rest of their lives. Preventing accidents like these involves putting plans into action and stepping up automated systems to reduce the strain on workers,” Pemberton states. “It is unclear at this time what caused the machine to activate, though finding ways to keep employees safe in the event of an unusual occurrence is best for avoiding such horrific outcomes. Beyond company responsibility for machinery, each one should promote safety and continue education and safety programs for all workers.”
Accidents in food processing operations are not completely unavoidable, but with strict adherence to safety precautions, training, and culture, the likelihood tragedy occurs can be reduced.
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