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Diacetyl (2,3-butanedione) is a chemical used to add flavor and aroma to food and other products. Diacetyl and its substitutes are commonly manufactured in microwave popcorn and flavoring production plants, and they also are used in the making of beverages, snack foods, baked goods, prepared canned and frozen foods, and candy (OSHA, 2010a, b). Food and Drug Administration (FDA, 2011) classifies diacetyl and its substitutes as "generally recognized as safe (GRAS)."
While the substance may be safe to consume, that does not mean it is safe to work around. Through extensive research and case studies, NIOSH has found that diacetyl is a standard air contaminant in the popcorn and flavoring industry (OSHA, 2010a, b) . Numerous jobs may expose workers to diacetyl, including mixing, weighing, pouring, transferring or other handling activities, as well as during cleaning and maintenance operations, quality assurance and laboratory work (OSHA, 2010a, b).
Ih May 2000, numerous workers at a microwave popcorn processing facility displayed similar respiratory symptoms and, ultimately, developed bronchiolitis obliterans (OSHA, 2011a, b, c). Since bronchiolitis obliterans is an uncommon lung disease, the local health department (Missouri Department of Health and Senior Services) launched an investigation and requested NIOSH's assistance. NIOSH (2003a, b; 2006) linked the development of bronchiolitis obliterans to occupational exposure to diacetyl. Bronchiolitis obliterans became known as popcorn workers' lung due to the correlation of the disease with the butter flavoring of microwave popcorn (Kanwal & Kullman, 2007; NIOSH, 2003a, b). Many lawsuits from popcorn and flavoring plant workers, as well as regulatory concerns, soon followed.
NIOSH's investigations sparked OSHA's interest. The agency added microwave popcorn processing plants to its national emphasis program (NEP) in 2007 (OSHA, 2007a, b; 2011a, b, c). OSHA launched this program to address controls required to reduce and eliminate occupational exposure to diacetyl. In addition, OSHA (2007a, b) added the industry to the targeted inspection list and offered compliance assistance to processing plants.
Health Effects & Treatment
OSHA Administrator David Michaels stated, "It is alarming that workers continue to be at risk of dying from exposure to diacetyl and diacetyl substitutes. Illnesses and death from these chemicals are preventable" (OSHA, 2011c). Inhalation of and physical contact with diacetyl can result in many health effects; contact can lead to eye, nose,...