If you are like me, you get excited about manure processing.
When touring a manure processing facility, I eagerly wait to ask questions about how each system works, how it performs, what problems the operator has run into, and of course whether they would install it again.
What many of us are far less excited to talk about is safety. Regardless, safety is important to ask about, and even more important to actually do.
Putting off a safety assessment or delaying updates to a safety plan is an easy way to end up in a bad situation, telling yourself “I meant to do that.” The best time to start is immediately. After you finish reading this, take a walk through your manure processing system. Bring a notebook and a few other people who see things differently than you do, and start identifying hazards. Look for confined spaces, risks from manure gases, slip and fall hazards, and exposure to moving or rotating parts. Once hazards are identified, the next step is figuring out how to reduce risk. Can a hazard be eliminated entirely by making a design or operational change? Can the risk be reduced through better guarding, ventilation, signage, or communication? Where are chains, barriers, or warning signs needed, and do those signs cover all the languages spoken by people who work on or visit your farm?
Pinch points are a major but sometimes overlooked hazard in manure processing systems, particularly in manure conveyance systems that move material from one processing step to another. Chains, belts, pulleys, cables, and rotating shafts can create severe pinch points. Getting a finger, hand, foot, or piece of clothing caught in these areas can result in serious injury or amputation. Many separation systems include rotating components that operate continuously and may not appear dangerous at a glance. Shields and guards are critical for preventing injuries and must always be kept in place during operation. Older systems deserve special attention, as guards may be missing, damaged, or removed over time and should be replaced if they are not present or no longer adequate.
In addition to moving parts, be aware of components that may become warm or hot during operation. Bearings, motors, gearboxes, and other mechanical components can heat up and pose burn risks, particularly during cleaning or maintenance. These hazards are often located near rotating equipment, increasing the risk of injury if someone gets too close. Heat should be treated as a hazard just like motion, and workers should know which parts of the system become hot during normal operation.
Falls are another serious risk, especially when ladders or elevated access points are needed to reach manure processing equipment for inspection or maintenance. Ladders and stairs must be properly secured, in good condition, have tread for grip, and be appropriate for the task. Workers should never climb while carrying tools or working near operating equipment. Whenever possible, consider whether ladders can be eliminated altogether by adding platforms, stairs, or guardrails that provide safer access. Many falls occur during routine maintenance, not unusual events, so these access points deserve careful attention.
Transfer channels, receiving pits, tanks, and other manure structures present a serious hazard. These areas should be clearly identified and physically protected using grates, covers, chains, or guardrails to prevent anyone from falling in. Signage should be visible and understandable to anyone who may be on the site, including visitors and contractors. Do not assume familiarity with the system means awareness of the risk. Any opening large enough for a person to fall into should be protected at all times, not just during operation. These protections are especially important in low-light conditions, during maintenance, or when surfaces are wet or icy.
Some of the highest-risk activities occur during cleaning and maintenance. These tasks can involve exposure to manure gases, sharp components, hot surfaces, fall hazards, and moving equipment that can cause catastrophic injuries if someone reaches into an operating system. Lockout–tagout procedures are essential before performing any maintenance. Equipment must be fully powered down and secured so no one can accidentally start it while work is being done. This means never reaching into a processing system while it is operating, not even for a quick adjustment or “just one thing.” The system must be completely off before any work begins.
Maintenance often involves chemicals as well. Workers need to be trained in chemical safety, have access to safety data sheets, and know where those sheets are located before using any product. Training should happen before chemicals are used, not after an incident.
Many manure processing systems are housed inside buildings, and those buildings must be designed with manure gas safety in mind. Adequate ventilation and air exchange are critical to protect human health, just as barns are designed to protect animal health. Buildings should be designed to prevent gas accumulation, eliminate dead air zones, and provide ventilation where manure is present. Electrical and mechanical components in these spaces should be appropriately rated, including explosion-proof equipment where required.
Confined spaces require special attention and specific training. Never assume it is safe to enter a confined space, even briefly, or even if you have done so in the past without consequence. Entry into confined spaces should follow established safety procedures every time. Think carefully about who might enter these areas unintentionally, including small children, and ensure that all necessary protections are in place.
Mobile equipment introduces another set of risks. Areas where manure or separated solids are moved with skid steers, tractors, or other equipment can become extremely slippery, and in winter conditions can quickly turn icy. Equipment can slide unexpectedly, and the risk of crushing injuries is very real. Operate equipment only when other people are not present in the area, use audible backup alarms, and keep work areas as clean as possible to reduce slip hazards.
Design choices can further reduce risk. For example, transfer systems can be equipped with pressure-drop alerts so pumps automatically shut off if a pipe ruptures or leaks, helping prevent spills and exposure. Proper design can eliminate many risks!
Most importantly, once hazards have been identified and risks reduced or eliminated, all employees must be trained in terms and languages they can understand. If you do the work to improve safety but fail to communicate those risks and procedures, you have not actually made the system safer. Regularly scheduled and documented training, updated as systems or practices change, protects not only the people who work on or visit your farm, but also you as the operator. •
Rebecca Larson is a professor and extension specialist with the University of Wisconsin-Madison.
