How to minimise hazards in a coffee roastery

A coffee roastery is like any other workplace, where operators have a responsibility to keep themselves and their colleagues safe from hazards. The job is not only physically demanding, requiring lifting and moving heavy sacks of green coffee, but it also poses other long-term health risks if proper procedures aren’t in place.

One of the main concerns is the release of volatile compounds and chemicals during the roasting process. While most modern roasteries are required to install extensive ventilation systems, micro-roasters may face a greater risk, as they often operate in smaller spaces without adequate ventilation and infrastructure. 

As this segment of the market grows, it is increasingly important that operators recognise the potential risks associated with roasting coffee and take proactive measures to ensure workplace safety.

This starts with equipment. Poor ventilation, inadequate air filtration, and neglected maintenance can expose employees to toxic emissions, increasing the risk of serious injury.

I spoke with Cree Ou at DiFluid and coffee content creator Daniel Foong to learn more.

You may also like our article on how to create a safe and healthy roastery.

Why is safety so important in a roastery?

Workplace health and safety are critical in any roastery. The work can be strenuous and potentially dangerous if operators don’t properly manage the risks.

Roastery employees handle equipment set at very high temperatures, ranging from 160°C to 220°C (320°F to 428°F). Even brief contact with surfaces above 43°C (109°F) can cause severe burns and injury.

Lack of routine equipment maintenance is another safety culprit. Failing to regularly clean chaff collectors, cooling trays, and air ducts, for instance, can lead to buildup and create fire hazards, putting both people and nearby equipment at risk.

Coffee can easily burn or catch fire if overroasted, so roasters must be attentive and stay diligent with their maintenance tasks. 

Roastery work often involves physically demanding tasks, including lifting heavy sacks of coffee, standing for long hours, and working in hot environments.

Sacks of green coffee weigh anywhere from 50kg to 70kg (110lbs to 154lbs), which is up to three times the safe single-person lifting limit, according to the UK’s government body responsible for workplace safety. Handling injuries account for over a third of all workplace injuries in the UK, underscoring the importance of proper ergonomics and ample support, such as lifting aids.

Roasteries are busy and often crowded spaces, so operators must set up their facility to optimise their workflow and prioritise staff safety – and this is especially important for smaller facilities.

There should be clear pathways, adequate space around machinery, and designated work zones to ensure staff safety. All exits, first aid kits, and fire extinguishers should also be clearly marked and easily accessible.

A lack of proper training can also lead to various safety risks for coffee roasters. Every staff member should know how to operate equipment and understand the importance of using safety devices – like turning on ventilation or wearing masks – to prevent accidents.

What are the health risks of working in a coffee roastery?

The roasting process itself generates carbon emissions and other hazardous gases from fuel combustion. Roasting also releases smoke, odours, fine particles, and volatile organic compounds (VOCs), including diacetyl (2,3-butanedione) and acetyl propionyl (2,3-pentanedione) into the atmosphere. 

These emissions not only contribute to greenhouse gas pollution but can also pose serious long-term health risks if proper safety and health measures aren’t in place. 

“VOCs such as benzene and formaldehyde are highly volatile and can irritate mucous membranes when inhaled, and long-term exposure may result in chronic pharyngitis or rhinitis,” says Cree Ou, a structural engineer at DiFluid, which designs and manufactures tools and technologies for specialty coffee professionals. “These fine particles (≤2.5 µm) can carry toxic substances deep into the respiratory and circulatory systems.”

Prolonged exposure to VOCs and fine particles can cause various health problems, ranging from eye and respiratory irritation to nervous system damage and increased cancer risk.

When inhaled, there is a minimal chance that chemicals such as diacetyl and acetyl propionyl can contribute to a rare lung disease called bronchiolitis obliterans, more commonly known as “popcorn lung”.

“Benzene has been classified by the International Agency for Research on Cancer (IARC) as a Group 1 carcinogen, and long-term exposure can increase the risk of leukemia, such as acute myeloid leukemia,” Cree says. “Formaldehyde and polycyclic aromatic hydrocarbons (PAHs) are associated with an increased risk of cancers such as nasopharyngeal and lung cancer.” 

Traditional roasters that feature open-structure atmospheric drum housings add to these dangers. The burner draws in air and releases emissions directly back into the roasting space. 

Confined roasting environments can also exacerbate this problem.

“Small home roasters like me often think it’s sufficient to open windows, but without a proper ventilation system, we can still potentially inhale and may irritate our lungs or cause respiratory issues in the long run,” says Daniel Foong, a coffee content creator in Australia.

Coffee grinding in production facilities can also produce high levels of diacetyl and carbon monoxide, which can lead to serious respiratory health risks. 

Safety solutions for smaller coffee roasters

Operators have a responsibility to maintain a safe workspace for themselves and their team. A big part of that is minimising exposure to harmful chemicals and health hazards.

Regular equipment maintenance and a clean facility help reduce the risk of smoke and fire. All staff members should also have easy access to safety equipment, including first aid kits, gloves, and dust masks. 

It’s equally important to invest in tools that help reduce exposure to toxic emissions, including ventilation systems and air quality monitors to test the air for VOCs.

However, safety and proper ventilation are often overlooked, especially in smaller roasteries. While large-scale roasteries require complex and energy-heavy ventilation systems, these setups aren’t practical for smaller operations.

“A proper ventilation system is usually bulky or expensive,” says Daniel. “To suit small roasters’ needs, smaller footprint, efficient, and quiet ventilation systems usually work better.”

The DiFluid AirWave, for example, is a modular catalytic air filtration and purification system that offers odour removal, precise temperature control, and 130m³/h suction power for optimised airflow.

“The AirWave is compact and thermally insulated, and it’s designed to efficiently handle exhaust gas from machines roasting up to 1kg of coffee,” says Cree. “This makes it especially suitable for small-scale roasters with limited space and capacity needs.” 

The OmniVision Integration feature adjusts energy use and filtration efficiency, helping lower energy consumption. The AirWave’s fully recyclable metal body also helps reduce maintenance and lowers the equipment’s environmental impact.

How automation is helping roasters prioritise health and safety

Most roasters understand the importance of workplace health and safety. However, with rising operational challenges and tighter margins, it’s not always at the forefront of their priorities.

Newer systems, such as the DiFluid AirWave, utilise smart technology to automate key health and safety tasks, enabling roasters to concentrate on other areas of operations.

“Users can adjust the air speed depending on the roast level,” says Daniel. “This can be done within minutes, so the user can now focus on roasting in a safer environment.”

The AirWave also combines high-temperature decomposition and catalytic purification to optimise air filtration automatically.

“When exhaust gas first enters the heating zone, small-particle-size materials undergo pyrolysis and volatilisation in the high-temperature environment. Larger particles are removed by a pre-positioned physical filter,” Cree explains. “The gas then flows into the catalytic reaction zone, where VOCs are completely oxidised into CO₂ and H₂O on the catalyst surface. 

“Test results show that the removal efficiency for key pollutants such as VOCs can reach up to 99%, significantly reducing emission hazards and ensuring environmental and personnel safety.”

The AirWave also features a 400°C self-cleaning mode that reduces airflow obstructions and can extend the lifespan of the filtration materials by up to 300%.

“The self-cleaning mode uses higher temperatures to clean the internal catalyst, while the system automatically adjusts to optimal airflow,” says Cree. “This allows roasters to operate without worrying about exhaust gas buildup, helping them maintain a healthier and safer workplace with less manual intervention.”

Between the heavy lifting and exposure to hazardous emissions, coffee roasting can be a demanding and tough job. Investing in proper health and safety measures will remain essential for reducing injuries and health risks in roasteries.

As operators continue to face tighter margins, rising costs, and an increasingly long to-do list, there will be an even higher demand for intelligent, automated systems that help them prioritise health and safety without adding to their workload.

Enjoyed this? Then read our article on what roasters need to know about analysing green and roasted coffee.

Photo credits: DiFluid

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Please note: DiFluid is a sponsor of Perfect Daily Grind.

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