Hazard Identification, Risk Assessment, and Control Measures in Industrial Systems: Process Safety in the California Corn Chip Industry

The International Labour Organization (ILO) reports that 2.3 million people die each year from work-related illnesses or accidents. These incidents result in hospitalizations and prolonged absences from work. It is estimated that in the United States, the cost of these problems represents 4% of the annual global gross domestic product. This study focused on the analysis, evaluation, and control measures in the corn chip manufacturing industry in California, with the goal of minimizing risks and hazards to workers. The Risk Control Hierarchy (RCH) was applied along with a semi-quantitative risk matrix validated with historical accident data (2022–2024). The results indicate a 12% reduction in accident rates after implementation, from 18.5 to 16.3 incidents per 100,000 work hours. Engineering controls, particularly the design of the ventilation system and process automation, contributed most significantly to the risk reduction. It is concluded that carrying out this type of analysis serves as a basis for planning efficient and reliable management activities and strategies to prevent occupational risks to which workers are exposed in this type of manufacturing industry.