In brief
The most serious risk in candied chestnut production is hot syrup boiling above 100 °C that sticks to the skin; carrying it in buckets and adding ingredients to the pan are the most dangerous moments. The peeling machine, steam, repetitive hand movement with the chestnut knife and –18 °C stores are the other headings. Training and medical examinations of new seasonal workers must be completed before they start work, and hygiene rules and PPE selection should be planned together.
Confectionery production safety: candied chestnuts in Bursa
Candied chestnuts are one of the products most closely identified with the city of Bursa. According to the records of the Turkish Patent and Trademark Office, Bursa Kestane Şekeri (Bursa candied chestnut) was registered as a designation of origin under number 652 on 20.01.2021 in the name of the Bursa Chamber of Commerce and Industry; the registration document states that production began in the early 1900s in the Confectioners' Bazaar and that all stages must be carried out within the borders of Bursa province (registration document). In other words, where this product is concerned, confectionery production safety is entirely a matter for workshops in Bursa.
From this point of view, the production method in the registration document shows clearly where the risks are concentrated:
| Stage | Equipment and work | Main risk |
|---|---|---|
| Receipt and storage | Carrying sacks, frozen storage at –18 °C | Manual handling, being shut in the cold store, cold |
| Outer shell peeling | Peeling machine that scores the shell, elevator | Entanglement in moving parts, noise |
| Inner skin cleaning | Steam softening, cleaning on the belt with a chestnut knife | Steam burns, cuts, repetitive hand movement |
| Boiling | Boiling pans with stainless steel baskets | Hot water, lifting heavy and wet baskets |
| Syrup preparation and cooking | Dissolving sugar, cooking for 45 minutes to 1 hour in open or closed pans | Syrup splashing and boiling over, steam, gas burners |
| Resting and packaging | Hot trays, jars, tins and vacuum packing | Burns, broken glass, trapping in the sealing jaws |
The registration document states that an average of 10–12 kg of sugar and 4 kg of water are used for 10 kg of chestnuts. This ratio also shows how concentrated the syrup in the pans is: as the sugar content increases, the boiling point of the syrup rises above 100 °C.
Syrup burns: the most serious risk at the pan
A syrup burn is more serious than a hot water scald. Syrup reaches temperatures above the boiling point of water, sticks to the skin and keeps releasing its heat there. Burns mostly happen at these moments:
- Splashing when hot syrup is poured over boiled and drained chestnuts or when ingredients are added to the pan
- The pan boiling over, or syrup splashing out during stirring
- Steam hitting the face when the lid of a closed pan is opened
- Colliding with another worker in a narrow space next to the pan
Measures:
- Around the pan: Only the person doing that job is at the pan; walkways do not pass between pans.
- Fill level: The pan is filled leaving room for stirring and boiling.
- Adding ingredients: Chestnut baskets and syrup are added slowly and from low down to reduce splashing.
- PPE: Heat-resistant gloves suitable for food contact; arm protection up to the elbow, a waterproof apron and a face shield for jobs with a splash risk.
- First aid: There is running water near the pan section. Because syrup dissolves in water, the burned area is cooled by rinsing under cool running water for at least 20 minutes; stuck syrup is not scraped off and clothing stuck to the skin is not pulled off. For details, see our article on first aid for burns.
For open gas-fired pans, the tightness of hoses and connections, flame control on burners and ventilation in small premises are also headings for the same section.
Hot syrup handling and sticky floors
In workshops, syrup is often prepared in a separate pan and carried by bucket to the cooking pan. In hot syrup handling, the bucket swings while walking, the person slips or collides with someone, and syrup spills onto the legs and feet.
| Practice | Risk | Safer option |
|---|---|---|
| Carrying by hand in buckets | Spillage, leg and foot burns, back strain | A pump and fixed pipeline, or a lidded wheeled transport container |
| Emptying the pan by tilting it by hand | Uncontrolled tipping of the pan, splashing | Geared or reduction-gear tilting mechanism, bottom outlet valve |
| Lifting baskets by hand | Hot water splashing, back strain | Hoist or lifting device, two-person lift |
When sugar and water combine, the floor first becomes slippery and then sticky once it dries. Spilled syrup should be cleaned up immediately with hot water, floor drains kept open and workers given work shoes with slip-resistant soles. For general measures against slipping, see our article on preventing slips, trips and falls.
A hoist used to lift baskets is lifting equipment and is subject to a periodic inspection once a year. For steam-heated pans, the steam boiler and pressure vessels are also covered by periodic inspection; from 1 January 2027, steam boilers will be inspected by inspection bodies. These inspections are carried out by authorised persons and bodies; we plan the dates and follow up the closure of deficiencies. For details, see our article on steam boiler safety.
Chestnut peeling machine, steam and the chestnut knife
The chestnut peeling machine peels the dried outer shell by scoring it; the chestnuts are then carried by elevator and softened with steam so that their inner skins can be cleaned. Points to watch in this section:
- The rotating and drawing-in parts of the machine and elevator should be enclosed with guards; to remove a jammed chestnut, the machine should be stopped and isolated. For general guarding rules for food machinery, see our article on food machinery safety.
- An arrangement should be in place so that steam does not hit the face and arms when the lid of the steam softening unit is opened.
- On the belt, shell fragments embedded in the flesh are cleaned off with special chestnut knives. This job means repeating the same wrist movement for hours: a knife kept sharp, adjustable belt height, breaks and job rotation reduce hand and wrist problems. For symptoms, see our article on carpal tunnel syndrome.
- Cut-resistant gloves suitable for food contact can be used against the risk of cuts.
Peeled chestnuts are stored at –18 °C. A cold store needs a door that opens from inside, an alarm and clothing suitable for the cold; you can find details in our article on working in cold storage.
Seasonal peaks: new workers and longer hours
Chestnuts arrive in autumn; peeling and freezing work peaks during this period. In periods when sales increase, the cooking and packaging sections become busy. In both periods, short-term workers are added to the staff and working hours get longer.
- Training: Every new worker receives at least 2 hours of face-to-face induction training before starting work; basic training is completed within 3 months at the latest after starting. Rules at the pan and first aid for syrup burns should be covered on the first day.
- Medical examination: A pre-employment examination is carried out. Verify the workplace's hazard class from the NACE code in ISG-KATİP (the Ministry's online OHS registration system); in hazardous and very hazardous work, a worker cannot start without a fitness-for-work report.
- Overtime: Under Art. 41 of Labour Law No. 4857, overtime cannot exceed 270 hours per year and requires the worker's written consent. Fatigue is a direct cause of attention errors at the pan.
- Time allocations and first aid: When headcount increases, OHS specialist and physician time and the number of first aiders are recalculated. You can use the OHS obligations calculator for the calculation.
We gave an example of a calendar dividing pre-season preparation into weeks in our article on the season at tomato paste factories.
Balancing hygiene and OHS
In food production, hygiene rules and OHS rules often point in the same direction; where they conflict, the solution that meets both must be chosen.
| Topic | Hygiene requirement | OHS requirement | Common solution |
|---|---|---|---|
| Jewellery | Must not get into the product | Catching on machines, metal conducting heat | No jewellery in the production area |
| Hair | Hairnet | Entanglement in rotating parts | Hairnet, long hair tied back |
| Gloves | Food-safe, clean | Protection against heat and cuts | Heat- or cut-resistant gloves suitable for food contact |
| Cleaning | Frequent washing and disinfection | Wet floors, mixing of chemicals | Slip-resistant shoes, labelled containers, not mixing products |
| Disinfectant | Alcohol-based hand and surface disinfectant | Flammable product | Using and storing it away from gas burners |
| Workwear | Clean and light-coloured | Closed and long-sleeved against hot liquids | Long-sleeved clothing and a waterproof apron |
Mixing bleach with acidic products during cleaning releases hazardous gas; we explained the rules in our article on cleaning staff risks. A hygiene training certificate and OHS training are separate obligations; one does not replace the other. For details, see our article on the hygiene training certificate.
At candied chestnut and confectionery workshops in Bursa, Bursa Sistemer plans the arrangements at the pan and for carrying through its OHS specialist service, and the seasonal staff's examinations and burn first aid through its workplace physician service, together. For other headings in the food sector, see our food sector page.
Frequently Asked Questions
What should be done first for a syrup burn?
The burned area is immediately held under cool running water and cooled for at least 20 minutes. Because syrup dissolves in water, rinsing also removes it; stuck syrup is not scraped off, clothing stuck to the skin is not pulled off, and no ice or cream is applied.
Do seasonal workers also need OHS training?
Yes. Whatever the length of employment, every new worker receives at least 2 hours of induction training before starting work, and basic training is completed within 3 months at the latest after starting.
Which equipment in a confectionery workshop is subject to periodic inspection?
Steam boilers and pressure vessels, lifting equipment such as hoists, the internal electrical installation and earthing, and fire installations are covered by annual periodic inspection. The inspection is carried out by authorised persons registered in EKİPNET (the Ministry's periodic inspection registration system) or, for the relevant equipment, by inspection bodies.
Does a hygiene certificate replace OHS training?
No. Hygiene training aims to protect the consumer and OHS training aims to protect the worker; the two are based on separate legislation and are obtained separately.
A certified specialist matched to your hazard class: site inspections, approved logbook, training plan, annual plan and report follow-up.
Bursa SİSTEMER OSGB Technical Team — written from the field experience of our OHS specialists and workplace physicians. Legal information is valid as of the publication/update date; contact us for an assessment specific to your business.