Rare lung illness hits popcorn workers in Midwest

SIOUX CITY, Iowa -- An Iowa popcorn plant worker has been diagnosed with a rare lung disease linked to inhaling artificial butter flavoring used in microwave popcorn.

Federal health officials are testing other workers at the Sioux City-based American Pop Corn Co., makers of Jolly Time popcorn.

It is the first reported case at an Iowa popcorn factory. The disease also has sickened at least eight workers at a Missouri plant, where another 21 employees also have shown signs of lung problems.

Concerns about the Missouri case, which occurred in a plant owned by Gilster-Mary Lee Corp. in Jasper, Mo., prompted American Pop Corn to offer free tests to all workers, Elsen said.

Gilster-Mary Lee Corp. has its headquarters in Chester, Ill. The company produces over 8,000 items in over 500 different private label brands in 14 manufacturing facilities across four states, according to the company's Web site.

At least four Missouri workers have sought lung transplants, according to the Centers for Disease Control and Prevention.

The Iowa man was not identified by the company or health officials, who cited confidentiality rules. The man still works at the plant.

His case was described as a "light case" by Tom Elsen, a company vice president. Elsen said the man does not have "a life-threatening situation."

Elsen said the worker's condition was discovered after a federal health team visited the plant last year after the Missouri illnesses prompted a national investigation into the rare disease called popcorn packers' lung, but medically diagnosed as bronchiolitis obliterans, a type of irreversible lung damage.

The disease is not new, but in the past has been associated with inhaling damaging amounts of chemicals such as chlorine or ammonia, according to the CDC.

John Johnson, an environmental engineer with the state health department, said he is not aware of any reports of illness at Iowa's four other popcorn plants.

Elsen said American Pop Corn is cooperating with the investigation, conducted by the National Institute for Occupational Safety and Health, and the Iowa Department of Public Health.

No eating danger

"Obviously, there's nothing to hide. We want to make sure our workers are operating in a safe environment," Elsen said.

Health investigators said there is no evidence of danger to people who eat microwave popcorn. The disease appears to be caused by inhaling large amounts of butter flavoring vapors.

The Iowa worker had noticed his breathing wasn't normal for the past two or three years, said Dr. Richard Kanwal, a physician with the team. No deaths have been linked to the disease.

An inspection of the Sioux City plant last fall found it was well ventilated and mixing room workers for years have worn respirators to filter the air they breathe.

The affected employee no longer works in the department where butter flavorings are mixed with other ingredients.

The plant employs about 150 people, but only two people on each of three shifts work in the mixing room, Elsen said.