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Popcorn lung, or bronchiolitis obliterans, is a rare obstructive pulmonary disease caused by inhaling diacetyl, a chemical used to flavor butter popcorn. Symptoms include reduced lung capacity, shortness of breath, and wheezing. Safety measures have been implemented to protect workers, and manufacturers have reduced the use of diacetyl. One consumer developed popcorn lung from consuming large amounts of microwave popcorn.
Popcorn lung, or popcorn workers lung, is officially known as bronchiolitis obliterans. It can also be referred to as constrictive bronchiolitis. It is a rare fixed obstructive pulmonary disease in which granulation tissue, or scar tissue, gradually blocks the bronchioles or airways. While there are many other causes of bronchiolitis obliterans, it got its most common name because it can be caused by repeated inhalation of diacetyl, which is used to flavor butter popcorn.
Bronchiolitis obliterans is indicated by significantly reduced lung capacity, shortness of breath, wheezing, and a dry cough. These symptoms are often misdiagnosed as asthma or pneumonia. It is caused by inhalation of toxic fumes, as well as viral infection, graft rejection and collagen vascular disease. In its advanced stages, it is not reversible and is only treatable with a lung transplant.
Although diacetyl is a chemical, it occurs naturally and is found in butter, cheese and wine. It gives popcorn that “natural” buttery flavor that so many people love. Unfortunately, this seemingly innocuous ingredient caused several popcorn factory workers and, as of 2007, at least one consumer, to become seriously ill. The first documented cases occurred in Jasper, Missouri, in 2000 at the Gilster-Mary Lee plant, where eight workers were diagnosed with popcorn lung. These workers had been exposed to diacetyl for an extended period of time while they were microwaving bags of popcorn.
The National Institute for Occupational Safety and Health (NIOSH) conducted a study of 117 popcorn factory workers and found that they suffered from higher rates of airway obstruction, chronic cough, shortness of breath, throat, tightness in the chest and wheezing than normally found in the general population. Because diacetyl is a chemical approved by the Food and Drug Administration for use as a flavoring, there were few precautions in place to protect workers from adverse effects. Since 2000, however, NIOSH has advised the implementation of safety measures for handling diacetyl in order to prevent future lung damage.
Although the Association of Flavor and Extract Manufacturers has assured consumers that there is virtually no risk of developing popcorn lung from consuming buttered popcorn, manufacturers have been recommended to reduce the use of this chemical, primarily to protect plant workers. In 2007, ConAgra, the largest U.S. maker of popcorn from brands like Act II and Orville Redenbacher, teamed up with the Weaver Popcorn Company to replace the flavor.
Since then, 19 factory workers have sued International Flavoring & Fragrances, which is the second largest flavor maker in the world, and won. In 2004, four of the workers received US$53 million (USD) in settlements.
Although consumers have been assured that the flavor is safe for consumption, one consumer developed popcorn lung as a result of his above-average consumption of microwave popcorn. Over a ten-year period, he ate two bags of buttered popcorn every night, inhaling the bags when they came hot from the microwave.
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