Microwave popcorn producers have begun removing Diacetyl from their products due to the risk of lung disease in workers and consumers. This comes more than a year after EPA and CDC reports indicated the chemical Diacetyl was not safe.

Until now the concern was only about cases of Bronchiolitis Obliterans (or popcorn lung) among popcorn plant workers exposed to synthetic butter containing Diacetyl. Due to recent medical cases, consumers are becoming the focus of Diacetyl exposure as well.

Diacetyl

Diacetyl is a natural byproduct of fermentation known as a vicinal diketone. At low level, Diacetyl gives beer or wine a slippery feel. At higher levels one can taste a butterscotch flavor.

Diacetyl also gives popcorn its butter taste. The US National Institute for Occupational Safety and Health has long advised that when used as an artificial butter flavoring one should avoid inhaling it over a long period.

Bronchiolitis obliterans is an uncommon and serious lung disease that has been found in workers of several factories that produce artificial butter flavorings. Experts say that young, healthy, non-smoking male workers are the most susceptible.

Bronchiolitis Obliterans is also known as "popcorn lung" since Diacetyl is heavily used in popcorn industry and most sufferers of Bronchiolitis Obliterans work in plants that produce popcorn. However, any worker who works with diacetyl has a higher risk of developing the disease, compared to the rest of the population.

A popcorn worker in Missouri, was awarded $2.7 million in July 2005, after developing bronchiolitis obliterans from inhaling diacetyl at work.

Bronchiolitis Obliterans or Popcorn Lung

Bronchiolitis Obliterans is a disease of the lungs. The bronchioles are plugged with granulation tissue. It is a rare and life-threatening disease. This disease must not be confused with BOOP (bronchiolitis obliterans organizing pneumonia), a completely different disorder of the lungs.

A patient with bronchiolitis obliterans may experience shortness of breath and have a dry cough, he/she may also be wheezing a lot. His/her lung capacity will be at about 16% to 21% lung usage, compared to a normal capacity of 80% or more.

There is no cure for this disease, apart from a lung transplant. Treatment is extremely limited.