Assessing Hazardous Substances Exposure in a Manufacturing Environment

The Challenge

A large manufacturing facility operating multiple production areas required independent occupational hygiene support to evaluate employee exposure to a range of hazardous substances, including:

• Airborne inhalable and respirable dust.
• Volatile Organic Compounds (VOCs).
• Formaldehyde.
• Ozone.
• Antimony compounds.

While existing controls and health surveillance arrangements were in place, the organisation needed robust, defensible evidence to:

• Confirm compliance with Workplace Exposure Limits (WELs).
• Understand exposure patterns across different work activities.
• Verify that risks were being controlled to as low as reasonably practicable (ALARP).
• Identify any practical improvements to strengthen long-term control.
   

The Approach

Sysco Environmental carried out a structured hazardous substances assessment in line with the Control of Substances Hazardous to Health (COSHH) Regulations, HSE guidance L5, EH40 and relevant MDHS methodologies.

The assessment programme included:

• Personal air monitoring of operatives across multiple exposure groups.
• Static air monitoring to assess background concentrations and contaminant spread.
• Monitoring for dusts, VOCs, aldehydes, ozone and process-related substances.
• Review of ventilation arrangements, work practices and housekeeping methods.
• Evaluation of RPE provision, training and health surveillance arrangements.
• Accredited laboratory analysis using recognised analytical methods.
   

Monitoring was undertaken during normal operating conditions, ensuring the results reflected typical day-to-day exposure.

The Findings

The monitoring results demonstrated that:

• All measured substances were below their respective Workplace Exposure Limits.
• Exposure levels across production areas were generally low and well controlled.
• Dust, VOC and gas concentrations did not present a significant risk under existing controls.
• Static monitoring confirmed limited migration of contaminants beyond active work areas.
• Housekeeping practices, particularly dry sweeping and compressed air use, had the potential to unnecessarily increase airborne dust if not managed carefully.
• Existing health surveillance arrangements were appropriate and effective

The findings confirmed regulatory compliance while highlighting opportunities to reinforce good practice and prevent avoidable exposure.

The Recommendations

Although no exceedances were identified, Sysco Environmental provided proportionate, preventative recommendations focused on maintaining control and minimising future risk, including:

• Avoiding dry sweeping, favouring HEPA-filtered vacuuming or wet cleaning methods
• Minimising the use of compressed air for cleaning tasks to prevent dust clouds.
• Ensuring LEV systems are examined and tested at statutory intervals.
• Continuing routine review of COSHH assessments and exposure data.
• Ongoing communication of monitoring results to employees to reinforce awareness.

These measures were designed to support continuous improvement, not reactive compliance.

The Outcome

The assessment delivered:

• Clear, defensible evidence of COSHH compliance.
• Reassurance that existing controls were effective across varied production activities.
• Practical insight into small behavioural and housekeeping changes that reduce risk.
• Confidence that employee exposure was being responsibly managed and monitored.

Most importantly, it provided the organisation with clarity and assurance, ensuring that low exposure levels were not assumed — but proven.

Why This Matters

Hazardous substances risks are not limited to exceedances alone. This case study demonstrates how proactive occupational hygiene monitoring supports informed decision-making, validates control measures and helps organisations stay ahead of risk — protecting both people and business continuity.