COSHH Exposure Assessment & Control in Industrial Laundry Facility in West Yorkshire

The Challenge

A high-throughput industrial laundry facility processing contaminated textiles from manufacturing and printing environments required a formal COSHH assessment to verify worker safety and regulatory compliance.

The site processed approximately 13.5 tonnes of material daily, across operations including:

• Soiled textile sorting
• Automated washing systems
• Clean sorting and packaging
• Chemical storage and effluent treatment

These processes created potential exposure to:

• Volatile Organic Compounds (VOCs)
• Inhalable dusts
• Solvent vapours (e.g. toluene, ethyl acetate)
• Carcinogens, including benzene

Although ventilation and PPE were in place, the business lacked quantitative exposure data and needed to confirm whether controls were truly effective under COSHH. 

Our Approach

Sysco Environmental conducted a comprehensive COSHH air monitoring programme, aligned with:

• COSHH Regulations 2002 (as amended)
• HSE Approved Code of Practice (L5)
• EH40 Workplace Exposure Limits

1. Exposure Mapping

Key exposure groups identified:

• Soiled sorting operatives
• Clean sorting/packing staff
• Engineering/effluent operatives
• Chemical handling areas

2. Air Monitoring Strategy

• Personal monitoring (breathing zone sampling)
• Static monitoring for background exposure
• Sampling aligned with HSE MDHS methods
• Laboratory analysis via ISO 17025-accredited facilities

3. Substances Assessed

• Inhalable dust
• Benzene (Carc, Sk)
• Toluene (Sk)
• Ethyl acetate, acetone, xylene, VOCs

Key Findings
1. WEL Compliance Achieved

All personal exposure levels were below Workplace Exposure Limits (WELs). 

However, this did not eliminate risk.

2. Significant Exposure Risks Identified

Toluene exposure exceeded 10% of WEL in sorting areas
Benzene detected at ~25% of WEL near a dry filling process

Both are denoted substances, meaning:

Exposure must be reduced As Low As Reasonably Practicable (ALARP) - not just below limits.

3. Control Gaps Observed

RPE Issues:

• Available but inconsistently used
• No face-fit testing programme 

Ventilation Gaps:

• LEV present but lacking monitoring indicators
• No LEV in welding/effluent area (non-compliant)

Work Practices:

• Dry sweeping contributing to airborne dust
• Over-reliance on PPE

COSHH Insight

This assessment reinforces a key occupational hygiene principle:
“Compliance with WELs does not guarantee adequate control.”

Under COSHH:

• Carcinogens and sensitisers require stricter thresholds
• Exposure must be reduced beyond compliance
• Engineering controls must take priority over PPE

Our Recommendations

A prioritised improvement plan was delivered:

Engineering Controls

• Install LEV for welding activities (mandatory)
• Upgrade existing LEV systems with airflow indicators

Respiratory Protection

• Implement face-fit testing programme
• Upgrade to vapour-specific RPE (A1 filters)
• Introduce powered respirators for extended use

Process Improvements

Replace dry sweeping with:

• HEPA vacuum systems
• Wet cleaning methods
• Introduce task rotation

Compliance & Monitoring

• Maintain health surveillance programme
• Conduct annual exposure reviews
• Integrate findings into COSHH assessments

The Outcome

The client achieved:

1. Verified COSHH compliance supported by real exposure data
2. Identification and control of previously unrecognised risks
3. Improved protection against carcinogens and solvent vapours
4. Enhanced HSE inspection readiness
5. A clear pathway to achieving ALARP exposure levels

Key Takeaway

“If you’re only measuring against limits, you’re already missing part of the risk.”

This project demonstrates the importance of moving beyond compliance to true exposure control and risk management.

If your site involves dusts, solvents, or mixed exposures - and you don’t have recent, defensible exposure data - you may not be as compliant as you think.

Speak to Sysco Environmental about a COSHH exposure assessment today.