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:

Verified COSHH compliance supported by real exposure data
Identification and control of previously unrecognised risks
Improved protection against carcinogens and solvent vapours
Enhanced HSE inspection readiness
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.