How a Moulding Facility in Hampshire Tackled Rubber Fume Exposure Before It Became a Risk

Sysco Environmental Ltd conducted a COSHH-compliant air monitoring assessment at a rubber moulding facility in Hampshire, which manufactures components for the pharmaceutical, aerospace, food processing, and defence industries. The purpose of the assessment was to evaluate exposure to rubber process dust and fumes generated during pressing, trimming, and moulding operations.

Monitoring focused on personal exposure for press machine operatives across various machines during routine operations. The facility operates day and night shifts, with a wide range of press machines in use. While most machines were operational during the assessment, several were offline, providing a representative snapshot of regular conditions.

Health Risks of Rubber Dust and Fumes

Rubber Process Dust

• Health Effects: Respiratory irritation, chronic bronchitis, rhinitis, and potential development of chronic obstructive pulmonary disease (COPD).

• Mechanism: Inhalation of fine airborne particles that can settle in the respiratory tract.

Rubber Fumes

• Health Effects: Classified as a possible carcinogen. Chronic exposure may contribute to respiratory sensitisation and long-term health deterioration.

• Mechanism: Thermal decomposition during moulding releases VOCs and chemicals that can be absorbed via inhalation.

Monitoring Methodology

The assessment followed HSE’s MDHS 47/3 for rubber fume sampling and was conducted in line with COSHH Regulation 10 for air monitoring.

Key Parameters:

• Personal Monitoring: Conducted across multiple operators using body-worn sampling pumps positioned in the breathing zone.

• Sampling Period: 280 minutes average duration (4.6 hours) during normal production.

• Substances Monitored: Inhalable rubber dust and cyclohexane-soluble rubber fumes.

Monitoring Results

Conclusion: All results were below the Limit of Detection (LOD). While exposures did not exceed WELs, recommendations were made to ensure levels remain As Low As Reasonably Practicable (ALARP) due to the carcinogenic classification of rubber fumes.

Key Recommendations for Risk Control

Engineering Controls

• Observation: No Local Exhaust Ventilation (LEV) was installed on press machines.

• Recommendation: Install LEV on moulding and trimming stations, especially where operators enter partial enclosures. Fit air flow indicators and maintain a 14-month testing cycle in line with HSG258.

Respiratory Protective Equipment (RPE)

• Observation: RPE was not used consistently across the site. No face-fit testing had been carried out.

• Recommendation: Provide FFP3-rated masks for spray booth use and specific dust-generating tasks. Implement face-fit testing, track usage, and adopt filter change protocols. For tasks exceeding one hour, powered respirators should be used.

Housekeeping

• Observation: Dry sweeping observed, which increases airborne dust.

• Recommendation: Replace with HEPA-filtered vacuum systems or wet cleaning. Where dry sweeping is unavoidable, ensure RPE is worn.

Health Surveillance

• Status: Ongoing programme in place including lung function, hearing, and biological monitoring.

• Recommendation: Maintain and periodically review the programme, especially due to the carcinogenic nature of rubber fumes.

Training

• Observation: Site training was comprehensive but could benefit from regular refreshers.

• Recommendation: Provide annual training covering:

  • Hazards and control of rubber fumes and dust

  • RPE use and maintenance

  • Spill response and equipment checks

  • COSHH awareness and symptom reporting

Conclusion

Rubber dust and fume exposure at the Hampshire facility was found to be within safe limits, with all readings below the detection threshold. However, the assessment highlighted opportunities for improving control measures, particularly around ventilation, respiratory protection, and cleaning practices.

By implementing the recommendations from Sysco Environmental Ltd, the facility can:

• Further reduce exposure risks to harmful substances

• Strengthen COSHH compliance

• Demonstrate a robust approach to worker health protection