Wood Dust Exposure Monitoring in Recycling – Sysco Environmental Ltd Case Study

How a Wood Recycling Facility Tackled Dangerous Wood Dust Exposure

Wood recycling plays a vital role in the UK’s circular economy, transforming waste timber and packaging products into materials for wood board manufacturing, agriculture, and even biofuel. However, the shredding, cutting, and handling of reclaimed wood can release high concentrations of inhalable and respirable dust, which pose significant occupational health risks.

Sysco Environmental Ltd conducted an air monitoring assessment at a wood waste recycling facility in Birmingham. The site processes up to 700 tonnes of mixed wood per week, including hardwoods, softwoods, and engineered boards. Tasks such as shredding, pallet assembly, and vehicle loading create conditions where employees may be exposed to hazardous levels of wood dust, classified under COSHH as both carcinogenic (hardwood) and respiratory sensitisers (softwood).

Why Wood Dust Is a Risk in Recycling

During shredding, cutting, or moving aged or dried wood waste, fine airborne particles are released. Hardwood dust is classified as a Group 1 carcinogen by the IARC due to its link with nasal and sinus cancers. Softwood dust, though not classified as a carcinogen, is a potent respiratory sensitiser, linked to asthma and chronic bronchitis.

In this case, exposure levels in some work areas exceeded Workplace Exposure Limits (WELs) by over 900%, particularly during the use of compressed air to clean shredding equipment.

Air Monitoring Results (Selected Highlights)

Role/Area	Hardwood Dust (mg/m³)	% of WEL (3 mg/m³)	Result
Blow-out Process (Excavator Operative)	27.5	917%	Exceeded
Loader Shovel Operative	10.91	364%	Exceeded
Bandsaw Operator (Pallet Assembly)	11.25	375%	Exceeded
Respirable Dust (All roles)	0.18 – 0.90	Below 25%	Within safe limits

Recommended Controls to Reduce Risk

• Substitute compressed air cleaning with industrial vacuum systems or wet cleaning to reduce airborne dust clouds.

• Install Local Exhaust Ventilation (LEV) on shredders and saws.

• Mandate use of FFP3-rated RPE in high-exposure areas and provide air-fed hoods during “blow-out” tasks.

• Upgrade forklift cabins with full enclosures and seal vehicle doors during operation.

• Enforce PPE use (especially safety glasses) and implement a filter change log for respirators.

• Enhance housekeeping with HEPA-filter vacuums and minimise dry sweeping.

Interesting Facts About Wood Recycling

• The UK recycles over 4.5 million tonnes of wood annually.

• Recycled wood is primarily used to produce chipboard, animal bedding, and biomass fuel.

• Wood recycling reduces landfill waste and significantly cuts down on greenhouse gas emissions compared to incineration.

Conclusion

This assessment confirmed that wood dust levels can easily exceed legal exposure limits in high-volume recycling operations. Although some control measures were in place, further engineering, administrative, and PPE improvements were necessary to reduce exposure to ALARP (As Low As Reasonably Practicable).

Sysco Environmental Ltd provided tailored recommendations to support COSHH compliance and ensure long-term respiratory health for operatives at the site.