Rubber Manufacturing Exposure Monitoring Case Study | COSHH & LEV Assessment
A specialist manufacturer supplying the automotive and industrial sectors engaged Sysco Environmental to assess employee exposure to rubber fumes, rubber process dust and associated airborne contaminants. The assessment identified significant exposures requiring further control improvements while confirming compliance with Workplace Exposure Limits.
The Challenge
Rubber processing operations can generate airborne contaminants associated with:
Compression moulding
Injection moulding
Plastic processing
Finishing and inspection activities
The client required evidence-based monitoring to:
Evaluate employee exposure levels
Verify effectiveness of Local Exhaust Ventilation (LEV)
Assess compliance with COSHH Regulations
Identify opportunities for further exposure reduction
Sysco Environmental's Approach
A detailed workplace exposure monitoring programme was undertaken using recognised occupational hygiene methodologies.
Substances assessed included:
Rubber fume
Rubber process dust
Formaldehyde
Acrolein
Styrene
Hydrogen cyanide
Both personal and static monitoring techniques were employed to evaluate worker exposure and background airborne concentrations.
Key Findings
Workplace Exposure Limits Achieved
All monitored substances were below their applicable Workplace Exposure Limits.
Significant Rubber Fume Exposure Identified
Despite compliance with WELs, exposure monitoring identified significant exposure levels for:
Rubber fume
Rubber process dust
Particularly within:
Compression moulding operations
Rubber injection moulding processes
Because rubber fumes are classified as a carcinogenic-denoted substance, exposures above 10% of the WEL were considered significant and required further action.
LEV Performance Opportunities
Monitoring results and site observations indicated opportunities to improve LEV performance and capture efficiency across production areas.
Recommendations Delivered
Sysco Environmental recommended:
LEV Improvements
Replacement of inefficient ductwork
Reduction of flexible ducting
Improved enclosure of processes
Installation of strip curtains around extraction points
Respiratory Protection Programme
Face-fit testing
Appropriate RPE selection
Air-fed respiratory protection where required
Workplace Practices
Improved housekeeping controls
Elimination of compressed-air clothing cleaning
Enhanced washing and welfare arrangements
Continued health surveillance
Follow-up exposure monitoring
Outcome
The client gained:
Verification of COSHH compliance
Detailed understanding of rubber fume exposure risks
Clear LEV improvement strategy
Prioritised occupational hygiene action plan
Evidence-based recommendations to reduce future exposure levels
The project demonstrates how occupational hygiene monitoring can move beyond simple compliance by identifying opportunities to reduce exposure to carcinogenic substances as low as reasonably practicable (ALARP).
Services Delivered
Rubber Fume Monitoring
Rubber Process Dust Monitoring
COSHH Assessments
LEV Assessment Support
Occupational Hygiene Consultancy
Respiratory Protection Programmes
Health Surveillance Recommendations