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Plastic Fumes Exposure Monitoring & Testing

Plastics are ubiquitous in modern manufacturing and industry, from construction and transport to electronics and packaging. However, heating or processing plastics can release a range of harmful fumes and vapours. Without proper monitoring, exposure to these fumes may lead to serious occupational health hazards including respiratory illnesses, neurological effects, and even cancer.

At Sysco Environmental Ltd, we specialise in helping organisations assess and manage worker exposure to plastic fumes through precise air quality monitoring and compliance-based risk management.

Why Choose Sysco Environmental Ltd for Your Plastic Fumes Exposure Analysis?

Comprehensive Monitoring: We identify, evaluate, and quantify plastic fume exposure during production processes such as heating, moulding, or extrusion.
Expert Compliance: Ensure full compliance with COSHH and EH40 regulations, particularly in relation to carcinogenic and asthmagenic substances.
Tailored Solutions: We customise our monitoring programmes to meet the unique needs of each client, taking into account specific processes and materials.
Your satisfaction is our aim: Our customer testimonials reflect the trust and value our clients place in our service.
Ensuring quality service: Download our Due Diligence Guide to learn how we maintain consistent quality across all our environmental assessments.

Sysco Environmental Ltd brings extensive experience in plastic fumes monitoring, supporting a range of industries from injection moulding and extrusion to packaging and composite manufacturing. Our scientifically robust assessments help ensure safe and compliant workplaces.

Contact Barry

0800 433 7914

Contact Paul

0800 433 7914

Our Plastic Fumes Monitoring Process

Initial Consultation: We start with a detailed discussion to understand your operational processes and exposure concerns.
Risk Assessment: We observe critical areas of concern to determine where fume exposure is likely and assess your current compliance position.
Data Gathering: Air sampling is conducted using validated methods to measure worker exposure levels to hazardous substances including styrene, formaldehyde, acrolein, and PAHs.
Control Evaluation: We assess the effectiveness of Local Exhaust Ventilation (LEV), general ventilation, and PPE systems currently in use.
Reporting: A detailed technical report is provided, fully compliant with BOHS and HSE occupational hygiene standards.
Action Plan: We develop an evidence-based plan to help you mitigate risk and prioritise cost-effective improvements for exposure reduction.

The Importance of Plastic Fumes Occupational Monitoring

Plastics emit a range of hazardous substances when processed at high temperatures. These include styrene, aldehydes (such as formaldehyde and acrolein), phenol, PAHs, and hydrogen chloride. Many of these are classified as carcinogenic or asthmagenic and pose both short-term and chronic health risks.

Hazardous Substance	Short-term Health Effects	Long-term Health Effects
Formaldehyde & Acrolein	Headaches, nausea, pulmonary oedema	Respiratory illness, cancer
Styrene	Neurological effects, altered vision/hearing	CNS damage, hearing loss
Phenol	Respiratory irritation, CNS effects	Liver dysfunction
1,3-Butadiene	Respiratory irritation, neurological effects	Cancer
Butane (and other alkanes and alkenes)	CNS effects, dizziness	Liver and kidney damage
PAHs	Respiratory irritation, red blood cell damage	Asthma-like symptoms, reduced immunity
Hydrogen Chloride	Pulmonary oedema, respiratory distress	Reactive Airway Dysfunction Syndrome (RADS)

Exposure to plastic fumes is especially relevant in the following sectors:

Plastic manufacturing and processing
Injection moulding facilities
Packaging and recycling industries
Composite material production
Automotive and electronics manufacturing

Without adequate monitoring, duty holders risk non-compliance with COSHH and HSE guidance, particularly for carcinogens and respiratory sensitizers where exposure must be kept as low as reasonably practicable.

What Do Our Plastic Fumes Monitoring Reports Cover?

To understand the level of detail and precision in our assessments, download an example report below. Our reports demonstrate how we capture, interpret, and report exposure data to the highest professional standards.

Our reports include:

A summary of the assessment, including fume-producing activities and operational context
Time-weighted exposure data compared against Workplace Exposure Limits (WEL)
Assessment of control systems and personal protective equipment
Photos and schematics for visual clarity
Recommendations for reducing exposure and improving control strategies
Relevant HSE guidance documents
Option for Face Fit Testing services for RPE evaluation