This article explores the potential health effects of working in a dusty environment.It also acts as a guide to controlling dust emissions in accordance with the HSE.

The effective management of dusty environments is essential to protecting the operatives working across your food production site.

Finding the right approach can also help to drive standards of food safety and productivity, securing a reduction in wasted time, effort, resources, and product.

With this in mind, we have created a comprehensive guide to dust management, addressing the key health and safety concerns, and sharing important guidance relating to HSE and COSHH. We have also highlighted four solutions that could help you to make improvements in this area.

What are the potential health effects of working in a dusty environment?

In 2013, HSE published Dust in the workplace: General principles of protection. This leaflet outlines the best way to control and limit dust exposure in work environments. It also addresses the potential health effects of repeated exposure to dust. The health effects listed below are arguably the most pertinent to those working in the food production industry, but there are a wide range of other effects to consider. Click here for further information.   

Discomfort and distraction 

If your team is exposed to a high number of dust particles, they may experience irritation of the nose and throat. In some cases, this can make breathing difficult. Dust can also get in the eyes, compromising vision. As a result, your operatives could become uncomfortable, frustrated, and less productive. They could also become more prone to accidents or injury, distracted by the constant source of irritation. 

Breathing difficulties and ongoing health conditions 

Some dusts (e.g. flour and grain) are respiratory sensitisers and have the potential to trigger occupational asthma. Symptoms of this condition include coughing fits, wheezing, tightness of the chest, and either a streaming or blocked nose. This can even lead to extrinsic allergic alveolitis, which can present as a fever, continued breathlessness, and weight loss. 

What are the legal requirements surrounding dusty environments? 

Under the Control of Substances Hazardous to Health (COSHH), many dusts, including flour, are assigned specific Workplace Exposure Limits (WELs), with increasing emphasis on measuring and actively reducing exposure levels in line with HSE guidance. 

However, HSE still advises sites handling substances without a WEL to “set their own in-house standards, taking into account good control practice”. This will involve carrying out a thorough risk assessment of your site, considering the following factors: 

  • The type of dust exposure
  • The square footage of the environment
  • The potential health risks to employees
  • How the dust exposure occurs
  • The necessary control measures
  • Any relevant emergency procedures

Updated HSE guidance on flour dust exposure limits

As mentioned above, flour dust is subject to defined Workplace Exposure Limits (WELs):

  • Long-term exposure limit: 10mg/m3 (averaged over 8 hours)
  • Short-term exposure limit: 30mg/m3 (averaged over 15 minutes)

However, recent guidance from the HSE has made it clear that because flour dust can cause occupational asthma, exposure should be reduced as far below these limits as is reasonably practicable.

The HSE suggests that if effective control measures are in place, levels of below 2mg/m3 (averaged over 8 hours) should be achievable.

This represents a significant shift, as instead of simply staying below legal thresholds, sites should be striving to reduce exposure to the lowest possible level.

View the updated HSE guidance on flour dust exposure

How do you control and limit dust emissions at your food factory?

HSE recommends a variety of control measures for the management and reduction of dust emissions, ranging from improved ventilation to the use of closed containers.

The damping down of materials is also suggested; however, this is unlikely to be a suitable choice for factories with dry environments – handling ingredients such as bread flour and spices.

Other control measures include minimising the height that your materials are allowed to fall from and automating the dustiest parts of your process. Again, this may not be something your site will be able to action or control. 

Below, we have listed the most relevant control measures presented by HSE. We have also highlighted solutions that could help you to drive standards in each area: 

Sites are advised to “maintain a high standard of cleanliness”

The key to maintaining a high standard of cleanliness at your site is to make sure you are using the right tools for the job. In dry environments with a lot of dust, it is ill-advised to use hard-bristle brushes as they are likely to produce a dust cloud. However, you may find that a sweeper with extra-soft-bristles resolves this issue, gently moving the dust without causing too much disruption.

Squeegees are another option to consider. Although they are often found in wet environments, they are also suited to dry conditions – capable of moving dust without stirring up a cloud.

Double-blade squeegees are a great choice for moving dust in a safe and controlled way. Used in a dry environment, it is also less likely that the space between the blades will become a harbourage point, especially if your equipment is cleaned correctly.

However, it’s important that you weigh up the introduction of any new equipment against your site’s existing policies, along with the expectations of your customers and relevant auditing body. It might be that you decide a single-blade squeegee is better suited to your application.

Learn more about the Klipspringer range of Hygiene Equipment

One of the suggested control measures from HSE is to “use a vacuum cleaner or wet method to keep floors and surfaces clean and to remove any spillages”

As previously discussed, a wet method will likely be the wrong choice for a food factory handling dry ingredients. Fortunately, vacuum cleaners provide a suitable alternative, helping to limit the amount of dust in a working environment, without over-agitating the particles to produce a cloud.

What’s important is finding the right attachment for your vacuum. If you are working in an ATEX environment, you will require a vacuum cleaner and attachments designed with this specific application in mind. Alternatively, for a standard dusty environment, you should consider the benefits of a squeegee vacuum attachment or a brush attachment with silicone bristles.

In the interest of providing support in this area and resolving a common industry challenge, Klipspringer has developed a range of vacuum cleaners and colour-coded attachments. In the image above you will see seven examples of the attachments we supply, but there are sixteen designs in total, available in up to five distinct colours.

Explore the full range of Vacuum Cleaners and Attachments

HSE asks that sites are “encouraging workers to work with care and instructing them how to control the dust produced by their work activities”

As with any health and safety concern at your food production site, training and ongoing support is vital. As recommended by HSE, you need to make sure your team is aware of the potential health effects of repeated exposure to dust.

Your operatives should also know exactly how to combat this issue – controlling and (where possible) limiting the amount of dust particles in their working environment. One of the best ways to reinforce key messaging is through the introduction of visual management solutions and safety signage. By placing highly-visual health and safety signs around your site, you can ensure the safe management of dust is at the forefront of everyone’s mind. You can also highlight the importance of essential actions such as using the right equipment, managing any spills immediately, embracing a ‘clean-as-you-go’ approach, and wearing the correct PPE.

Learn more about Visual Management Solutions

Another potential control measure is to “provide [your team with] personal protective equipment (PPE) such as gloves and coveralls”

On the subject of PPE, HSE also highlights the importance of personal protective equipment. From selecting the right protective clothing to making sure each item of PPE is the right size for your operatives, there are a wide range of factors to consider.

Just remember that although HSE recognises the importance of effective personal protective clothing, it also states that “PPE should only be considered as a control measure as a last resort.” Put simply, it should be used by your site, but never as the only measure in place to keep your operatives safe.

Discover our complete range of PPE and gloves

That brings us to the end of our guide to controlling and limiting dust emissions in a food factory. We hope this article has highlighted the potential health effects of working in a dusty environment and has inspired you to take the necessary measures to protect your team.

As addressed throughout this guide, the effective management of dust will not only keep your operatives safe, but will also help to drive standards of food safety and productivity.

If you require further guidance in this area or would like to learn more about the solutions mentioned in this article, the Klipspringer team would be happy to help with your enquiries. You can contact us on 01473 461800 or sales@klipspringer.com. Alternatively, you can use the form below to arrange a consultation. 

If you would like further support as you manage dust emissions, we would be happy to help. Share your details below and one of our friendly team members will be in touch.