Rising Scrutiny on Hazardous Substances in Food Production

The Health and Safety Executive (HSE) has stepped up its regulatory focus on the Control of Substances Hazardous to Health (COSHH) Regulations 2002, placing the UK food and drink manufacturing and processing sector under intense scrutiny. Regulatory authorities are intensifying proactive inspections to curb preventable occupational lung diseases, focusing particularly on respiratory sensitisers such as flour dust, grain dust, and potent cleaning chemicals.

Recent legal actions underscore the strict stance regulators are taking against non-compliant operators. For instance, a major food manufacturer was recently penalized with a £120,000 fine after HSE inspections revealed that employees were exposed to excessive levels of inhalable dust. Investigators found that inadequate local exhaust ventilation, dry sweeping with brushes, and the use of compressed airlines to clear dust deposits put workers at grave risk of developing occupational asthma.

Core COSHH Failings Identified by Inspectors

HSE inspection campaigns across large bakeries and food processing facilities have highlighted persistent compliance gaps. Common failures frequently cited by enforcement officers include out-of-date or incomplete COSHH risk assessments, poorly maintained extraction equipment, and a lack of proper exposure monitoring data. Furthermore, inspectors have flagged instances where personal protective equipment (PPE) management was treated as a primary solution rather than relying on robust engineering controls.

  • Inadequate containment and LEV (Local Exhaust Ventilation) maintenance allowing dust leakage.
  • Reliance on unsafe cleaning practices, including dry sweeping and compressed air blowdowns.
  • Insufficient worker training regarding chemical handling and the early signs of respiratory sensitization.
  • Failure to enforce strict occupational exposure limits (OELs) set for hazardous dusts and chemical agents.

Legal Obligations and Employer Responsibilities

Under Section 2(1) of the Health and Safety at Work etc. Act 1974 and the specific mandates of COSHH, employers have an absolute duty to ensure, so far as is reasonably practicable, the health, safety, and welfare of all employees. When handling hazardous substances like flour or aggressive sanitation agents, companies must implement a hierarchy of control—prioritizing elimination and substitution, followed by comprehensive engineering controls and effective ventilation systems.

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Failure to meet these legal requirements can lead to severe operational disruption, unlimited corporate fines, enforcement notices, and potential custodial sentences for negligent dutyholders. Industry experts advise safety managers to review their existing exposure controls and ensure comprehensive workforce training is up to date.

To support organizations in meeting these rigorous regulatory standards and cultivating a safer working environment, comprehensive training solutions are readily available through Abertay Training at https://www.abertaytraining.co.uk.