HSE Sounds Alarm: Food Industry Faces Rising COSHH Incident Rates

The Health and Safety Executive (HSE) has issued a stern reminder to food manufacturing and catering businesses across the UK to diligently review and update their Control of Substances Hazardous to Health (COSHH) regulations compliance. This urgent call comes in response to a discernible upward trend in reported incidents involving hazardous substances within the food sector, leading to occupational ill-health and, in some cases, serious injury.

While specific detailed statistics for the most recent reporting period are still being compiled, preliminary data from the HSE indicates a concerning increase in reports filed under the Reporting of Injuries, Diseases and Dangerous Occurrences Regulations (RIDDOR) related to exposure to cleaning chemicals, allergens, and other hazardous materials commonly found in food production environments. This trend underscores the critical need for robust risk management and comprehensive training initiatives.

A spokesperson for the HSE commented, "The food industry, from farm to fork, inherently involves a diverse array of substances that, if not properly managed, can pose significant health risks to workers. Cleaning agents, disinfectants, flavourings, and even certain food dusts can be hazardous. We are seeing an uptick in incidents that could largely be prevented through better adherence to COSHH principles, particularly in smaller and medium-sized enterprises."

Common COSHH Hazards in the Food Sector

The food industry presents a unique set of COSHH challenges due to the specific nature of its operations. Businesses must contend with a variety of hazardous substances, often used intensively and in close proximity to food products. Key areas of concern include:

  • Cleaning and Disinfection Chemicals: Caustic detergents, sanitisers, acids, and alkalis are routinely used to maintain hygiene standards. Incorrect handling, inadequate ventilation, or lack of personal protective equipment (PPE) can lead to skin burns, respiratory problems, and eye injuries.
  • Food Dusts: Flours, spices, sugar, and other powdered ingredients can cause respiratory sensitisation, leading to occupational asthma. The HSE's 'Breathe Freely' campaign has long highlighted the dangers of airborne particulates across various industries, with food manufacturing being a significant contributor.
  • Allergens: While primarily a food safety concern for consumers, airborne allergen particles during processing can also affect workers, particularly those with pre-existing sensitivities.
  • Refrigerants: Leaks from refrigeration systems can expose workers to hazardous gases, leading to asphyxiation or chemical burns depending on the refrigerant type.
  • Pest Control Substances: Insecticides and rodenticides, while essential for hygiene, are highly toxic and require strict control measures during application and storage.

The HSE emphasises that simply having Material Safety Data Sheets (MSDS) or Safety Data Sheets (SDS) on file is insufficient. Businesses must actively interpret this information, conduct thorough risk assessments, and implement practical control measures.

Strengthening Control Measures: A Proactive Approach

To mitigate the risks associated with hazardous substances, the HSE advises food businesses to adopt a proactive and systematic approach to COSHH management. This involves several critical steps:

1. Comprehensive Risk Assessment

Businesses must conduct detailed COSHH risk assessments for all hazardous substances used or generated in their operations. This includes identifying the substance, evaluating the risks it poses, determining who might be harmed and how, and assessing the likelihood and severity of harm. The assessment should not be a one-off exercise but reviewed regularly, especially when processes change or new substances are introduced.

Related training: If you are looking to qualify as a trainer in this area, see manual handling trainer courses or explore conflict management trainer courses for nationally recognised UK and Ireland qualifications.

2. Hierarchy of Controls

The HSE advocates for the application of the hierarchy of controls to minimise exposure:

  • Elimination: Can the hazardous substance be removed entirely?
  • Substitution: Can a less hazardous substance be used instead?
  • Engineering Controls: This includes local exhaust ventilation (LEV) systems, enclosed processes, and automated dosing systems to reduce exposure at the source.
  • Administrative Controls: Safe work procedures, reduced exposure times, good housekeeping, and clear signage.
  • Personal Protective Equipment (PPE): Respirators, gloves, eye protection, and protective clothing should be used as a last resort, after all other controls have been considered and implemented. It is crucial that PPE is correctly selected, maintained, and worn.

3. Information, Instruction, and Training

Adequate training is paramount. All employees who work with or near hazardous substances must receive comprehensive information, instruction, and training on the risks involved, safe working procedures, correct use of PPE, and emergency protocols. This training should be refreshed periodically and be easily understandable for all staff, including those with language barriers.

4. Health Surveillance

Where appropriate, health surveillance programmes should be implemented, particularly for workers exposed to substances known to cause occupational diseases such as asthma or dermatitis. This allows for early detection of health effects and intervention.

The HSE's guidance, such as HSG258 'Controlling airborne contaminants at work: A guide to local exhaust ventilation (LEV)' and HSG262 'Managing risks from skin exposure at work', provides detailed information for businesses seeking to improve their COSHH compliance. Furthermore, the HSE website offers sector-specific advice for food manufacturing and catering, highlighting common pitfalls and best practices.

By proactively addressing these areas, food businesses can not only comply with their legal obligations under COSHH and RIDDOR but also foster a safer working environment, reduce ill-health, and enhance overall productivity. The cost of prevention is invariably less than the cost of an incident, both in terms of human suffering and financial penalties.

For businesses looking to enhance their understanding and implementation of COSHH regulations, Abertay Training offers comprehensive courses designed to meet UK and Irish regulatory requirements. More information can be found at https://www.abertaytraining.co.uk.