Expert Advice on Dust and Fume Extraction Systems is Vital!

TL;DR: Dust and fume extraction systems are essential for protecting worker health ensuring legal compliance and preventing explosive and environmental risks in UK industry. COSHH HSE DSEAR and ATEX regulations require effective control of airborne particulates through correctly designed LEV systems. Expert assessment correct system selection ATEX-certified components and regular testing and maintenance are critical to maintaining safety compliance efficiency and long-term operational performance.

In a manufacturing, processing or handling environment it is inevitable that dust, mist or fume particulates are produced and become airborne requiring effective dust and fume extraction systems. The control of such particulates are governed in the UK by the Health and Safety Executive (HSE) and under the Control of Substances Hazardous to Health (COSHH) regulations.

The regulations are in place to protect the health of workforces and the surrounding environment. Prosecutions are made against those businesses who do not comply with the required control and measurements.

It is therefore important to ensure the control of hazardous airborne substances for:

• Legal compliance of your business.
• The health and welfare of your workforce.
• Care for your equipment and infrastructure. 
• Protection of the environment.    

Why Dust and Fume Control Is a Legal Requirement

The Health and Safety at Work Act, specifically COSHH, states that a company’s workforce must be protected from hazardous airborne substances. When inhaled, swallowed or when in contact with the skin, these substances can cause an array of health issues which can be long term, or sometimes, unfortunately fatal.

Because of these risks and requirements an employer must:

• Produce a risk assessment on substances produced from their operations. Special consideration should be given to potentially explosive dust.
  
• Prevent or efficiently control particulate exposure for employees to comply with Workplace Exposure Limits (WELs).
  
• Provide control measures in the form of a Local Exhaust Ventilation system as part of compliant dust and fume extraction systems
  
• Ensure operatives have sufficient training and information in regards to the LEV systems – importantly being able to identify if the system is failing. 

The HSE constantly champions the legal right for clean air for workers. Their website has undisputed information on legal responsibilities, best practice as well as tool box talks.

Health Risks of Airborne Dust and Fumes

Historical working routines and long serving employees can sometimes lead to a blasé approach to protection against substances produced as a result of certain processes. Continual exposure to some of the most common dust and fumes can lead to long-term chronic illnesses and respiratory diseases, including some terminal diagnoses such as cancer. 

The below list is by no means exhaustive but gives examples and a stark warning of why dust & fume control along with PPE should be taken extremely seriously.

Industry/Process	Particulate Produced	Primary Health Issues
Mining, Construction & Stone Masonry grinding, chopping & drilling.	Respirable Crystalline Silica (RCS)	Silicosis – incurable lung scarring. Lung Cancer. COPD.
Welding, fabrication, forging and casting.	Welding & smelting fumes as well as fine metal particulates.	Lung Cancer. Neurological damage. Kidney Failure.
Woodworking, carpentry, furniture making	Wood dust & shavings (especially hardwood)	Nasal/sinus cancer Occupational asthma Skin & eye irritation COPD
Bakery	Flour, cereal and sugar dust etc.	Occupational asthma, rhinitis and conjunctivitis.

How Dust and Fume Extraction Systems Work

Hazardous airborne particulates are sufficiently controlled by suitable dust and fume extraction systems incorporating Local Exhaust Ventilation (LEV).

Simplified – A dust collector works by capturing particulates at source, preventing release into the atmosphere. Drawn into the unit via negative pressure, the dirty air is then filtered or separated with the clean air being pumped back out and recirculated.

Different machines have different mechanisms to filter and separate, all dependent on the type of matter. Extraction systems are also available that provide easy waste collection, separation and storage.

Choosing the Right Dust and Fume Control System

Assessing the process, environment and the particulate type is key to providing exacting dust extraction.

Focus should be fixed on:

• Size of Particulate.
• Volume of hazard.
• Level of carcinogenic or toxic values.
• Is the dust sticky, abrasive or moist etc.
• Airflow capacity and pressure required. 
• Air recirculation requirements. 
• Location and operation – space, noise, maintenance.

To ensure that all this is accurately measured and noted it is essential to engage with an industry or occupational health expert. A physical site survey will be required, preferably when the process is active. Any further information that can be provided regarding operations will achieve a dust extraction system correctly tailored to operational requirements.

ATEX and DSEAR Requirements for Explosive Dust 

We have established that an accumulation of dust and fumes can be detrimental to health. However there is another, more instantly deadly factor to consider – the combustible nature of some dust and fumes. 

Combustible Dust – When dispersed into the atmosphere fine dust particles can be at risk of ignition or causing an explosion. The danger is prevalent when five situations come together that will cause an explosion.

Combustible Fume (Flammable Gases)   – When these mix with air the result is the formation of an explosive atmosphere.

Environmental Protection and Emissions Control

Due to the severe conclusion, if the combustion equation comes together, there are a set of directives in place to protect workers, reduce risk and to ensure safe operation of equipment used in explosive atmospheres. These directives are:

DSEAR – implemented for workplaces

This UK legislation (comparable to the ATEX 153 mentioned below) is legally enforceable. It requires an employer to:

• Identify dangerous substances and calculate fire and/or explosion risks.
• Put in place control methods including dust and fume extraction along with a good housekeeping regime.
• Indicate hazardous zones (see below for zone banding)

ATEX (Atmospheres Explosibles) – Applies to equipment

A European set of directives fostered by the UK aimed at the safe operation of equipment in explosive atmospheres.

ATEX 153 (Worker Protection) – As DSEAR above.

ATEX 114 (Equipment Certification) – Strict safety standards for equipment that will be used in explosive atmospheres.

The DSEAR (ATEX 153) and ATEX 114 work alongside each other.

A Quick Guide to Dust and Fume Zones

The identification of dust and fume zones is part of the DSEAR compliance and also plays an imperative part in the specification of a dust and fume collector.

	Zone	Description
ATEX Dust	20	Constant threat of explosive dust cloud formation. (i.e. inside dust filters)
	21	Probable risk (dust created by pouring, bagging, mixing.
	22	Low risk (general areas)
ATEX Fume	0	Constant threat (i.e. inside tanks etc.)
	1	Probable risk (spray booths etc.)
	2	Low risk, general areas)

Dust is also classified in accordance to its explosion strength.

Dust Classification	Severity	Example
ST0	No explosion	Non-combustible dust
ST1	Mild to moderate explosion	Wood, food, plastic dust.
ST2	Powerful Explosion	Numerous metal dust, Sugar.
ST3	Very Powerful Explosion	Reactive dust such as Aluminium and magnesium.

IMPORTANT – Your Responsibility & Explosive Particulates

Before engaging with a dust extraction supplier and discussing your requirement the onus is on you to have carried out – as per legislation – a DSEAR assessment. You will also have to identify the dust classification (ST) which may involve particulate testing.   

Armed with this information ensures the manufacturer will design- in ATEX features for safe operation, compliance and highly efficient dust & fume control.

Why ATEX compliance Matters for Dust and Fume Collectors?

Extraction systems are often required to operate in areas that have a grading of an explosive atmosphere. The filters will also handle, internally, dispersed, fine particulates within a confined space. This can be the perfect equation for a dust explosion. Because of this mix, ATEX certification for such equipment will be a legal requirement.

Examples of components to be ATEX approved where relevant:

• Fans
• Filters
• Panels
• Sensors
• Rotary Valves
• Explosion Vents
• Isolation Valves

A dust extractor must also be capable of handling the specific dust type (i.e. ST1 ST2)

Examples of Dust and Fume Collector ATEX design features:

• Roof mounted explosion venting
• Flameless venting
• Flame propagation valves
• Pressure shock resistant pipework
• Anti-static filter bags  

What are the consequences of Non-ATEX compliance?

The Stark Results of a Non-ATEX Dust & Fume Collector Operating in an Explosive Atmosphere 

Ultimately adhering to ATEX compliance is about protecting people’s lives and averting business altering damage to buildings, equipment and stock. 

To safeguard your business from the result of ATEX bad practice when specifying dust and fume extraction systems be sure to engage with a manufacturer or supplier that:

• Understand combustible dust and fume hazards
• Have the experience to design systems according to zone and dust class risks
• Incorporate certified ATEX components where required
• Will supply certification.
• Provides project and after-project support 

Protecting the Environment

Environmental Regulations

In the UK industries are governed by the EPR regulations on the control of industrial emissions, pollution prevention and protection of the environment.

Enforced in England by the Environment Agency (NRW Wales, SEPA, Scotland & NIEA, Northern Ireland) it requires the control of the release of dust, fumes and VOCs into the environment. Sectors governed include woodworking, solvents, metalworking, welding, cutting and sanding.

Businesses are required to control, with best available techniques (BAT), total particulates released into the atmosphere, preventing nuisance emissions, such as dust clouds, smells and smoke.

Dust and fume extraction is a necessity of ERP to control emissions in turn protecting the environment.

Energy Saving Systems and Waste Reuse

A well designed dust extraction system that encompasses energy efficiency with intelligent waste handling options can be an additional asset to sustainable and environmentally friendly operations.

Systems are available that incorporate a cascading fan or switched operation. Simply put, the smart performance monitoring of operational dust collection points (such as those provided on CNCs) will identify when it is not in operation. The number of fans operating will then be reduced, providing long term energy savings.

When choosing such an extraction system, attention should be given to whether a fan has simply been slowed down to save energy or switched. If switched, there will be remaining operational fans to ensure the HSE guidance of 18 m/s is met to prevent the build – up of particulates.

Waste not Want Not.

Sustainable use of some dust and mist waste products can be achieved with an extractor that can separate waste, sending it to a collection or storage point for re-use, conversion into a different product or indeed safer, more ethical disposal reducing landfill waste.   

Dust & Fume Extraction Systems are a Non-Entity if not Maintained Regularly & Compliantly  

The responsibility of dust and fume control compliance doesn’t stop once a system has been chosen, installed and commissioned. To ensure the system continually offers up performance and compliance it is essential to put in place a rigorous testing and maintenance regime. If not – all the time, research and financial investment – will amount to nothing!

The regulations for LEV test & maintenance

Regulation 9 of the COSHH regulations requires LEV (Local Exhaust Ventilation) systems to be maintained in effective working order and in good repair. It is therefore mandatory under both COSHH and HSE regulations that LEV testing should be carried out at no more than 14 month intervals. (The employer, manager or responsible person within an organisation is responsible to ensure a timely test and maintenance regime.)

The test should be carried out by a P601 engineer who will provide full reporting along with a remedial action plan so compliance can be maintained.

 A solid LEV testing and Maintenance Regime Provides Many Benefits:

• Legal compliance to COSHH & HSE requirements.
• Enhanced health & safety for the work
• The maintenance of system performance and energy efficiency
• Operational cost savings minimising expensive breakdowns and emergency repairs
• Verification that the extraction system is still performing as per original specification

Good Dust & Fume Control is the Sum of Many Parts

Right from the start, to implementation and beyond, the decisions you make when choosing and operating dust and fume extraction can make an evidential difference. Between compliance and non-compliance. Prosecution and non-prosecution. Efficient and non-efficient. Protected and non-protected workforce and buildings. The right choices are paramount.

Step one of your dust and fume control compliance? To engage with industry professionals and certified manufacturers to guarantee the right dust and fume collector for your operations.

---

Helpful websites

www.hse.gov.uk
www.bohs.org
www.gov.uk/government/organisations/environment-agency

---

FAQs

What are dust and fume extraction systems?
Dust and fume extraction systems are engineered solutions that capture airborne particulates at source preventing inhalation exposure environmental release and explosion risk.

Why are dust and fume extraction systems required by law?
They are required under COSHH HSE DSEAR and ATEX regulations to protect worker health ensure clean air and prevent fire and explosion hazards.

What industries require dust and fume extraction systems?
Industries including manufacturing welding woodworking food processing mining pharmaceuticals and metalworking all require effective dust and fume control.

What is the role of ATEX in dust and fume extraction?
ATEX ensures equipment used in explosive atmospheres is designed and certified to prevent ignition explosion and flame propagation.

How often must LEV systems be tested?
LEV systems must be thoroughly examined and tested at least every 14 months by a qualified P601 engineer.

Can dust and fume extraction systems improve sustainability?
Yes energy-efficient extraction systems reduce power consumption enable waste reuse and help businesses meet environmental regulations.