Tackling Flour Dust Exposure Risks in Mills and Bakeries

In flour milling and bakeries, dust exposure is a serious health risk that can have long-lasting effects on workers. These risks are amplified in environments with poor dust control, making it a critical issue in occupational hygiene. Various research and exposure studies have been conducted to try to better understand the impact of flour dust on the human respiratory system, and to get to grips with its effect on the overall health of workers in the milling and baking industry.

History of Flour Dust Exposure

The adverse health effects of flour dust exposure have been known at least as far back as the 1700s, when flour millers’ lung was documented by Bernardo Ramazzini, a Florentine physician. But it wasn’t until the 1930s that allergic responses to flour dust were extensively examined in bakers, when conditions such as “Baker’s Lung” were highlighted. With the implementation of the Control of Substances Hazardous to Health (COSHH) regulations in the late 20th century, systematic measures were enforced to protect workers' health comprehensively in the UK. Despite these advances, flour dust remains one of the top causes of occupational asthma even today, cited by the UK SWORD reporting scheme in 2021 as a leading cause of newly reported respiratory disease, second only to asbestos.

Health Risks of Flour Dust Exposure

Flour dust, consisting of finely ground wheat, proteins, starches and enzymes, is a major occupational allergen. According to Occupational and Environmental Medicine, flour dust is one of the most common causes of occupational asthma, with a reported annual incidence ranging from 1 to 10 cases per 1000 bakery workers[JP1] . Chronic conditions like asthma and chronic obstructive pulmonary disease (COPD) are linked to long-term exposure, with symptoms such as coughing, wheezing, and breathlessness noted as common early warning signs. Additionally, the Health and Safety Executive (HSE) states that among all occupations, bakers have the second highest incidence rate of occupational asthma, with flour and grain reported as the second highest causal agent.[RP2] [JP3] 

Regulatory Requirements

The current UK workplace exposure limit (WEL) for flour dust is set at 10 milligrams present in one cubic metre of air, averaged over an 8-hour period. This limit forms part of COSHH regulations, regulated by the HSE. However, literature records that ill-health effects have been reported at exposures below 0.5 milligrams per cubic metre in some cases, suggesting that compliance with UK WELs may not always adequately protect health. As a sensitiser, regulations further require employers to control exposure to flour dust to As Low As Reasonably Practicable (ALARP). This underscores the importance of implementing effective hygiene controls and best practices to minimise flour dust exposure in the workplace.

Effective Dust Control Strategies

Within many bakeries today, recent technological developments such as specialist “lowdust” flours have been explored to further help reduce worker exposure. However, this substitution is not always possible and even where low dust flours are used, it remains essential for flour milling and bakery facilities to prioritise occupational hygiene measures to protect worker health and ensure regulatory compliance.

This begins with identifying key hazards and risks in the workplace, followed by thorough evaluation and monitoring of exposure levels and effectiveness of controls. Most importantly, facilities must implement effective control measures to provide reliable, long-term protection for all potentially exposed workers. Key best practices as advised by the HSE and industry bodies such as the Federation of Bakers include:

• Local Exhaust Ventilation (LEV): Well designed, well maintained and correctly operated LEV systems capture dust at the source, which is key in preventing flour dust from becoming airborne, reducing exposure levels by up to 50% (Journal of Occupational and Environmental Hygiene).
• Training and Awareness Programs: Education on correct cleaning methods such as using damp methods instead of dry sweeping, or proper storage and handling practices such as using sealed containers, is essential to promote best practices in the workplace.
• Personal Protective Equipment (PPE): Protective equipment such as FFP3 respirator masks, eye protection, gloves, and suitable clothing should be used in areas with high dust concentration, where exposure cannot be adequately controlled by other means.
• Health Surveillance: Regular health assessments for workers can help identify adverse symptoms linked to flour exposure. This monitoring supports early intervention and aids occupational hygiene in assessing the effectiveness of control measures in place.

Prioritising Health with Tailored Hygiene Services

Mitigating flour dust exposure presents immediate challenges for food sector businesses, but it also offers significant long-term benefits for workforce health and operational performance.

With extensive consultative experience in dust monitoring and control assessment, Envirochem’s occupational hygiene services are designed to help you make quality, continuous improvements in worker health. We provide actionable steps tailored to your specific needs and site requirements, fostering better health outcomes for your personnel and for your business.

For tailored advice and actionable strategies to enhance your workplace safety, get in touch with one of our experts.