IAQ for manufacturing facilities: Maintaining safe workplaces
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Manufacturing facilities are some of the busiest and most active industrial premises on the planet, with many running around-the-clock shifts with constantly moving production lines. The number of personnel, equipment and space grows to meet increasing demand from the business, but often raises potential interior safety matters as a result.
Indoor air quality has become a growing concern for many leaders in charge of manufacturing operations. Inadequate working conditions caused by hazardous air can cause a range of issues, from operational obstacles to compliance violations.
Facility administrators have focused more than ever on how to keep air quality at acceptable levels in growing manufacturing operations. This guide will look at how to maintain a safer environment through improving indoor air quality.
Why is indoor air quality important for manufacturing facilities?
Indoor air quality (IAQ) is a measurement of the air quality within the interiors and surroundings of a building. It is an important metric to help determine the environmental safety for personnel and equipment working on the premises.
As manufacturing facilities often have many pollutants from the various industrial machinery inside, IAQ is a common concern for administrators and supervisors. Poor air quality can cause worker health issues and equipment malfunctions, resulting in productivity loss.
Improving the air quality can benefit manufacturing facilities, where studies show that enhancing IAQ can have a significantly positive impact on productivity. Devices that help observe the air can help facility administrators and line managers understand real-time IAQ and take swift action to help ensure health and safety and keep manufacturing operations running.
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Does your facility have an IAQ issue?
Manufacturing facility administrators can use IAQ to improve the overall working environment and yield productivity benefits. The first step to understanding how to take action on inside air quality is understanding whether there’s an issue on the premises.
Standard identifiers of IAQ issues inside facilities include:
- Increased worker illness: If there is an increasing number of workers taking sick leave or complaining about similar symptoms, there may be an issue with IAQ.
- Visible mold growth: Mold may begin to grow and become visible on equipment and specific areas inside the facility.
- Respiratory issues: More staff suffering from respiratory issues may signify that air quality is suboptimal.
- Loss of concentration: A drop in productivity due to growing lapses in concentration may be a symptom of poor air quality inside the facility.
- Condensation: Increased condensation on windows may appear from rising humidity as a result of an IAQ issue.
- Musty odors: Musty and chemical smells around the facility may indicate inadequate IAQ.
- High humidity: If humidity levels are often over 50% inside the building, there could be an issue with the air quality.
Other signs of poor IAQ aren’t easily identifiable by humans. Many gases, dust particles or other hazardous substances could be in the air, some of which humans have difficulty detecting, such as radon.
While there are many IAQ issues that humans can detect, some are odorless and invisible. Ensuring that the facility has various technologies to help detect and alert potential IAQ issues can help keep the facility safe.
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What’s inside:
- Dangers and risks to look out for
- Expert tips for improving air quality
- Latest IAQ technologies and sensors
- Real-world case studies
What are the possible hazards associated with IAQ?
There are several possible hazards associated with IAQ in manufacturing facilities, ranging from health to overall productivity. As many of them aren’t visible or easily detectable by humans, leaders often overlook the risks.
If responsible parties don’t take action, they can fester into a more significant issue. Manufacturing facilities will need a combination of technology and awareness to minimize hazards.
Here are some of the associated risks posed by IAQ:
Health and safety
The health and safety of staff working inside the manufacturing facility are a primary concern to administrators and supervisors overseeing operations. The enclosed nature of spaces and the number of pollutants inside the premises can contribute to a poorer IAQ, ultimately posing risks to human health.
Manufacturing facilities often have higher levels of carbon monoxide, dust particles, asbestos, radon and other allergens that can have an impact on workers. Human illnesses and issues that can potentially stem from the air contamination include:
- Eye, throat, skin and nose irritation
- Headaches
- Dizziness and fatigue
- Respiratory issues
- Heart disease
- Cancer
Dust particles and condensation on equipment can also create safety hazards on the facility’s surfaces. When they settle, they can create risks of slips, posing risks of injury to personnel.
Some airborne chemical particles that fall onto equipment and surfaces also may be flammable, meaning that there’s a significant fire risk should the substance come into contact with an ignitable item.
Product contamination
Dust, molds and pesticides are common air contaminants in buildings that not only pose risks to personnel, but also the products the facility manufactures. Particles can attach themselves to the items produced, compromising their quality and overall integrity.
An example would be the presence of mold in food manufacturing plants, where potentially harmful mycotoxins enter the air, attaching to the ingredients used to create the food or beverage product. Other contamination risks include oil vapor from industrial production machinery falling onto the factory line, potentially making items flammable.
Product contamination hazards from poor IAQ mean that health and safety concerns can extend beyond those working in the manufacturing facility. Consumers are also at risk.
Productivity
Poor IAQ can affect productivity levels, ranging from worker absences to general discomfort caused by various substances in the air. Prolonged exposure to dust particles and potentially harmful chemicals can lead to long-term illnesses or reduced worker efficiency, resulting in increased facility costs and potentially lower revenue.
The efficiency of manufacturing facilities is often a primary driver for business growth, where any operational lapses, such as production delays, can affect the bottom line. IAQ is subsequently a significant hazard to productivity.
Equipment malfunction
Various equipment in manufacturing facilities is subject to malfunction if the IAQ is not at healthy levels. Machinery such as heating, ventilation and cooling (HVAC) systems and industrial production units can succumb to dust and moisture buildups, potentially leading to unscheduled maintenance that can be costly and time-consuming.
Fire hazards caused by airborne chemicals can also cause damage to equipment if exposed to sparks or flames. They can also cause shorts in the cabling that links energy sources.
Some substances may also degrade equipment over time, such as blockages caused by dust in ventilation ports or corrosive material such as hydrogen chloride that causes component damage in machinery.
Compliance
There are jurisdictions in the United States that have regulatory frameworks around IAQ, such as California and New Jersey, meaning that manufacturing facilities will have to comply with air quality standards to operate. However, many don’t have direct IAQ regulations to follow, but do have worker safety rules around ventilation and air contaminants in workplaces.
Administrators may need to check the regulations around IAQ levels inside their manufacturing facilities to determine if they need to be at specific levels to operate. Non-compliance could have a severe impact on the business, causing delays or customer loss.
Seven methods for improving IAQ in manufacturing facilities
Manufacturing facilities are often complex premises with many appliances and industrial machinery that can compromise air quality. However, there are methods to help mitigate hazards and risks, improving the working environment for personnel.
Here are seven methods to help improve IAQ at your manufacturing facility.
1. Identify sources causing poor IAQ in the facility
Identifying the key pollutants on the premises can help determine the best course of action to improve IAQ, including installation of detection devices and air filtration systems. In manufacturing facilities, the primary pollutants can include:
- Fuel-burning machinery
- Cleaning products
- HVAC and humidification systems
- Pesticides
- Outdoor air pollution
- Incorrect waste disposal
- Tobacco and vape products
- Improper storage of chemicals and degradable items
- Molds, lead and asbestos
Performing an audit of the facility and identifying potential sources of poor IAQ allows administrators and building managers to implement solutions such as extraction systems or enforce new air quality policies.
2. Implement environmental detection systems
Technology can be a vital asset in keeping IAQ inside manufacturing facilities at acceptable levels. Environmental detection systems that measure the air quality index (AQI) paired with real-time analysis and notification systems can be a beneficial asset in improving IAQ on the premises.
Where humans find certain aspects of IAQ detection challenging, technology can help fill the gaps. Advantages to implementing environmental detection systems include:
- Real-time notifications for changes in air quality
- Consistent IAQ detection
- Temperature and humidity reporting
- Tobacco and vape detection
- Analysis and data reporting
- Compliance with IAQ regulations
3. Regularly audit and maintain HVAC and air filtration devices
HVAC systems are beneficial to the comfort of workers inside manufacturing facilities, keeping the large, active spaces cool and helping to provide fresher air. However, if they are not regularly maintained, the systems can become a pollutant themselves, distributing dust or other particulate matter (PM) around the facility.
Conducting scheduled audits of the facility’s HVAC systems can help keep the air cleaner and the machine optimal. Maintenance should include changing the air filters, inspecting for leaks, debris and general performance checks.
4. Keep staff trained on the importance of IAQ
Technology and risk mitigation strategies can be effective methods to improve IAQ inside manufacturing facilities. However, it’s also essential to keep staff trained on the importance of air quality and how they can contribute to maintaining a safe working environment on the premises.
Regular training programs can include best practices for improving IAQ, reasserting the prohibition of tobacco and vape use inside, how to report concerns and the correct use of protective equipment. Where personnel have information about how important IAQ is to themselves, there can be more incentive to act and perform duties in a way that helps keep the air cleaner.
5. Ensure use of personal protective equipment (PPE)
Manufacturing facilities are often indoor, confined spaces, meaning that workers should have protection from potentially harmful substances produced by industrial machinery. Managers and supervisors should ensure that all staff wear the correct PPE when performing their duties while on the premises to help prevent them from coming into contact with dust, chemicals, molds and other pollutants.
The general AQI inside the facility will determine the appropriate PPE category to implement for personnel. Everyday items used in manufacturing are gloves, respirators, face masks, safety glasses and coveralls.
However, the most effective PPE can vary depending on the facility’s manufacturing needs. OSHA offers insight into best practices for various types of operations.
6. Integrate software to analyze and inform on IAQ
Integrating software that pairs with hardware can help administrators and facility managers stay on top of IAQ levels. Many devices that measure air quality feature Internet of Things (IoT) sensors that transmit information to platforms in real-time for analysis.
Software can go beyond providing notifications to relevant personnel. It can also analyze previous readings to help administrators make informed decisions on bettering the working environment for staff and helping maintain adequate IAQ levels.
7. Maintain thorough cleaning schedules throughout the facility
Finally, regular cleaning of the facility should be on the agenda of administrators and managers. Keeping surfaces and equipment free of dust particles, chemical compounds and other debris can help reduce hazards to both personnel and equipment, thereby maintaining an optimal operation.
There are many eco-friendly methods of cleaning manufacturing facilities to minimize the release of chemicals into the air. Advanced techniques from specialists can help reduce the number of contaminants and comply with any environmental regulations.
Conclusion
Manufacturing facility administrators should consider options to form an effective IAQ strategy for a comfortable working environment. Keeping the air quality at safe levels can promote the health and safety of personnel, maximize productivity and prolong equipment.
A combination of staff awareness, detection technologies and analysis platforms can be the foundations of a scalable strategy to minimize risks and hazards to business operations. A healthier working environment as a result of adequate IAQ is often one of the key drivers behind desired business growth.