Monitoring indoor air quality (IAQ) in manufacturing facilities

What is indoor air quality?

The Environmental Protection Agency (EPA) defines IAQ as ​“the air quality within and around buildings and structures, especially as it relates to the health and comfort of building occupants.” IAQ is measured by analyzing air samples to identify concentrations of dangerous pollutants in the air.

The Occupational Safety and Health Administration (OSHA) states that indoor air pollutants originate from three sources, chemical, biological and particulate matter. IAQ in manufacturing facilities can be impacted by all three sources due to the nature of industrial operations.

Common contaminants in manufacturing facilities include:

• Volatile Organic Compounds (VOCs): emitted from industrial solvents, additives and as byproducts of manufacturing treatments, long-term exposure to VOCs can cause headaches, nausea, kidney issues and damage to the central nervous system.
• Toxic dust particles: dust and fine particles are released into the air during the cutting, scouring and mixing of raw materials. These particles can cause irritation and respiratory illness.
• Carbon oxides (CO/CO2): emitted by machines that burn fossil fuels like coal and natural gas, excess carbon monoxide (CO) and carbon dioxide (CO2) exposure reduces oxygen levels in blood, causing dizziness, confusion and damage to organs.
• Particulate Matter (PM): refers to any small particles and liquid matter suspended in the air. Material handling and fuel combustion can release PM, leading to lung damage.

The importance of indoor air quality monitoring for manufacturing facilities

Poor air quality in manufacturing facilities can cause damage to equipment, contribute to the development of serious health issues in workers and negatively impact productivity. Indoor air quality monitors for manufacturing facilities help operators quickly identify IAQ issues and address them to maintain compliance with regulations.

Below are some key aspects of manufacturing operations that benefit from industrial air quality monitoring sensors.

Health and safety

Poor air quality can lead to health problems, including:

• Eye, nose and throat irritation
• Dermatitis and rashes
• Asthma, bronchitis and lung cancer
• Chronic obstructive pulmonary disease
• Gastroesophageal reflux disease

Regulatory bodies like OSHA define Permissible Exposure Limits (PELs) for various airborne pollutants to help operators assess the safety of their work environments. Indoor air quality monitors for manufacturing facilities help identify elevated levels of contaminants to help ensure safe working conditions for employees.

Employee productivity

Poor IAQ can cause work environments to become unpleasant, with high concentrations of dust, gasses and PM causing irritation and limiting workers’ ability to perform tasks. Continuously monitoring IAQ in manufacturing facilities can help identify issues early and respond before they impact employee comfort.

Equipment maintenance

IAQ issues can cause high concentrations of PM and moisture to accumulate in ventilation systems and machine components, clogging up equipment, promoting mold growth and damaging infrastructure. PM can also gather on electrical devices and switches, causing equipment to overheat.

Regulatory compliance

Facility operators must comply with regulations related to air quality to mitigate the adverse effects of poor IAQ. For example, OSHA requires operators of workplaces where employees engage in yarn manufacturing and slashing and weaving operations to ensure no workers are exposed to airborne concentrations of lint-free respirable cotton dust greater than 200 µg/​m3 mean concentration, averaged over an eight-hour period, as measured by a vertical elutriator or an equivalent instrument.

The OSHA General Duty Clause Section 5(a)(1) can also be relevant to IAQ monitoring, stating, ​“Each employer shall furnish to each of his employees employment and a place of employment which are free from recognized hazards that are causing or are likely to cause death or serious physical harm.” If a manufacturing process produces a hazardous breathable byproduct, like cotton dust or silica dust, for example, systems must be devised to protect staff from exposure.

Similarly, if flammable dust is identified in a facility, employers will be expected to maintain compliance with relevant National Fire Protection Association (NFPA) codes and standards.

Operators must also track OSHA PELs using IAQ monitors for manufacturing facilities to identify potential exposure limit breaches as early as possible. Additional National Institute for Occupational Safety and Health (NIOSH) guidelines provide Recommended Exposure Limits (RELs) for hazardous substances, helping set compliance thresholds.

Manufacturing facilities with elevated IAQ risks

While contaminants like carbon oxides and PM are present in almost all workplaces, manufacturing facilities often experience IAQ issues related to industry-specific processes. When certain materials are cut, blended or milled, toxic dust particles may be released into the air. The following manufacturing facilities create some of the most at-risk types of toxic dust.

Metalworking operations

Small particles are released into the air when metals are welded, sanded, cut or manipulated during manufacturing. Excess exposure to metals like lead, chromium and nickel can cause heavy metal poisoning in humans, while fine metal dust is linked to long-term lung damage and respiratory disease.

Woodworking facilities

Small fibers released into the air during wood manufacturing negatively impact IAQ, increasing the risk of workers developing health issues, clogging up machinery and damaging ventilation systems. Microscopic wood dust is also a fire risk. In dry environments, dust clouds can ignite and cause explosions if left unaddressed. 

Chemical processing plants

Coating, blending, mixing and milling hazardous chemicals can release toxic contaminants into the air. The risks associated with these toxic dusts vary depending on the chemicals used at each facility. However, most of these contaminants can cause skin and eye irritation, respiratory issues and pose a fire risk due to their flammable and explosive properties.

Pharmaceutical companies

Active Pharmaceutical Ingredients (API) used in medication manufacturing can pose serious health risks if over-consumed. The production of tablets and single-dose products emits microscopic API particles into the air. Without precautions like indoor air quality monitors, workers can inhale these particles, increasing their health risks.

Plastic processing plants

Plastics contain toxic ingredients that can harm workers if inhaled or ingested, with dust and fumes commonly emitted during different stages of production. Studies show a clear link between microplastics and serious health risks.

Identifying IAQ issues in manufacturing facilities

Identifying issues with IAQ in manufacturing facilities requires continuous commitment from employers and employees. While some signs of poor IAQ are detectable through sight or smell, others may be less apparent until they begin affecting workers.

Signs to look out for include:

• Employee illnesses: frequent reports of respiratory and skin issues among workers can indicate poor IAQ in the manufacturing facility.
• Abnormal odors: dust, gases and PM can cause lingering musty odors and influence the growth of foul-smelling molds.
• Moisture accumulation: damp walls, floors and work surfaces can be a sign of poor IAQ, indicating abnormal humidity levels.
• Equipment failure: PM and dust particles can enter machinery through air intake and cooling ports, shortening equipment lifespan.
• Dust buildup: layers of dust on surfaces and around machinery can indicate poor ventilation system performance, leaving PM in the air.

By the time the visible signs appear, poor IAQ may already be impacting the workers and equipment. You can proactively address these issues by using indoor air quality monitors for manufacturing facilities, maintaining a healthier and safer workplace.

How to improve indoor air quality in manufacturing facilities

Improving IAQ in manufacturing facilities is a continuous process, with staff across all aspects of the business involved in identifying and addressing issues. Here are the best practices for improving IAQ in manufacturing facilities:

1. Implement indoor air quality monitoring systems 

Indoor air quality monitors for manufacturing facilities can be installed in high-risk areas, like workstations and ventilation ducts, to provide real-time IAQ metrics. These sensors can help detect contaminants that may not be visible to the naked eye, including carbon oxides, toxic dust particles, PM and VOCs.

Thresholds for target pollutants can be set in line with regulatory guidelines like OSHA PELs, with instant alerts sent to managers if contaminant levels begin to rise. Modern sensors can also be linked to HVAC and manufacturing security systems, allowing for automated responses such as ventilation systems engaging, alarms sounding and affected locations being locked down.

2. Use High Efficiency Particulate Air (HEPA) filters

HEPA filters can help capture and remove dust particles, preventing PM from recirculating into the facility. HEPA filters have been shown to remove at least 99.97% of dust, pollen, mold and bacteria particles down to a size of 0.3 microns, helping manufacturing facilities maintain a healthier and safer indoor climate.

3. Regularly clean air filters and equipment 

Air filters can lose efficacy if they’re not regularly cleaned and maintained, so it’s important to set up a regular cleaning schedule. Regardless of how often HEPA filters are cleaned, they should be replaced every 6 – 12 months to continue working efficiently.

Maintaining good IAQ at manufacturing facilities also requires regular equipment upkeep. Scheduling periodic downtime to clean air intakes and ports can reduce the buildup of dust and particulate matter (PM), helping to prevent these contaminants from entering the air supply.

4. Conduct frequent IAQ assessments

Frequent indoor air quality assessments should be conducted to help ensure newly installed IAQ monitoring air filtration systems are working as intended. A thorough IAQ investigation, as outlined by OSHA, will include the following steps:

• Identify pollutant sources
• Evaluate HVAC system performance
• Observe production processes and work practices
• Measure contamination levels and staff exposures
• Conduct employee interviews and collect statements
• Review medical data for signs of IAQ-related illness

Facility managers must also check all surfaces for signs of moisture and mold growth, maintain heat and humidity levels in the optimal range and ensure regular cleaning and maintenance tasks are consistently performed and logged.

Monitor air quality in real-time with the all-in-one HALO Sensor

In manufacturing facilities where pollutants from industrial processes can significantly impact worker health and production quality, continuous IAQ monitoring helps detect issues early, supporting a healthier, safer environment. HALO Smart Sensor is an all-in-one solution for monitoring IAQ at manufacturing facilities and addressing various health and safety issues. 

These multi-sensor devices enable facility managers to stay proactive about indoor air quality by tracking critical environmental factors such as:

• Temperature
• Humidity
• Air pressure
• Light levels
• Volatile organic compounds (VOCs)
• Particulates (PM1, PM2.5 and PM10)
• Ammonia (NH3), nitrogen dioxide (NO2), carbon monoxide (CO) and carbon dioxide (CO2)

Beyond air quality, HALO Smart Sensors detect additional environmental and safety-related factors. With the ability to detect vaping, smoking, aggression and tampering attempts, HALO is a comprehensive safety solution for manufacturing environments. HALO integrates seamlessly into your existing safety infrastructure and security technology, sending real-time alerts and enabling you to respond to any safety or IAQ concerns promptly.

Conclusion

Indoor air quality monitoring in warehouses, factories and manufacturing facilities is critical in ensuring a safe, clean and healthy workplace environment. Poor IAQ can lead to significant issues with employee health and productivity, as well as non-compliance with relevant health and safety regulations. Operators must make sure their facilities are adequately protected against pollutants and contaminants.

Indoor air quality monitors for manufacturing facilities can help detect IAQ issues early, enabling you to develop, implement and optimize preventative solutions to protect employees and equipment from harm. By continuously analyzing and proactively addressing issues with IAQ, you can help maintain a safe work environment.