Process Emissions Monitoring

What is process emissions monitoring?

Process emissions monitoring measures the airborne concentration of fugitive dusts, fumes, vapours and gases escaping from process equipment that workers may breathe in during normal operations. It quantifies real personal exposure so employers can judge whether existing controls are adequate.

IndustrialAirMonitoring.uk provides independent process emissions monitoring across chemical manufacture, metals processing, plastics, food production, energy sites throughout the UK. Our occupational hygienists deliver defensible exposure data that demonstrates compliance with the Control of Substances Hazardous to Health Regulations 2002 (COSHH) and the workplace exposure limits set out in HSE guidance note EH40.

Why process emissions monitoring matters

Under COSHH Regulation 10, employers must monitor exposure to hazardous substances where it is needed to protect health, where a workplace exposure limit could be exceeded, or where control measures need to be verified. Process emissions monitoring provides the objective evidence that satisfies this duty.

Uncontrolled exposure to process emissions is linked to respiratory and systemic effects depending on the substances released. Beyond the legal duty, robust monitoring protects your workforce, reduces the risk of enforcement action and civil claims, and gives insurers and clients confidence that exposure is being actively managed.

How we carry out process emissions monitoring

We measure exposure using source and area sampling combined with personal monitoring to link emissions to exposure, following the recognised MDHS / ISO methodology. Personal samplers are worn in the breathing zone for a representative full shift to derive an 8-hour time-weighted average, while static (background) samples help map contaminant sources across the workplace.

Samples are analysed by an accredited laboratory and the results compared with the relevant occupational exposure limit. Where short-term peaks are a concern we add 15-minute short-term exposure limit (STEL) sampling, so both the chronic and acute risk picture is captured.

Standards, limits and reporting

Process emissions is controlled to as low as is reasonably practicable, with sampling benchmarked against published occupational and in-house standards. We assess compliance using the BS EN 689 statistical decision framework, which accounts for exposure variability rather than relying on a single result.

Your report sets out the measured concentrations, the compliance position, the adequacy of existing controls such as local exhaust ventilation, and a recommended re-monitoring interval. It is written to be understood by managers and to satisfy HSE inspectors, auditors and insurers.

Our process emissions monitoring process

Our process emissions monitoring programmes follow a structured, four-stage workflow so the results stand up to scrutiny. Request monitoring or book a site assessment to begin.

1Scoping & site survey. We review your processes, COSHH assessments and previous process emissions monitoring data, then plan a representative sampling strategy using BS EN 689 similar exposure groups.
2On-site sampling. Qualified occupational hygienists carry out calibrated breathing-zone and static measurements across a representative shift, with full chain-of-custody documentation.
3Accredited analysis. Samples are analysed using the relevant MDHS / ISO laboratory method and the results are compared against the applicable workplace exposure limit.
4Reporting & recommendations. You receive a clear exposure report with compliance status, control recommendations and a re-monitoring interval — defensible evidence for HSE, insurers and auditors.

Frequently asked questions

Is this workplace or stack emissions monitoring?

Our focus is workplace exposure from process emissions and fugitive releases — not regulated stack emissions to the outside environment.

Why monitor process emissions?

To find where contaminants escape into the working environment so controls can be targeted at the source, reducing worker exposure.

Can you link emissions to exposure?

Yes — we combine source and area sampling with personal monitoring to connect emissions to actual worker exposure.