Manufacturing
Manufacturing DSEAR risk assessment expertise
We have provided DSEAR risk assessments for a wide range of manufacturers across the UK, including product assembly, plastics, coatings, furniture, doors, machinery, lighting, food-related production and specialist engineered goods.
These environments often involve flammable liquids, gases, sprays, combustible dusts and bulk storage arrangements across varied production processes. Our work focuses on identifying where hazardous atmospheres may arise, assessing existing control measures and providing practical recommendations to support safe, compliant manufacturing operations.
Devro (Scotland) Ltd
The challengeAn independent survey of operations associated with the Devro site in Moodiesburn was undertaken April 2012 at the request of senior management. Plant facilities allow for the preparation of a range of food casings …
Enesco Ltd
The challengeFine Ceramic Transfers are part of the Enesco Group Decor and carry out transfer print operations for a wide range of clients. Their site in Fenton, Stoke-on-Trent incorporates mechanised print facilities for finishing of …
Daido Industrial Bearings Europe Ltd
The challengeDaido Industrial Bearings Europe Limited, based in Ilminster, Somerset, UK, produce plain bearings, bushings and thrust bearings for medium speed diesel engines, turbochargers, and a range of other rotating and reciprocating machines. The facility …
UCM Magnesia Ltd
The challengeAn independent survey of UCM Magnesia operations at the Saltend site in Hull was undertaken August 2011 at the request of senior management. Facilities at the Saltend site allow production of Magnesium Oxide powders …
JSM Furniture
The challengeJSM operate a business that creates and supplies bespoke furniture and kitchens; these are created and sprayed within the workshop. JSM required a DSEAR assessment to be completed at the start of 2015 to …
Yamazaki Mazak
The challengeA visit was made to the Yamazaki Mazak UK Limited site at Worcester in June 2015 to consider compliance in respect of the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). Yamazaki Mazak specialise …
Howard Bros Joinery
The challengeHoward Bros Joinery is a bespoke sub-contract specialist joinery contractor, with an enviable reputation for the manufacture and installation of all aspects of bespoke joinery. As part of the manufacturing processes at its site …
IG Doors
The challengeA visit was made to IG Doors Limited site at Cwmbran in November 2015 to consider compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). They are the UK’s leading manufacturer and …
Ottima
The challengeA visit was made to Ottima factory based in Lancing, West Sussex in December 2015 to consider compliance in respect of the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). The factory operations included …
Hellermann Tyton
The challengeHellermann Tyton contacted the Mesh office with a requirement for prompt DSEAR assistance following an insurance assessor’s visit. Our consultant team was able to rapidly respond and attended the client site to carry out …
Big K
The challengeFollowing regulator action, a visit was made to Big K Products UK Ltd., Stoke Ferry, on 7th April 2016 to consider compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). They are …
Metallic Elephant
The challengeMetallic Elephant Limited specialise in the production of high quality hotfoil print blocks for a wide range of clients requiring embossed finishes to pliable materials.The site visited in Essex incorporates specialist process and manufacturing …
Ariens
The challengeA visit was made to Ariens (Countax), Oxfordshire in April 2017 to consider compliance in respect of the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR).The Great Haseley site is an established manufacturing facility …
Vaillant UK
The challengeVaillant UK manufactures market leading gas fired boilers from its plant in Belper. Due to changes in operational leadership it was felt appropriate to gauge where the site stood as regards compliance with DSEAR …
Linx Printing Technologies
The challengeLinx Printing Technologies operates two sites in St Ives, Cambridgeshire, and they both required DSEAR visits and RAs in 2017 and early 2018. The new site produces label printing machines, and the existing site …
Bailey Trailers
The challengeBailey Trailers of Sleaford manufactures market leading agricultural trailers and towed equipment. In September 2017 their insurers identified requirements for DSEAR assessment, primarily around their paint spraying operations, which were in use frequently and …
Boys and Boden
The challengeBoys and Boden has its own factory producing stairs for the construction industry. An internal audit identified a requirement for DSEAR RA at site. Hazards commonly encountered included dust from the CNC machinery on …
SMH Products
The challengeSMH Products is the UK’s leading manufacturer of mobile asbestos decontamination units. Following regulator action in late 2017, they required immediate assistance with DSEAR compliance issues. As such, the plant handles considerable quantities of …
O&S Doors
The challengeA visit was made to the O&S Doors site at Dungannon to consider compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR), after the site’s insurer required them to have a DSEAR …
Technical Signs
The challengeA visit was made to the Technical Signs site, at Watford, in 2020 to consider compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR), incorporating Amendment 1: June 2015. Technical Signs is …
Kevin Nash Group
The challengeA visit was made to the Nash Tackle site, in Dec 2019 to consider compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR), incorporating Amendment 1: June 2015. At the site, Nash …
TRT Lighting
The challengeA visit was made to the TRT Lighting’s Redditch site in January 2020, to consider compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR), incorporating Amendment 1: June 2015. At the site, …
ITM Power
The challengeA visit was made to ITM Power Sheffield site in July 2020, to consider compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR), incorporating Amendment 1: June 2015. At the site, ITM …
Sharpak Yate
The challengeA visit was made to the Bristol site of Sharpak Yate Ltd to consider compliance in respect of the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). The DSEAR regulations came into force in …
Altro
The challengeDSEAR Risk Assessments Ltd was commissioned to undertake a DSEAR review of the process operations at Altro in Letchworth Garden City. The site operations included a range of items that require assessment under DSEAR. …
DSEAR risk assessments for manufacturing facilities and production processes
Manufacturing environments can present a wide range of DSEAR risks depending on the materials used, the production methods involved and the way hazardous substances are stored, transferred and controlled across the site.
Typical risk areas include:
- Paint spraying, coating and finishing operations
- Storage and handling of flammable liquids and thinners
- Compressed gas systems and bulk gas storage
- Dust-producing machining, cutting or sanding processes
- Dust extraction and collection systems
- Mixing, dispensing and transfer of hazardous substances
- Battery charging areas and hydrogen generation
- Workshops, plant rooms and process support areas
Across many manufacturing sites, the main DSEAR risks arise where flammable vapours or combustible dusts can be released during normal operations. This may happen during spraying, mixing, cleaning, transferring materials, or where dust escapes from production or extraction systems.
Flammable vapours from paints, solvents, hardeners and thinners may build up in poorly ventilated areas or travel to an ignition source. At the same time, combustible dusts from wood, plastics, powders or processed materials can present a fire and explosion risk if allowed to accumulate or become airborne in sufficient concentration.
Our DSEAR assessments review how these risks develop in real operating conditions, including ventilation, extraction, ignition control, earthing, housekeeping, storage arrangements, maintenance systems and operational procedures. Where required, hazardous area classification is applied and supported by drawings and clear explanations of where Zones exist and why.
The aim is to give manufacturers a clear understanding of where their real risks lie, what controls are already effective, and what practical improvements are needed to reduce risk and maintain compliance.
Frequently asked questions
The most common risks are flammable vapours from paints, solvents and sprays, along with combustible dusts from cutting, sanding, machining, powders or other production processes.
Yes, particularly where flammable liquids, gases, sprays or dusts may create an explosive atmosphere during normal operation or foreseeable loss of containment.
In many cases, yes. Spray operations often involve flammable paints, thinners and vapours, which means ventilation, ignition control and suitable equipment are critical.
It usually includes review of hazardous substances, production processes, storage, extraction, ventilation, hazardous area classification and a prioritised action plan for improvements.