Paper / Card
Paper and cardboard DSEAR risk assessment expertise
We have provided DSEAR risk assessments for paper mills, cardboard production facilities and packaging manufacturers across the UK.
While many processes in this sector are not hazardous in normal operation, the presence of combustible dusts, starch powders and flammable substances can create fire and explosion risks under certain conditions. Our work focuses on identifying where these risks may arise and ensuring appropriate controls are in place to support safe, compliant operations.
Smurfit Kappa
The challengeThe Smurfit Kapa site at Mold allow for large scale production of cardboard and paper-based packaging materials for sale to a wide client base. The majority of processes are not hazardous in normal operation however …
Graphic Packaging
The challengeThe Graphic Packaging operation based in Bristol had identified the need to undertake a DSEAR assessment after a corporate audit was completed. The action was raised as the operations on site involved two areas …
DS Smith – Devizes
The challengeA visit was made to DS Smith Devizes factory based in Wiltshire, in September 2015 to consider compliance in respect of the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). This was requested as …
DS Smith – Sittingbourne
The challengeDS Smith’s Kelmsley mill continuously produces card and cardboard for the packaging markets. An internal audit identified a requirement for the powder storage and handling facilities to have DSEAR risk assessments. A visit was …
DSEAR risk assessments for paper mills, cardboard production and packaging facilities
Paper and cardboard manufacturing environments typically involve large-scale, continuous production processes, where materials are handled, transferred and processed at high volumes.
Typical DSEAR risk areas include:
- Paper dust and trim waste generated during production
- Dust extraction and collection systems
- Starch powder storage, transfer and mixing systems
- Bulk silos and material handling equipment
- Use of flammable liquids such as isopropyl alcohol
- LPG and compressed gas storage and use
- Conveying, cutting and finishing operations
Although many materials used in this sector are stable, fine dust generated from paper, cardboard and starch can form explosive atmospheres if dispersed in air at sufficient concentration. This risk can exist both inside process equipment and externally where dust escapes or accumulates.
Dust extraction systems play a critical role in controlling this hazard, but they must be properly designed, maintained and managed. Poor housekeeping, inadequate extraction or failures in containment can lead to dust build-up, which may result in fire or explosion if ignited.
In addition, the use of flammable liquids and gases introduces further risks, particularly where vapours may be released during storage, transfer or use.
Our DSEAR assessments review how these hazards arise in practice, including dust handling systems, ventilation, storage arrangements, ignition source control, maintenance regimes and operational procedures. Where required, hazardous area classification is applied, particularly around dust handling equipment and flammable substance use.
Clear reports and prioritised action plans are provided to help businesses implement practical improvements and maintain compliance with DSEAR.
Frequently asked questions
Yes. Fine paper dust can be combustible and may form an explosive atmosphere if dispersed in air at sufficient concentration and exposed to an ignition source.
Yes. Extraction and collection systems are often key risk areas and must be properly designed, maintained and inspected to control dust-related hazards.
They can be. Fine organic powders such as starch can be combustible and present a dust explosion risk under certain conditions.
In some areas, yes. This is typically required around dust handling equipment, silos, and where flammable liquids or gases are used.