Plastics
Plastics DSEAR risk assessment expertise
We have provided DSEAR risk assessments for plastics manufacturers, composites facilities and recycling operations across the UK.
These environments often involve the use of resins, solvents and additives, along with processes that generate flammable vapours and combustible dusts. Our work focuses on identifying where hazardous atmospheres may arise and ensuring appropriate controls are in place to support safe and compliant operations.
EMJ Plastics Ltd
The challengeA visit was made to EMJ Plastics Ltd. at Filey, North Yorkshire in January 2014, to consider compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). EMJ Plastics activity incorporates specialist facilities …
Advanced Composites Group
The challengeThe Advanced Composites Group site in Manchester involved routine handling of solvents such as Acetone, IMS and MEK along with some resins and flammable gases. The core process areas involved a number of automated …
CCL Decorative Sleeves
The challengeCCL identified the requirement to undertake a DSEAR assessment of both its Norfolk and Castleford sites. The business uses various flammable substances in its processing of quality shrink sleeve products; these include inks, solvents …
Centriforce
The challengeA visit was made to the Centriforce plastics recycling site at 14-16 Derby Road, Liverpool, on 6th August 2015 to consider compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). The site’s …
Sumika
The challengeSumika Polymer Compounds in Havant produces granulated thermoplastic polyolefin based compounds and elastomers for the automotive, white goods, electrical and general manufacturing industries. As part of this the processing operations on site generate quantities …
Long Valley Packaging
The challengeA visit was made to the two Longvalley manufacturing sites, at Barking, Essex, in 2020 to consider compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR), incorporating Amendment 1: June 2015. At …
DSEAR risk assessments for plastics manufacturing, composites and recycling
Plastics and composites manufacturing environments can present a combination of vapour and dust-related DSEAR risks, often occurring across multiple stages of the production process.
Typical risk areas include:
- Use of resins, catalysts and gelcoats (e.g. styrene-based products)
- Storage and handling of solvents such as acetone, MEK and IMS
- Mixing, dispensing and impregnation processes
- Extrusion and thermal processing generating VOC vapours
- Dust from trimming, cutting and finishing operations
- Recycling and material handling processes
- Screen printing and coating operations
- Static electricity and ignition risks
A key feature of this sector is the routine generation of flammable vapours, often from substances that can evaporate at or near ambient temperatures. Vapours may be heavier than air and can accumulate at low level or travel to ignition sources if not properly controlled.
In addition, dust generated from trimming, machining or recycling processes can create combustible atmospheres if allowed to accumulate or become airborne. This combination of vapour and dust hazards requires careful consideration of both ventilation and housekeeping.
Our DSEAR assessments review how substances are stored, handled and used in practice, including ventilation and extraction systems, containment, static control, ignition source management and maintenance procedures. Where required, hazardous area classification is applied and supported with clear zoning drawings.
The result is a practical, structured report that helps plastics and composites manufacturers understand their risks, prioritise improvements and maintain compliance with DSEAR.
Frequently asked questions
The main risks are flammable vapours from resins and solvents, along with combustible dust from trimming, machining or recycling processes.
Yes. Many resins, catalysts and solvents give off flammable vapours that can ignite if they accumulate and encounter an ignition source.
In many cases, yes. This is particularly relevant around solvent use, resin processes, extrusion operations and areas where vapours or dust may be present.
In many cases, yes. This is particularly relevant around solvent use, resin processes, extrusion operations and areas where vapours or dust may be present.