A leading Irish producer of fresh, ready-to-eat sandwiches for retail shops and service stations sought to enhance hygiene by installing a UV-C disinfection tunnel to reduce microbial contamination on packaging and ingredients moving from low-risk to high-care production areas.
After purchasing the equipment, the company’s health and safety manager attended our free UV safety webinar to better understand their legal obligations under European workplace safety directives, particularly regarding UV exposure risks. Our consultancy was engaged to ensure the safe operation of the UV-C tunnel, prioritising worker safety and regulatory compliance.
Initial consultation
Following the webinar, the health and safety manager contacted us with concerns about potential UV-C exposure risks to workers operating the disinfection tunnel. They sought clarity on legal obligations, including permissible exposure limits, and guidance on implementing a zero-exposure policy due to the hazardous nature of short-wave UV-C light.
During the initial consultation, we discussed the tunnel’s design, operator working positions, and existing safety measures. The webinar had provided foundational knowledge, enabling the client to make informed decisions about next steps. We recommended a site visit and UV safety assessment to evaluate exposure risks and ensure compliance.
Site visit
Our team arranged a site visit the following week to assess the UV-C disinfection tunnel at the client’s Dublin facility. We began with discussions with the health and safety manager and production supervisors to understand operator roles, working positions, and typical exposure durations. In the production area, we examined the tunnel’s setup, focusing on existing control measures such as UV-blocking curtains at the conveyor’s entry and exit points.
We measured personal UV exposure levels for operators at both ends of the tunnel, noting that while workers wore UV-blocking clothing, gloves, and long sleeves, small gaps in the curtains allowed residual UV-C exposure to the face. Additionally, we observed inconsistent use of eye protection, with only one of two operators wearing UV-blocking goggles.
We also recommended hazard awareness training for operators and maintenance personnel to address gaps in safety knowledge. A detailed UV safety assessment was conducted to measure exposure levels and ensure compliance with European directives, particularly the Artificial Optical Radiation Directive (2006/25/EC).
The client promptly adopted our recommendations, mandating UV-protective goggles for all operators. The client also scheduled hazard awareness training to be delivered to both operators and maintenance engineers, covering UV-C exposure risks, legal exposure limits, and the importance of control measures and personal protective equipment (PPE).
Outcomes
The UV-C disinfection tunnel significantly enhanced hygiene, reducing microbial contamination on sandwich packaging and ingredients. The new control measures eliminated UV-C exposure risks, ensuring full compliance with European workplace safety directives. The zero-exposure policy provided peace of mind for the health and safety manager, while operators reported greater confidence in the safety of their work environment. The training program addressed previous inconsistencies in PPE use, fostering a stronger safety culture.
Conclusion
This project highlighted the critical role of specialised UV consultancy in safeguarding workers while optimising advanced disinfection technologies. By combining a thorough safety assessment, tailored control measures, and comprehensive training, we enabled the client to safely operate their UV-C disinfection tunnel while meeting regulatory requirements.
The result was a safer, more efficient production process that supported their commitment to hygiene and worker well-being. Businesses seeking UV safety solutions can contact us to explore customised consultancy services.