How a pre-live safety check prevented serious worker injuries on a food production line
UV-C disinfection safety is not an afterthought – it’s a legal requirement, and a critical one. As UV-C disinfection systems become more widely adopted across food production, healthcare, and manufacturing, the risks of incorrect installation are growing too.
A food production company recently purchased and installed UV-C lamps directly over one of their conveyor lines to reduce microbial contamination on their produce. The equipment was well-specified – delivering high UV-C output appropriate for the disinfection task. But before commissioning, their safety lead had concerns and contacted us to carry out a UV-C safety assessment.
It was exactly the right call.
What our UV-C safety assessment found
The UV-C lamps in question are designed to operate inside an enclosed housing, where worker exposure cannot occur during normal use. Instead, they had been mounted in the open, directly above the production belt, with no guarding, enclosure, or safety controls in place.
UV-C radiation doesn’t require direct eye contact with the source to cause harm. A significant amount of UV-C light was reflecting off the light-coloured conveyor belt, and workers would be spending long periods in the area throughout their shift.
We measured personal UV-C exposure levels and assessed them against the statutory limits under the Control of Artificial Optical Radiation at Work Regulations 2010 (AOR Regulations):
- Unprotected skin at belt height would have exceeded the statutory exposure limit in seconds
- Unprotected eyes and face at working height would have exceeded the statutory exposure limit in minutes
The health consequences would have included arc-eye (photokeratitis – severe corneal inflammation) and erythema (UV radiation burns to the skin). Critically, UV-C causes no immediate sensation of heat or pain, meaning workers could have been seriously harmed before anyone was aware of the danger.
This UV-C disinfection installation, had it gone live without a safety assessment, would have caused real and serious injuries.
How the UV-C disinfection system was made safe
The solution was practical and cost-effective. An existing enclosed housing further up the production line was identified as a suitable relocation point for the UV-C lamps. Repositioned inside this enclosure, the lamps continued to deliver effective disinfection – but with full containment of UV-C radiation and no risk of worker exposure during normal operation.
We also addressed a second issue: the site had no means of verifying the UV-C dose being delivered, or whether it was achieving the intended disinfection outcome. We conducted validation testing to establish delivered UV-C dose based on belt throughput speed, and developed an ongoing process monitoring template to support continued compliance, resulting in a UV-C disinfection process that is both effective and safe.
UV-C disinfection safety: Know your legal obligations
This case is a clear reminder that all UV-C disinfection systems – along with any other workplace process involving artificial UV light, including UV inspection and UV curing – require a formal UV exposure assessment before use.
UV-C radiation is invisible, causes no immediate pain, and is easy to underestimate. Under the AOR Regulations, employers have a legal duty to assess worker exposure to artificial optical radiation, compare exposure levels against statutory limits for skin and eyes, and implement appropriate controls.
If you are commissioning a new UV-C disinfection system, reviewing an existing installation, or unsure whether your current UV processes comply with the AOR Regulations, a professional UV exposure assessment is not optional – it is a legal requirement.
UV-C safety services from Arden Ultraviolet
Arden Ultraviolet provides specialist UV safety consultancy to help organisations ensure their UV-C disinfection and other UV processes are safe, compliant, and effective. Our services include:
- Onsite UV exposure assessments – personal UV exposure measurement and evaluation against statutory limits
- UV risk management training – equipping safety and technical teams to identify and manage UV hazards in the workplace
- UV hazard awareness training – practical training for anyone working in proximity to UV equipment
We also offer a free UV safety webinar for any organisation wanting to understand whether their UV processes comply with the Control of Artificial Optical Radiation at Work Regulations, including statutory exposure limits for skin and eyes. No obligation – just practical, expert guidance.
If your organisation uses UV-C disinfection, UV curing, or UV inspection equipment and you are unsure whether you comply, get in touch with today.