Since October, HSE (Health and Safety Executive) has been inspecting businesses that use metalworking fluids in their machining processes. Is your company ready for this inspection? Before saying yes, consider an important piece of information. Half of the inspections carried out by the entity detected some kind of failure in the processes.
What are Metalworking Fluids
Metalworking fluids (MWFs) are a range of oils and other liquids used to cool and lubricate metal workpieces. These substances decrease the heat and friction between the cutting tool and the workpiece, and remove swarf (metal filings, chips) from the work area. As a result, they play a crucial role in extending the life of the cutting tool, improving the finish of the workpiece, and increasing the speed of the machining process.
There are several types of metalworking fluids, including straight oils, soluble oils, semi-synthetic, and synthetic fluids.
Straight oils are undiluted, non-emulsifiable oils used in machining operations. They are primarily used for their lubricating properties and are derived from petroleum, animal fats, vegetable oils, or other synthetic compounds.
Soluble oils, a type of emulsion mixed with water, have both cooling and lubricating properties. The emulsion is milky in appearance and can carry away heat and lubricate effectively.
Semi-synthetic fluids are a blend of soluble oils and synthetic fluids. They typically contain less than 30% oil and offer a good balance between cooling and lubrication.
Synthetic fluids are made from chemical compounds that do not include petroleum or other oils. They provide excellent cooling properties and are often used in applications requiring high levels of cleanliness and cooling.
What the HSE found
According to the HSE, most companies in the metalworking sector are not complying with their obligations. The main issues found during inspections were:
- Lack of local exhaust ventilation (LEV).
- Failing to complete regular fluid quality checks.
- Not providing health surveillance for lung and skin conditions.
There’s a good reason behind HSE’s concern. Metalworking fluids pose several health and safety risks, primarily due to their chemical composition and the manner in which they are used.
Workers can inhale the aerosols and mists generated during machining processes, leading to respiratory problems ranging from mild irritation of the airways to more severe conditions such as occupational asthma or hypersensitivity pneumonitis, especially when the fluids become contaminated with microbial growth.
Some studies have suggested a link between prolonged exposure to certain types of MWFs and an increased risk of cancer, particularly skin and respiratory tract cancers. Accidental exposure to concentrated metalworking fluids or their components can also cause chemical burns on the skin or eyes.
While uncommon, certain types of MWFs, especially those that are oil-based, can cause fire or explosion if they come into contact with hot surfaces or sparks.
HSE Recommendations
Despite all the risks, working with metalworking fluids can be safe if precautions are taken. The HSE recommends that companies implement local exhaust ventilation (LEV) systems, ensure fluid quality, and enforce health surveillance protocols.
Local Exhaust Ventilation (LEV)
The organisation strongly urges the installation of local exhaust ventilation (LEV) systems on CNC machines and other equipment that uses MWFs. LEV systems are engineered to effectively remove metalworking fluid mist, which can be hard to see under normal lighting conditions. If inhaled or touched for long periods, this mist can lead to respiratory issues and skin conditions. By capturing and extracting the oil mist at its source, LEV systems significantly reduce the concentration of airborne contaminants, minimising workers’ exposure.
Fluid Quality
Metalworking fluids can become breeding grounds for harmful bacteria if not properly maintained, leading to increased health risks for workers. Employers are encouraged to implement a routine monitoring schedule, ensuring that fluids are replaced or treated as necessary to keep them within safe operational parameters.
Health Surveillance
Health surveillance is a critical component of the HSE’s recommendations, aimed at early detection of any health issues that may arise from exposure to MWFs. Employers, under the guidance of occupational health professionals, must develop a health surveillance program. The protocol should encourage workers to promptly report any ill health symptoms related to their exposure to metalworking fluids or the mist generated during machining processes.
Work with Auto Extract to Safeguard Your Business
The consequences of doing nothing can be profound. Beyond the immediate human toll on employees harmed in the workplace, the repercussions can extend to legal consequences, with the potential for reputational damage and significant financial liability.
It’s time to take action with Auto Extract Systems (AES). With our expertise in removing hazardous substances directly at the source, we’re dedicated to improving air quality and protecting the health of your workforce. Our range of Local Exhaust Ventilation (LEV) systems is designed to meet the demands of your operation, ensuring compliance with health and safety regulations and creating a safer work environment for everyone.
Visit our website or call us to find out how we can make your workspace safer and compliant.
