LEV105 Understanding Masterbatch

A Local Exhaust Ventilation (LEV)–Focused Guidance Document

Masterbatch production underpins much of the modern plastics industry — yet it remains one of the most complex and underestimated exposure risks in polymer processing.

From fine polymer powders and hazardous additives to static electricity, combustible dust, fumes, and extruder fires, masterbatch manufacture presents a unique combination of respiratory, fire, and explosion hazards. Too often, these risks are managed reactively, with LEV systems added without fully understanding the materials, processes, or failure modes involved.

LEV105: Masterbatch and Control was written to address that gap.

This guide provides a clear, structured overview of masterbatch production through the lens of Local Exhaust Ventilation, focusing on how exposure is generated, how control is lost, and how effective engineering solutions can be designed, assessed, and maintained.

A Practical, LEV-Biased Engineering Guide

LEV105 is not a chemistry textbook and not generic plastics guidance.

It is a practitioner-focused document, written for those responsible for designing, inspecting, testing, or relying upon LEV systems in masterbatch environments.

The guide walks through the full production process — from raw material handling to extrusion — highlighting where airborne dusts, fumes, vapours, and secondary exposures arise, and how LEV should be applied at each stage.

Key topics include:

• What masterbatch is and how it is used in industry

• Types of masterbatch (colour, additive, filler, combination)

• Properties of common masterbatch additives and processing aids

• Typical hazardous substances used (LDPE, LLDPE, PP, additives)

• Combustible dust and static electricity risks

• Health effects of polymer dusts, fumes, and decomposition products

• Masterbatch manufacturing processes and extrusion stages

• High-risk activities: weighing, mixing, tipping, feeding, and bag handling

• Dust and fume release points along the extruder

• Common real-world failures of LEV systems in masterbatch plants

Throughout, the emphasis remains on how contaminants behave, and what that means for capture, containment, and worker exposure.

LEV Systems in Masterbatch Production

Masterbatch environments place heavy demands on extraction systems. Fine powders, greasy vapours, heat, and static all influence system performance and reliability.

LEV105 examines the two most common filtration approaches used in this sector:

• Mechanical shake filter units

• Reverse jet filter units

The guide compares their practical advantages and limitations, including:

• Impact on airflow and capture efficiency

• Downtime and maintenance requirements

• Filter blinding and volumetric flow loss

• Suitability for continuous production environments

It also highlights the often-overlooked need to separate dust and fume extraction, particularly where hot, greasy vapours risk blinding dry dust filters.

Achieving Effective Control

LEV105 sets out a clear, structured approach to control, aligned with COSHH and HSG258 expectations, including:

• Comprehensive risk assessment for masterbatch operations

• Applying the hierarchy of control

• Designing partial enclosures for weighing and mixing

• Correct hood selection and positioning at extruders

• Managing waste sacks and secondary dust release

• Monitoring performance through airflow indicators and testing

• Maintenance, cleaning, and access considerations

• Training, RPE integration, and emergency planning

The guidance is written to support defensible decision-making during COSHH Regulation 9 Thorough Examination and Test (TExT), as well as day-to-day operational control.

Why This Matters

In masterbatch production, small failures can have serious consequences:

• Fine polymer dusts can form combustible atmospheres

• Static discharge can ignite accumulated dust

• Poor extraction allows widespread contamination of the workspace

• Extruder fires introduce smoke and toxic decomposition products

• Inadequate LEV leads to chronic respiratory exposure

LEV105 helps practitioners recognise these risks early, understand their root causes, and implement proportionate, effective controls — protecting workers, processes, and compliance.

Who This Guide Is For

LEV105 is essential reading for:

• LEV engineers and testers

• Plastics and polymer processing engineers

• Occupational hygienists

• Health & safety professionals

• Designers, installers, and duty holders

• Regulators and inspectors working in plastics manufacturing

If you are responsible for exposure control in a masterbatch environment, this guide provides the practical insight needed to get it right.

Product Details

• Title: LEV105: Masterbatch and Control (LEV-Biased Guidance)

• Series: LEV Academy Technical Guides

• Format: Digital guide (PDF)

• Focus: LEV design, assessment, and control in masterbatch production

• Author: Louise Davies Wood

• Published: December 2024

• Regulatory Context: COSHH Regulations, HSG258