LEV105: Masterbatch Manufacture and Local Exhaust Ventilation

An LEV-Focused Technical Guide for the Masterbatch Industry

Masterbatch manufacture is one of the most challenging environments in which to design, operate and maintain effective Local Exhaust Ventilation (LEV).

From weighing fine pigments and powdered additives to mixing, extrusion and material handling, every stage of the process has the potential to generate hazardous airborne contaminants. Fine respirable dusts, polymer additives and coloured pigments present unique challenges for exposure control, whilst the behaviour of these materials can significantly affect the long-term performance of LEV systems.

Despite these challenges, very little practical guidance exists that explains how LEV should be applied specifically to masterbatch manufacture.

LEV105: Masterbatch Manufacture and Local Exhaust Ventilation has been written to address that gap.

A Practical Engineering Handbook

LEV105 is not a textbook on polymer chemistry, nor is it a replacement for HSG258.

Instead, it is a practical engineering handbook that explains how Local Exhaust Ventilation can be successfully applied throughout the masterbatch manufacturing process.

Written from the perspective of an experienced LEV engineer and Thorough Examination and Test (TExT) examiner, the handbook combines engineering principles with practical observations gathered from real manufacturing environments.

The emphasis throughout is on understanding how contaminants behave, where exposure occurs and how engineering controls can be designed, maintained and assessed to provide reliable long-term protection.

What the Guide Covers

LEV105 follows the complete manufacturing process and explains how effective exposure control can be achieved at every stage.

Topics include:

• Understanding the hazards associated with masterbatch manufacture
• Raw material handling and hazardous powders
• COSHH, Safety Data Sheets and hazard identification
• Engineering control strategies
• Partial enclosure design and application
• Mixing, weighing and manual charging operations
• Hopper charging and extrusion processes
• Dust behaviour and exposure mechanisms
• Maintaining LEV performance
• Filter systems and reverse pulse cleaning
• Ductwork contamination and system deterioration
• Thorough Examination and Test (TExT)
• Practical engineering case studies from real masterbatch installations
• Common LEV defects identified during TExT examinations
• Practical solutions based on industry experience

Built Around Real Manufacturing Processes

Unlike generic LEV guidance, LEV105 focuses specifically on the processes found within masterbatch manufacture.

The handbook includes numerous practical examples covering operations such as:

• Manual weighing of pigments and additives
• Small batch mixing
• Production-scale mixing
• Hopper charging
• Extruder feeding
• Automatic conveying systems
• Dust control during discharge operations
• Common enclosure arrangements
• Typical LEV failures and practical improvements

Each case study explains:

• how exposure is generated;
• why engineering controls succeed or fail;
• common defects encountered during TExT; and
• practical recommendations for improving control.

More Than Compliance

Whilst LEV105 supports compliance with the Control of Substances Hazardous to Health (COSHH) Regulations and complements HSG258 – Controlling Airborne Contaminants at Work, its primary objective is to improve engineering understanding.

Rather than simply describing regulatory requirements, the handbook explains how experienced LEV engineers assess real manufacturing processes, interpret system performance and apply engineering judgement to achieve effective exposure control.

Throughout the handbook, readers will find:

• Engineering Insights explaining key LEV principles.
• LEV Academy Tips drawn from practical experience gained during real Thorough Examination and Test examinations.

These features provide practical knowledge that extends beyond standard guidance documents and reflects the challenges encountered within operational masterbatch manufacturing facilities.

Who Should Read This Handbook?

LEV105 has been written for:

• LEV Engineers
• TExT Examiners
• Occupational Hygienists
• Health and Safety Professionals
• Plastics Manufacturing Engineers
• Process Engineers
• LEV Designers and Installers
• Maintenance Engineers
• Production Managers
• Duty Holders responsible for COSHH compliance

Whether you are designing a new LEV system, carrying out a Thorough Examination and Test, maintaining existing equipment or managing exposure risks within a masterbatch facility, LEV105 provides practical guidance grounded in real industrial experience.

Why LEV105 is Different

Most LEV guidance explains the principles of ventilation.

LEV105 explains how those principles are applied in masterbatch manufacture.

Rather than repeating the content of HSG258, this handbook focuses on the practical challenges that experienced LEV engineers encounter every day—from cohesive dusts and filter blinding to poorly positioned hoods, ineffective capture, and the gradual deterioration of system performance.

Drawing on years of practical experience, LEV105 bridges the gap between regulatory guidance and real-world engineering, helping readers understand not only what should be done, but why it matters.

Product Details

Title: LEV105: Masterbatch Manufacture and Local Exhaust Ventilation

Series: LEV Academy Technical Guides

Format: Digital PDF

Length: 85 pages

Author: Louise Davies Wood

Subject: Local Exhaust Ventilation in Masterbatch Manufacture

Designed for: Engineers, Occupational Hygienists, Duty Holders and TExT Examiners