Metalworking Fluids Audits Under the Control of Substances Hazardous to Health Regulations (COSHH), employers who use metalworking fluids (MWFs) are legally required to assess and control exposure to hazardous substances in mist, aerosol or direct contact form. Metalworking fluids are liquids used during machining, cutting, grinding or cooling to lubricate tools, reduce heat, and carry away swarf. Poorly managed fluids can give rise to harmful airborne mists, skin exposure, and microbial contamination that pose a serious risk to worker health.
At Envirochem, we provide specialist assessment of metalworking fluids exposure to support compliance, protect your workforce, and reduce the likelihood of costly operational disruption. Our audit approach helps to identify root causes of exposure and the effectiveness of control systems, whilst helping to ensure your fluid management strategy is safe, proportionate, and clearly documented.
What We Assess
Metalworking fluids present multiple routes of exposure. Inhalation of mist or vapour can irritate the lungs and contribute to occupational asthma and other respiratory conditions. Skin contact with contaminated fluids may cause dermatitis, whilst poorly maintained systems can support microbial growth that increases risk across the workplace.
In the absence of a suitable sampling method and clear exposure limits, we take an audit approach to assessment in order to:
- Identify risk of inhalation exposure
- Identify risk of dermal exposure
- Assess the effectiveness of controls and fluid maintenance systems against industry best practice
Our Process
Each assessment begins with a review of your machining operations, fluid types, and management practices. We work with your team to understand how fluids are stored, circulated and maintained, including whether any respiratory or skin complaints have been reported by workers. We also assess extraction systems, fluid change schedules, and PPE use to build a comprehensive picture of risk.
Where appropriate, we carry out real-time air sampling and aerosol counting to identify sources of exposure and assess how controls are being applied. Alongside this data, we use recognised qualitative assessment tools, based on the BOHS Guidance for Occupational Hygienists on the Assessment and Control of the Health Risks from Metalworking Fluid in order to benchmark your operations against regulatory guidance and good practice standards.
We then deliver a structured report outlining your current exposure risks and key areas of concern. This includes practical, proportionate recommendations to help you reduce inhalation risks, manage fluid condition, and improve long-term handling procedures. Our goal is to support sustained risk reduction through evidence-based action, not just one-off compliance testing.
The Impact of Uncontrolled MWF Exposure
Exposure to poorly managed metalworking fluids can lead to a range of preventable occupational health conditions. Workers exposed to airborne mist may develop asthma, extrinsic allergic alveolitis or long-term respiratory irritation. Direct skin contact with contaminated fluids can result in contact dermatitis or sensitisation, often leading to discomfort, lost work time and long-term absence from machining roles.
In some workplaces, fluid systems are allowed to stagnate, creating ideal conditions for microbial growth. This increases the risk of respiratory illness and contributes to poor fluid quality, which in turn reduces tool life, machining performance and product quality. These operational issues often go unnoticed until breakdowns or complaints begin to surface.
From a compliance perspective, inadequate fluid control can lead to enforcement notices and reputational damage. HSE inspections often focus on fluid condition, mist extraction and the presence of a robust COSHH risk assessment. Without auditing, it is difficult to demonstrate that control measures are effective or that staff are being adequately protected.
External audits support better decision-making on fluid maintenance, system upgrades, and PPE requirements, while helping businesses maintain a safe and efficient machining environment.
Why Choose Envirochem?
Envirochem provides a complete approach to MWF monitoring. Our consultants have extensive experience working with high-precision machining and manufacturing environments, and understand the pressures of maintaining both compliance and productivity, with members of the team involved in drafting technical guidance which is in use across the industry.
We tailor each assessment to your equipment and processes, working flexibly around production schedules to minimise disruption. Our reporting is designed to be practical and action-focused, giving you the clarity needed to prioritise improvements and meet your legal obligations under COSHH.
Speak to Our Team
If you are unsure whether your current fluid management approach meets regulatory standards, or would like to review your exposure controls, get in touch with our expert team. We’ll work with you to assess risks, identify practical improvements, and ensure your fluid systems are safe for workers and fit for purpose.
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