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A UKbased medical diagnostic products company, manufacturing test kits for the NHS as well as private healthcare providers, engaged EPIT Group for specialist Dangerous Substances and Explosive Atmospheres Regulations (DSEAR) consultancy to assess and manage the risks associated with flammable substances used within their production facility. The site involved the storage, handling and potential release of flammable gases and vapours, necessitating a comprehensive compliance strategy under DSEAR.
Challenge
Although some of the client’s equipment was subject to ATEX certification, much of the site’s risk stemmed from the potential release of flammable vapours resulting in the possible presence of hazardous areas. The client required a clear understanding of their DSEAR obligations, guidance on managing the elimination or reduction of hazardous areas as well as ignition risks, and support in implementing robust internal DSEAR compliance documentation.
Solution
EPIT delivered a tailored DSEAR consultancy programme to support regulatory compliance and operational safety:
- DSEAR Risk Assessing and Surveying
EPIT’s DSEAR consultants advised the client how to conduct and document a detailed risk assessment, identifying potential hazards related to gas and vapour release, and assessing likelihood and extent of explosive atmospheres being present, in line with DSEAR criteria. - Hazardous Area Classification
The facility was reviewed and classified according to DSEAR defined zones (Zones 0, 1, and 2). In most situations there were no hazardous areas due to very low quantities being released and local extract ventilation providing sufficient dilution. This zoning exercise ensured that the presence of dangerous substances was accurately reflected in operational planning and safety controls. - DSEAR Policy and Control Measures
EPIT advised on appropriate standards and best practices, helping the client formalise a DSEAR policy and implement proportionate control measures to reduce risk while maintaining production efficiency.
Results
The client successfully implemented a site wide DSEAR compliance strategy, enabling them to continue operations with confidence. By applying risk based controls and aligning with relevant standards, the organisation was able to demonstrate its commitment to safety and regulatory integrity.
Client Impact
- DSEAR Compliance Achieved: the client met regulatory requirements through structured assessment, zoning, and policy implementation.
- Informed Decision Making: operational teams gained confidence in identifying, managing, and mitigating hazards.
- Minimised Disruption: compliance was achieved without unnecessary certification or production delays.
EPIT’s DSEAR consultancy enabled this healthcare product supplier to operate safely in a regulated environment, delivering essential products while meeting the obligations set out in the Dangerous Substances and Explosive Atmospheres Regulations.
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