The Health and Safety Executive is carrying out a programme of inspections at large bakeries across Great Britain from January 2026, focusing on the control of flour dust and other hazardous airborne ingredients.
Inspectors will assess whether employers are adequately protecting workers from exposure to dusty substances, including flour and bread improver enzymes, which are known causes of occupational asthma and respiratory sensitisation.
Asthma Triggering
Flour dust remains one of the most common causes of occupational asthma in Great Britain. Once a worker becomes sensitised, even very small amounts of dust can trigger symptoms. In many cases, the condition is irreversible.
The regulator has warned that dust generated during routine bakery processes can linger in the air if not properly controlled. High risk tasks include dusting flour during dough handling, tipping and dispensing dry ingredients, and cleaning up flour spills.
Under the Control of Substances Hazardous to Health Regulations, employers must apply the recognised hierarchy of controls when managing exposure risks. HSE inspectors will examine whether bakeries have considered control measures in the correct order of effectiveness.
This includes eliminating dusty processes where possible, for example by using non stick belts instead of flour as a lubricant, or installing sensors to stop flour dusters when products are not present. Substitution with lower dust alternatives, such as low dust flour or liquid and gel based ingredients, should be considered before engineering controls such as local exhaust ventilation. Respiratory protective equipment should be used only as a last resort.
Surveillance Systems
Inspectors will also check that suitable health surveillance is in place for employees exposed to flour dust and similar substances.
Mike Calcutt, Deputy Director in HSE’s Engagement and Policy Division, said: “Too many workers in bakeries are suffering from unnecessary exposure to dusty ingredients including flour. When employers prevent exposure, the risk of asthma is removed. That’s the key principle we want bakeries to apply
“It may be possible to reduce the risk with ventilation or protective equipment, but these controls should not be selected where elimination and substitution would be effective. I urge employers to carefully consider dusty processes, eliminating risk and substituting to prevent exposure by weighing the long-term benefits in sustaining prevention against the true cost of ill-health and using controls lower in the hierarchy.”
HSE said previous inspection activity has demonstrated the benefits of correctly applying the hierarchy of controls. In one case, a large bakery reviewed its national use of flour and trialled low dust flours and dust suppressants, significantly reducing airborne dust levels and lowering the risk to workers. By prioritising elimination and substitution, the business reduced reliance on mechanical extraction systems and cut associated costs.
Guidance on controlling flour dust in bakeries is available via HSE. Low dust flour is now regarded as an established industry standard, and the Federation of Bakers’ Blue Book provides sector specific advice on dust control and health surveillance. Employers are being urged to review current arrangements and ensure compliance.
