Occupational Exposure to Gaseous Emissions in Molded Plastic Manufacturing: Health Impacts and Workforce Implications

Background and Objective: The manufacturing of molded plastics involves the release of volatile organic compounds, styrene and formaldehyde that pose health threats to workers. The purpose of this study was to examine the levels of exposure and the effects on lung function and workforce turnover in a molded plastic facility in New Hampshire. Materials and Methods: A complete (Mixed-Methods) study utilized both air monitoring (with measurements of Volatile Organic Compounds and Styrene/Carbon Disulfide/Fall-on-the-table Formaldehyde by Photoionization Detectors and Gas Chromatography) and physical data collection (spirometry and survey) from 38 workers at a molding facility. Data was analyzed using paired sample t-tests and statistical models with significance set at p<0.05 with calibrated and validated results and all aspects of ethical research were adhered to. Results: Comparing to the regulations established by the Occupational Safety and Health Administration (OSHA), exposure to VOCs (72.5 ppm) and styrene (61.4 ppm) were higher than OSHA limits seen in 76-88% of individual samples concentrating in locations surrounding purging stations. 68% of the workers reported strong odors; and 55% reported irritation. For those workers that indicated a strong odor and/or irritation, lung function decreased 8-9%. Conclusion: This suggests a risk for chronic exposure and ventilation improvements and/or improved engineering respiratory protection methods will need to be researched. Airborne emissions from molded plastic operations may pose a risk to respiratory health and may explain workforce turnover. So, ventilation, ongoing air sampling and PPE when warranted will need to be made available at minimum.