Start with responsibility and intended use
Where flammable liquids, vapours, gases or combustible dusts may create fire or explosion risk, the employer must assess and control the dangerous-substance risk. Equipment selection follows the classified environment and the complete process, not the product name alone. Define who supplies, integrates, installs, owns and uses the equipment, and record the final product, packaging, environment, operator tasks and maintenance interventions. A generic certificate or checklist cannot replace that project-specific scope.
Questions for the project team
- Which substances, concentrations, temperatures and release scenarios are credible?
- Where can a hazardous atmosphere occur during transfer, filling, cleaning, spills or maintenance?
- What zoning, equipment category, ventilation, bonding, earthing and ignition controls are required?
- How will changes of formulation, pack, extraction or room layout be managed?
Documents and evidence to plan
The exact records depend on the project, but the following deliverables provide a practical starting structure:
- DSEAR risk assessment by competent people
- hazardous-area classification where required
- equipment and protective-system specification
- bonding, earthing and ventilation verification
- safe procedures for operation, cleaning, spills and maintenance
Apply the controls across the machinery lifecycle
Review the requirement during specification, supplier selection, design review, factory testing, installation, site acceptance, training, routine operation, cleaning, maintenance and modification. A change that appears small—such as a new solvent, bottle size, cap, guarding opening, extraction system or line speed—can alter the original risk or conformity basis.
Current official sources
Use the official sources below as the starting point and check their update dates when the project is reviewed.
- HSE: Dangerous Substances and Explosive Atmospheres Regulations ↗
- GOV.UK: placing manufactured goods on the GB market ↗
Common questions
What is the starting point for dsear and explosive-atmosphere planning for filling lines?
Where flammable liquids, vapours, gases or combustible dusts may create fire or explosion risk, the employer must assess and control the dangerous-substance risk. Equipment selection follows the classified environment and the complete process, not the product name alone.
Does a conformity mark replace the user risk assessment?
No. Supply obligations and duties for safe installation, use, inspection, maintenance and workplace risk control are related but distinct.
Who should confirm the legal interpretation?
Use current official guidance and competent legal, safety, engineering, metrology or food-safety advice appropriate to the project and jurisdiction.
When should the assessment be reviewed?
Review it when equipment, product, packaging, formulation, process, controls, room layout, use or official requirements change, and after relevant incidents or findings.