Preventing hearing loss in the Australian food industry

Employers in the Australian food industry face many challenges, including protecting the hearing of employees exposed to hazardous noise levels and ensuring the integrity and purity of their products.

These challenges are particularly relevant in food processing plants where hygiene standards are strictly maintained, and production lines operate continuously.

According to Safe Work Australia, managing noise risks is not optional: it’s a legal obligation under the Work Health and Safety (WHS) Regulations.

Noise within the Australia food manufacturing environment is often problematic. From high-speed mixers to pneumatic conveying blowers to packaging lines, food workers are exposed to constant sound levels that can easily exceed safe limits. More than 1.1 million Australian workers are exposed to hazardous workplace noise every day, with food processing workers comprising a significant portion of these cases.

Prolonged exposure to noise above 85 dB(A) during an eight-hour shift can lead to irreversible hearing damage. This isn’t just a health issue affecting employees, it’s a business concern that can impact productivity. Noise-induced hearing loss (NIHL) can reduce productivity, increase absenteeism, and result in costly compensation claims. For employers, investing in effective hearing protection is not only a legal obligation under WHS regulations, but also a smart strategy to safeguard their employees’ well-being and operational efficiency.

Regulatory framework in Australia

In Australia, noise management in the workplace is governed by the model Work Health and Safety (WHS) Regulations, which apply across most states and territories. These regulations place a clear duty of care on employers to eliminate or minimise the risk of hearing loss so far as is reasonably practicable.

Noise exposure standards

• Workers must not be exposed to noise levels above 85 dB(A) averaged over an 8-hour shift.
• Peak noise levels must never exceed 140 dB(C).
• If you need to raise your voice to speak to someone one meter away, the noise level is likely above the safe threshold.

Employer obligations include identifying noise hazards, implementing control measures, providing personal hearing protection when necessary, and providing training designed to promote correct wearing of hearing protectors. Audiometric testing is also required by means of a baseline test within 3 months of employment and follow-up tests every 2 years for workers who regularly wear hearing protection.

Sources of noise in the food industry

Noise in food manufacturing environments comes from multiple sources, often operating simultaneously, which makes overall exposure levels very high.

Common sources include:

• Mixers and blenders: 90–95 dB(A)
• Grinders and bowl choppers: 85–95 dB(A), hammer mills up to 100 dB(A)
• Conveyor systems: 80–90 dB(A)
• Cutting and slicing equipment: up to 100 dB(A
• Cleaning equipment: 90–100 dB(A)
• Refrigeration units: 85–90 dB(A)
• Packaging lines: 85–95 dB(A)

In food manufacturing, the worst noise hotspots usually come from machines that create high-velocity air, impact/clatter, or high-speed rotating parts. Air compressors (especially older piston types), plus air leaks and blow-off nozzles are often amongst the top offenders. Large extraction and ventilation fans can add a constant background load (not always the loudest single source, but it raises everyone’s daily dose).

A National Acoustic Laboratories / Australian Acoustical Society paper (using measured workplace dosimetry plus ABS employment figures) estimated that in 2010 there were ~193,900 people employed in Food Product Manufacturing, and ~161,600 of them were exposed above the noise exposure standard (LAeq,8h 85 dB), i.e., a harmful daily noise dose.

Based on the above figures, over 83% of food manufacturing workers were exposed to excessive noise every day, compared to 20% of the general workforce. 

Best practices for preventing hearing loss

Preventing hearing loss in the food industry requires a comprehensive and consistent approach that encompasses:

1. Implementation of engineering controls, such as installing acoustic barriers and soundproof enclosures around noisy equipment.

2. Regular maintenance of machinery is essential to reduce friction and vibration noise, which are major contributors to excessive sound levels.
3. Where possible, investment in quieter machinery that can significantly lower exposure.

4. Administrative measures Such as job rotation that limits the time each worker spends in high-noise areas, and scheduling the loudest tasks during off-peak hours to reduce overall exposure.

5. Training employees to understand noise risks and the correct use of protective equipment.
6. When these measures are insufficient, personal protective equipment (PPE) is the last line of defense.

In the food industry, hearing protection must meet strict hygiene standards and integrate seamlessly with other protective gear such as hairnets and face masks. Custom-moulded earplugs are particularly effective because they provide a perfect fit, remain comfortable during long shifts, and can be easily cleaned. However, hearing protection in food processing faces a unique challenge: detectability. If an earplug falls into the production line, the entire batch may need to be discarded, resulting in costly waste. This is why metal detectable hearing protectors are essential.

QEOS Agro+: the ideal solution

Foreign-object contamination is a major, ongoing concern in Australian food processing, mainly because it can cause physical injury, and it’s a recurring driver of recalls and preventive controls.

An earplug is a legitimate foreign-body contamination risk in food processing and is exactly the kind of “small, easy-to-lose” item that foreign-body programs are designed to control. Soft and small, disposable earplugs are especially tricky because if they fall into a product such as powders, mince or bulk ingredients, they can quickly become hidden. Foam plugs can fragment, creating multiple pieces that are ‘invisible’ to metal detectors.

What truly sets Qeos Agro+ apart is its detectability: each component (earplug, cord and handles) is detectable by metal detectors, ensuring that if one or more of these items enters the production chain, it can be identified and retrieved before contamination occurs.

Additional features that help prevent a contamination risk in food processing:

• Qeos Agro+ hearing protectors are blue, making visual detection easier.
• They come with a cord and clip (both metal detectable) so can be securely fastened to a garment, if safe to do so.
• Being custom moulded to the user’s ears, they fit securely with or without the cord.
• They are made from Crylit, a hypo-allergenic resin that will not easily break, tear or shed fragments.
• They come with a storage case in which they can be securely stored when not being used.

Conclusion

Supplying food workers with Qeos Agro+ metal detectable customized hearing protectors protects product integrity and helps prevent- unnecessary losses, while maintaining compliance with strict hygiene standards.

By choosing Qeos Agro+, employers go beyond meeting regulatory requirements. They safeguard their employees’ hearing, maintain the purity of their products, and reduce the risk of costly production waste. In an industry where safety and quality are non-negotiable, Qeos Agro+ offers a reliable, efficient, and hygienic solution that supports both compliance and operational excellence.