Background
A manufacturing facility sought respiratory protection for employees intermittently exposed to acetic acid vapors during short, frequent tasks (2 minutes, 3x/day). Their existing standard masks with particulate filters were deemed ineffective due to two key challenges:
- Facial Hair: Staff were not clean-shaven, compromising the seal of tight-fitting masks.
- Chemical Exposure: Acetic acid (CAS 64-19-7) required specialized filtration beyond particulate protection.
The facility referenced HSE EH40 guidelines, noting a Workplace Exposure Limit (WEL) of 20ppm over 15 minutes. Their goal was to upgrade to a solution ensuring compliance and safety without requiring staff to shave.
Key Challenges
- Seal Integrity: Facial hair rendered traditional masks ineffective.
- Chemical Filtration: Acetic acid vapors demanded acid gas filtration, not just particulate protection.
- Intermittent Use: Short exposure periods required a system that balanced practicality with reliability.
Solution Exploration: Powered Air Purifying Respirators (PAPR)
PAPR systems were identified as ideal for this scenario. This was a mandatory requirement, as a study by the Health and Safety Executive (HSE) found that protection (on tight-fitting RPE) could be reduced by as much as 33% due to stubble, and this effect worsened as facial hair grew.
✅Positive Pressure – They provide positive pressure, eliminating reliance on a facial seal. See more here (Health and Safety Executive)
✅No Fit Test Required – These devices feature a battery-operated fan that directs filtered air into a loosely fitted hood or helmet, eliminating the need for an airtight seal. For futher details this blog is helpful – HSQE – Can You Have a Face Fit Test with a Beard?
✅Integrated Filters to Offer Protection Required – integrated filters targeting acid gases. Two options were evaluated:
Option 1: 3M Versaflo TR-600 Series
Components:
3M Versaflo TR-619UK Powered Air Turbo Starter Kit with M-306 Helmet (includes helmet, battery, and blower).
£1,450.00 Inc. VAT
TR-6580E ABEK2K1HGP Filter (combines acid gas, organic/inorganic vapors, ammonia, and particulate protection).
£98.50 Inc. VAT
Advantages:
- Modular design for versatility.
- Explicitly compatible with ABEK filters for acid gases.
Considerations:
Protection Levels
Based on the technical information provided on the product page, the 3M Versaflo TR‑6580E ABE2K1HGP filter is engineered to provide combined protection against particulates, organic vapours, and acid gases—including nuisance-level acid gases such as acetic acid.In practical terms, if your process results in short-term exposures (about 2 minutes, up to three times a day) and the acetic acid concentration remains within the nuisance range (for example, around the HSE EH40 reference of 20 ppm for a 15‑minute period), this filter should be suitable for protecting your user when used with a compatible TR‑600 or TR‑800 series PAPR system.
Exposure Verification
It’s important to verify that the actual acetic acid concentrations in your application do not exceed the filter’s rated capacity. You should review the detailed technical data (breakthrough times, service life, and maximum concentration ratings) in the filter’s datasheet to ensure it meets your specific needs.
Additional Resources:
Option 2: Sundström SR500 + SR570 System (Most Cost Effective Solution)
Components:
SR500 + SR570 PAPR Ready Pack (includes helmet, blower, and SR510 particulate filters).
Price £1,050.00 Inc. VAT
SR597 A1BE2K1 Gas Filters – Pack of 2 (covers acid gases, organic/inorganic vapors, ammonia).
£78.50 Inc. VAT
Advantages:
- Cost-effective alternative with comparable protection. £420.00 less for the full kit, including filters, compared to Versaflo option.
Considerations:
-
While acetic acid (CAS 64-19-7) isn’t explicitly listed, it typically falls into the category of weak acidic gases. At nuisance-level exposures—such as your short, intermittent exposures—the SR 597 should offer sufficient protection when used in conjunction with an appropriate particulate filter (like the SR 510 P3 R) as required by the fan unit (SR500/SR500 EX).
- Based on the product leaflet (below) for the SR 597 A1BE2K1 Gas Filter, this filter is designed to offer combined protection by covering:
- Type A – organic gases/vapours (for solvents with boiling points > +65 °C)
- Type B – inorganic gases/vapours (such as chlorine, hydrogen sulphide, and hydrogen cyanide)
- Type E – acidic gases/vapours (such as sulphur dioxide and hydrogen fluoride)
- Type K – ammonia and certain amines (e.g. ethylene diamine)
Summary:
If your acetic acid concentrations are within the nuisance range (similar to the 20 ppm 15‑minute reference value you mentioned), then the SR 597 A1BE2K1 Gas Filter is expected to provide sufficient coverage. However, for higher concentrations or longer exposures, you should verify that the breakthrough time for acetic acid falls within your process requirements.The best choice depends on your actual acetic acid concentrations, work duration and whether you already require particulate filtration.
In many cases where exposures are short and within nuisance levels (as in your application), this option should work—provided the cartridge’s breakthrough time meets your requirements.It’s important to verify the technical data (attached) for breakthrough times, service life, and maximum concentrations for your chosen cartridge(s) against your specific process conditions.
Additional Resources:
- Sundstrom SR500 Product Leaflet
- Sundstrom SR500 Operating Instructions
- Sundstrom SR500 System Overview
- Sundstrom SR597 Product Leaflet
Key Decision Factors
Filter Specifications:
- Both systems use ABEK-type filters (or equivalents) to neutralize acid gases.
- Technical datasheets must be studied to confirm breakthrough times for acetic acid at the facility’s exposure levels (≤20ppm).
Cost Comparison
- 3M Versaflo: Higher initial investment but modular for future upgrades.
- Sundström SR500: Lower upfront cost with bundled particulate/gas filters. Save £420.00 (inc VAT) for full kit, helmet +filters.
Compliance:
- Both systems meet HSE standards when used within filter limits.
Conclusion & Takeaways
- PAPR systems are ideal for non-clean-shaven users, ensuring protection through positive pressure.
- ABEK-type filters (or equivalents) are critical for acid gas exposure. Always cross-reference technical data with workplace conditions.
- Cost vs. Flexibility: Balance initial investment with long-term needs (e.g., modularity, filter availability).
- Consult Experts: Collaborate with safety professionals to validate selections and conduct workplace testing.
By prioritizing compliance, user comfort, and rigorous risk assessment, facilities can safely manage chemical exposures while accommodating diverse workforce needs.
Need Help? Contact our respiratory protection specialists for personalized guidance on PAPR systems and filter selection.
