Factory Noise Surveys
Factory noise surveys assess machinery, production processes, worker activities and employee exposure across real operating conditions. We combine area, task and personal measurements with an occupational hygiene interpretation so manufacturing employers understand exposure, prioritise controls and meet their duties under the Control of Noise at Work Regulations 2005.
Machinery
Source-focused
Production
Real operating conditions
Exposure
By similar group
Manufacturing noise assessment
Machinery, tasks and worker exposure
What it is
What is a factory noise survey?
A factory noise survey is an occupational assessment of noise inside a manufacturing or production environment. It evaluates machinery, processes, worker tasks and the noise exposure employees receive while doing their jobs, rather than the noise emitted from the building to neighbouring areas.
Production noise is frequently variable. Machine speed, product mix, the number of machines running concurrently, operator movement, maintenance work and shift differences can all change exposure materially across a day or week. A factory noise survey is planned to reflect representative operating conditions so the measured exposure is meaningful.
Findings support compliance with the Control of Noise at Work Regulations 2005 and inform practical noise-control decisions. A factory survey is occupational in scope and distinct from environmental boundary-noise assessment, which considers noise emitted to surrounding areas for planning or community-impact purposes. For the wider service overview, see our workplace noise surveys page.
Common sources
Common factory noise sources
Production environments vary widely. The sources below are commonly encountered, but no individual factory will contain all of them — the relevant sources are confirmed during scoping.
- Presses and stamping
- CNC machining
- Cutting equipment
- Grinders
- Compressors
- Pneumatic tools
- Conveyors
- Extraction systems
- Industrial fans
- Pumps
- Packaging machinery
- Bottling lines
- Impact processes
- Metal handling
- Process alarms
- Maintenance tasks
- Material loading and unloading
When you need a survey
When a factory noise survey is needed
- Employees need to wear hearing protection
- Difficulty communicating near machinery
- New machinery or production lines installed
- Changed layouts or production volumes
- Reported hearing concerns from workers
- Outdated or missing noise risk assessment
- Uncertain employee exposure
- High peak or impact noise activities
- Failed or damaged engineering noise controls
- HSE or internal compliance review
- Commissioning of new processes
- Different exposure patterns between shifts
Walkthrough & scoping
Factory walkthrough and scoping
Scoping makes sure the survey reflects representative production conditions rather than a snapshot of a single shift or quiet period.
- Review of production processes
- Machinery and equipment inventory
- Production schedules and demand patterns
- Worker roles and task allocation
- Shift patterns and rota arrangements
- Maintenance, cleaning and changeover activities
- Existing risk assessments and survey history
- Current hearing protection arrangements
- Known high-noise areas
- Any previous measurement data available
Measurement strategy
Measurement strategy
Most surveys combine several methods. The exact mix depends on the factory — not every method is required everywhere. Background on representative measurement is on the workplace noise monitoring page.
Area sound-level measurements
Characterising background and zonal noise across production areas.
Operator-position measurements
Capturing exposure at the locations workers actually occupy during tasks.
Task-based measurements
Quantifying noise during specific activities of different duration and frequency.
Machinery-source measurements
Identifying dominant equipment and the contribution of individual machines.
Personal noise dosimetry
Worker-worn monitoring for mobile, multi-task or variable exposure groups.
Peak sound-pressure measurement
Specifically targeting impact, pressing and pneumatic discharge events.
Production observations
Documented activity records to interpret measurements in operating context.
Workplace noise mapping
Visual representation of measured levels across production areas where useful.
Repeat measurements
Captured under different operating conditions where exposure varies materially.
Production conditions
Production lines and changing operating conditions
Exposure changes with production demand. A single measurement taken during an unusually quiet period can substantially underestimate the noise workers actually receive.
- Start-up, steady production and shutdown phases
- Different products or materials being processed
- Variation in machine speed and feed rates
- Number of machines operating concurrently
- Operator movement between positions
- Cleaning, maintenance and changeover work
- Short high-noise interventions
- Shift-to-shift variation in staffing and demand
Machinery assessment
Machinery noise assessment
Source-focused measurement helps identify the equipment driving exposure and the workers most affected. This complements the broader exposure picture captured by area and personal monitoring — see workplace noise monitoring.
- Identifying dominant sources within the area
- Operator exposure at the actual working position
- Distance, orientation and shielding from the source
- Guarding, enclosure and acoustic treatment condition
- Vibration and structural transmission paths
- Compressed-air discharge and pneumatic processes
- Impact noise from forming and material handling
- Maintenance condition of bearings, panels and silencers
- Machine cycle and duty patterns
- Interaction between multiple simultaneous sources
Employee exposure
Employee exposure assessment
Workers are grouped by similar exposure where appropriate, with additional measurement for individuals whose pattern of work differs materially. Detailed interpretation of LEX,8h, weekly exposure and action values is covered on the noise exposure assessment page, and worker-worn monitoring on the personal noise dosimetry page.
- Similar exposure groups by role and area
- Fixed-position machine operators
- Mobile operators moving between stations
- Multi-task workers covering several processes
- Maintenance and engineering staff
- Production supervisors and team leaders
- Forklift and materials-handling drivers
- Cleaning and changeover teams
- Different exposure patterns between shifts
- Daily and weekly personal exposure
- Peak sound-pressure exposure
Factory noise mapping
Factory noise mapping
A workplace noise map can be a useful visual aid, but it does not replace employee exposure assessment — the two are complementary rather than interchangeable.
- Higher-noise areas and the boundaries between them
- Visual support for hearing-protection-zone review
- Relative contribution of individual machines
- Helping prioritise control measures
- Worker, visitor and contractor briefing material
- Records that can be reviewed after process changes
Peak & impact noise
Peak and impact noise
Peak sound pressure (LCpeak) is assessed separately from average exposure. Short, very high-level events can exceed peak action and limit values even where time-averaged exposure is moderate.
- Pressing and stamping operations
- Metal drops and tipping
- Hammering and forming
- Pneumatic discharge
- Impact and percussive tools
- Product ejection from machinery
- Material handling and loading
- Cartridge-operated tools where used
Noise control
Noise-control opportunities
The most appropriate combination of controls is site-specific. Recommendations are framed against actual production, machinery and worker patterns rather than generic catalogue solutions. Employer duties for control at source are summarised on the noise at work regulations page.
- Quieter purchasing specifications for new equipment
- Machine enclosure and acoustic guarding
- Vibration isolation and damping
- Silencers on exhausts and air discharge
- Compressed-air pressure and nozzle control
- Conveyor and impact-point modifications
- Preventive maintenance to address noise-related wear
- Remote operation and control-room separation
- Physical separation of workers from sources
- Reducing unnecessary exposure time and rotating tasks
- Production scheduling to limit concurrent high-noise work
- Replacement of worn or noisy tooling
Maintenance & condition
Maintenance and machinery condition
Noise often increases as equipment wears. Survey findings can highlight machines that warrant maintenance attention, but they do not replace engineering inspection of the equipment itself.
- Worn bearings and drives
- Loose panels and guards
- Damaged or removed acoustic guards
- Compressed-air leaks
- Vibration from mounting wear
- Worn cutting tooling and inserts
- Poor lubrication of moving parts
- Damaged or degraded silencers
- Imbalance in rotating equipment
- Degraded isolation mounts and pads
Hearing protection
Hearing protection in factories
A factory noise survey will normally include observations on hearing protection. A dedicated review of attenuation, fit and PPE compatibility is delivered through our hearing protection assessment service.
- When hearing protection is required
- Matching attenuation to measured exposure
- Defined hearing-protection zones and signage
- Communication and warning-signal needs
- Compatibility with hard hats, eyewear and respirators
- Avoiding both underprotection and overprotection
- Training, fitting and supervision
Survey process
Survey process
- 1
Consultation and scope
Initial discussion to define areas, processes, shifts and survey objectives.
- 2
Information review
Review of risk assessments, prior surveys, machinery information and PPE arrangements.
- 3
Representative site visit
Visit timed to capture normal production conditions rather than quiet periods.
- 4
Walkthrough and observation
Documented review of processes, tasks, worker movement and high-noise activities.
- 5
Measurement plan
Plan covering area, operator-position, task, machinery and dosimetry coverage as needed.
- 6
Calibration checks
Pre- and post-measurement calibration of all sound-level instrumentation.
- 7
Area and task measurements
Sound-level measurements at production locations and during defined activities.
- 8
Dosimetry where appropriate
Worker-worn monitoring for mobile, variable or multi-task exposure groups.
- 9
Worker and supervisor discussions
Brief conversations to validate observed activity and surface non-routine work.
- 10
Review of production conditions
Confirmation that measured periods reflect normal operating patterns.
- 11
Data validation
Quality checks on captured data, including review of any non-representative events.
- 12
Exposure interpretation
Calculation and interpretation of LEX,8h and peak exposure against action values.
- 13
Control recommendations
Practical, prioritised recommendations framed for the site's operations.
- 14
Technical report
Clear written report covering scope, methods, findings, exposures and recommended actions.
Deliverables
What the client receives
- Documented survey scope
- Process and machinery observations
- Area and task measurement results
- Employee exposure findings by similar exposure group
- Peak-noise findings for impact and pneumatic processes
- Identified higher-risk worker groups
- Action-value interpretation against CNWR 2005
- Workplace noise-map findings where included
- Hearing-protection observations and suitability comments
- Practical noise-control recommendations
- Prioritised action plan for the site
- Clear written technical report
- Practical next steps for review and re-survey
A factory noise survey provides competent occupational hygiene advice on exposure, hearing protection and noise control. It does not constitute legal certification or a guarantee of compliance.
Types of factory supported
Types of factories supported
Factory noise surveys for a wide range of UK manufacturing and production environments, including:
Metal fabrication
General engineering
Automotive manufacturing
Plastics production
Food production
Packaging
Woodworking
Printing
Recycling
Bottling
Assembly lines
Textile production
Chemical processing
Building-product manufacturing
Common mistakes
Common factory survey mistakes
- Measuring during an unusually quiet period
- Ignoring maintenance and changeover tasks
- Focusing only on the loudest single machine
- Not accounting for mobile and multi-task workers
- Relying on supplier or catalogue noise data
- Ignoring peak and impact noise
- Assuming hearing protection alone solves the issue
- Failing to consider different shifts
- Not recording task duration alongside levels
- Using consumer phone apps as measurement tools
- No reassessment after machinery or layout changes
- Overlooking damaged or removed engineering controls
Why us
Why choose Workplace Noise Surveys
Industrial workplace focus
Surveys planned and delivered for manufacturing and production environments rather than environmental contexts.
Occupational hygiene-led approach
Exposure interpretation, control hierarchy and CNWR 2005 framing applied as standard.
Representative production measurements
Visits scheduled to capture realistic operating conditions, not convenient quiet periods.
Employee exposure interpretation
Findings expressed by similar exposure group and reviewed against action values.
Practical machinery understanding
Comfortable working safely around presses, CNC, conveyors and live production equipment.
Control-focused recommendations
Prioritised actions framed around what is reasonably practicable for the site.
UK regulatory context
Decisions framed within the Control of Noise at Work Regulations 2005 and supporting guidance.
Green Air Monitoring network
Supported by the wider Green Air Monitoring occupational hygiene network across related disciplines.
For the broader service, see our workplace noise surveys, supporting workplace noise monitoring, exposure interpretation via noise exposure assessment, worker-worn monitoring via personal noise dosimetry, reverberation and sound-spread work via workplace acoustic surveys and PPE review via hearing protection assessment. Learn more about us or get in touch. For sector-specific assessments, see our engineering workshop noise surveys and machinery noise surveys. For wider engineering context, read our Noise Control Measures in Industry guide.
FAQ
Factory noise survey FAQs
What is included in a factory noise survey?+
A factory noise survey typically combines a documented walkthrough of production areas, area sound-level measurements, operator-position and task-based measurements, personal noise dosimetry for representative workers, peak sound-pressure measurements where impact processes are present, and observation of real operating conditions. Findings are interpreted against the exposure action and limit values, and reported with practical control recommendations.
How long does a factory noise survey take?+
Duration depends on the size of the facility, the number of distinct production areas, the variety of machinery and tasks, shift coverage and whether full-shift dosimetry is required. A small single-shift production unit may take part of a day; a multi-area manufacturing plant with several shift patterns can require two or more visits to capture representative conditions.
Does production need to remain running during the survey?+
Yes, in almost all cases. A meaningful factory noise survey must reflect representative operating conditions — machinery running at normal production speed, typical product mix and routine worker activity. Measurements taken during a shutdown or unusually quiet period do not represent the exposure workers actually receive and can underestimate risk.
Will every employee need to wear a noise dosimeter?+
No. Dosimetry is usually applied to a representative sample of workers grouped by similar exposure — for example, machine operators, mobile maintenance staff, forklift drivers and supervisors. The objective is to characterise each group's exposure, not to instrument every individual. Where exposure within a group varies, additional workers are added to the sample.
Can the survey cover several shifts?+
Yes. Where day, evening and night shifts run different product mixes, staffing patterns, machine speeds or maintenance windows, exposure can differ materially between them. A factory noise survey can be scoped to include multiple shifts, either through repeat visits or extended dosimetry coverage, so each pattern is represented.
Can a factory noise survey identify the noisiest machines?+
Yes. Source-focused measurements at operator positions and around machinery help identify dominant contributors, including individual presses, CNC equipment, compressors, conveyors and pneumatic processes. This supports prioritisation of engineering control, purchasing decisions for replacement equipment and targeted maintenance.
What is factory noise mapping?+
Factory noise mapping is a visual representation of measured sound levels across production areas. It can help identify higher-noise zones, support hearing-protection-zone boundaries, illustrate the contribution of individual machines and inform visitor and contractor briefings. A noise map is a complement to — not a substitute for — personal exposure assessment.
Will the survey assess hearing protection?+
A factory noise survey will normally include observations on currently issued hearing protection, including suitability for the measured exposure, compatibility with other PPE and consistent use during exposure. A more detailed product-level review is delivered through our dedicated hearing protection assessment service.
Can the survey help prioritise noise-control measures?+
Yes. Identifying dominant sources, the workers most exposed to them and the proportion of exposure each contributes allows control measures — enclosure, damping, isolation, silencers, scheduling or replacement — to be prioritised where they will most reduce risk. Recommendations are framed practically against the way each factory actually operates.
Should a survey be repeated after installing new machinery?+
Yes. New machinery, revised layouts, increased production rates and changes in product mix can all alter exposure. A focused reassessment after significant changes confirms whether the existing risk assessment remains valid and whether hearing protection arrangements are still appropriate.
Can maintenance activities be included?+
Yes, and they should be. Maintenance tasks — compressed-air discharge, hammering, grinding, machine commissioning and cleaning — often produce short-duration high-level exposure that routine production measurements miss. Where these tasks are predictable, they are scoped into the survey alongside production measurements.
Is a factory noise survey the same as an environmental noise survey?+
No. A factory noise survey is an occupational assessment focused on noise inside the workplace and the exposure received by employees. An environmental noise survey measures noise emitted from the site to surrounding areas — typically for planning, boundary-noise or community-impact purposes. The two have different objectives, methods and regulatory drivers.
Arrange a Factory Noise Survey
Speak to a UK occupational noise specialist about a factory or manufacturing noise survey for your site. We respond to most enquiries the same working day.