Noise Monitoring in Logistics

Pack it in or monitor the noise in the warehouse, says Tim Turney, Global Marketing Manager at Casella, a global monitoring equipment manufacturer, who explains the risk of excessive noise exposure in logistics hubs and the benefits of implementing an effective noise monitoring programme.

Noise is often an overlooked operational risk in logistics, overshadowed by output, efficiency optimisations and time restraints. However, the Health & Safety Executive’s (HSE) recent investigatory campaign uncovered ‘serious gaps’ in noise safety knowledge among employers and employees in noisy workplaces. Logistics hubs are often subjected to levels over the safe prescribed limits as a result of machinery, manual handling equipment and commercial vehicles which, over a long period of time, can cause irreparable hearing loss to employees.

Too often, logistics managers will simply provide hearing protection to employees without considering the risks associated with over-attenuating PPE that can actually bring about additional risk, or considering other control measures in the hierarchy of controls.

Unmanaged noise can expose organisations to regulatory penalties, worker health claims, reputational damage, and hidden productivity losses that quietly erode margins and most importantly, leaves employees permanently suffering from partial to complete deafness. Consumer habits and market demands are creating busier logistics hubs which translates to a noisier working environment for employees.

The UK enforces management through the Control of Noise at Work Regulations 2002, which state that employers must reduce noise exposure, provide noise control measures and personal hearing protection if noise is at a level that may cause hearing loss. Employees must have personal hearing protection made available to them at an action level and must wear hearing protection at the next exposure hearing level. This assumes that the correct hearing protection wear is effectively fitted, worn at all times and maintained in good condition.

In the UK, the HSE has set an exposure limit of 85 dB(A) over an eight-hour time-weighted average, where hearing protection should be always worn, between 80 dB(A) and 85 dB(A), hearing protection is optional.

The Business Case

Chronic exposure to elevated noise levels contributes to fatigue, heightens stress, and degrades situational awareness. Elevated ambient noise can mask alarms and verbal warnings, increasing the likelihood of collision or handling incidents which in turn increases absenteeism and reduces productivity. Studies have shown that those working in loud environments are also more likely to seek alternative employment at quieter sites with turnover and sick days directly correlating to the noise levels in a worksite .

The compound result of the stress caused by excessive noise often manifests in disruptive ways. A recent survey found that a quarter of workers have ‘snapped’ at either a co-worker or manager with 20% quitting due to the noise. However it impacts employees, it is likely to cause delays in processing, transferring and day to day tasks like packaging and palletising.

The starting point for any health and safety programme is identifying the sources and quantifying the levels of hazard. By conducting a comprehensive risk assessment across the site, breaking down activities by task family and environment to understand how noise fluctuates depending on area and task, employers can deploy noise measurement and control measures cost effectively. Consider how exposure accumulates across shifts, overtime, and seasonal peaks when facilities run hotter and longer. This mapping enables targeted, defensible interventions that reduce exposure without compromising throughput or service levels.

Measurement

Sound level meters (SLMs) and noise dosimeters can be used to quantify sound levels in a workplace. Sound level meters are handheld devices, ideal for spot measurements noise at specific locations or tasks. Ideal for commissioning new equipment, diagnosing hotspots at loading docks, comparing alternative alarm types, or validating the effect of engineering controls like barrier mats or dampers.

Always calibrate before and after surveys and modern instruments will record any deviations, take notes and include information about the location, people working there, the noise environment and any control measures in place, including PPE.

Noise dosimeters serve a purpose by measuring personal exposure over a full shift. Tasks in logistics environments are by their nature mobile, so a bodily worn device may be the best way to monitor exposure. They account for worker movement, task variation, breaks, and can identify any, providing a realistic time-weighted average for specific roles such as pickers, dock associates and maintenance technicians.

To use dosimeters effectively, position the microphone in the hearing zone near the shoulder, ensuring it is unobstructed by clothing or PPE. Modern noise dosimeters are often easy to set up and can stream real-time data directly to employers’ phones or tablet so readings can be checked remotely through the day without disturbing the wearer. Repeat measurements during known peak seasons to capture worst-case scenarios that could trigger additional controls. Using both SLMs and dosimeters creates a clear picture that supports prioritisation and investment.

Control

Once the levels of sound are understood across the facility, control strategies can be implemented that follow the hierarchy of controls. At the source, employers can select low-noise wheels and tires for material handling equipment, specify quiet conveyor rollers, add soft-close pallet stops, implement variable-speed drives, and adopt other sound dampening tools to reduce total noise output.

It’s often recommended to install barriers and sound absorber around particularly noisy static machinery.
Administrative controls can then minimise exposure by scheduling noisy tasks away from busy areas, creating quiet zones for precision work, and structuring maintenance windows outside of peak hours to confine noisy activities.

PPE should always be the final refuge for employers once all engineering controls and administrative controls have been considered. Hearing protection should be selected that matches the noise profile without over-attenuating as this can lead to unnecessary accidents where employees miss sound cues from vehicles or warnings from colleagues. Being struck by a moving vehicle is the second most frequent cause of workplace fatalities, according to the HSE.

Finally, conducting regular noise monitoring to calculate any changes in ambient noise levels allows employers to be agile in noise management, control and solutions. Allowing resources to be allocated when necessary, reducing overspend. At a minimum, noise surveys should be conducted every two years or whenever there are major changes to equipment, processes or working patterns. More frequent monitoring is also necessary if health surveillance reveals a decline in employee hearing quality. Where unsure, it is always recommended to consult expert advice and guidance.

Rock and roll ain’t noise pollution

Ultimately, a durable noise program depends on culture. Educating staff and managers on the dangers of long-term noise exposure and implementing a culture of responsibility will lead to better practice and caution when working in noisy environments. Logistics leaders who prioritise noise risk management create a calmer, safer, and more productive site, while also avoiding reputational and compliance penalties.