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Manufacturing

Derbyshire Manufacturing: 24/7 Washroom Services for 500+ Employees

How a large-scale manufacturing operation achieved HSE-compliant, single-invoice washroom management across three shifts and multiple production buildings.

Manufacturing Derbyshire 6 Services
🔧
24/7
Operating Hours
👷
500+
Employees
Full
HSE Compliant
📄
1
Invoice Streams
The Challenge

The Challenge: Washroom Services That Never Stop

Manufacturing environments present washroom service challenges that differ fundamentally from office or retail settings. Derbyshire Precision Manufacturing operates a large production campus in Derbyshire employing over 500 people across three shifts, running 24 hours a day, seven days a week. The nature of the work — precision engineering with exposure to cutting oils, metal particulates, and industrial chemicals — creates specific hygiene demands that standard washroom service providers rarely understand.

Manufacturing-specific challenges

  • 24-hour operation: With three overlapping shifts and no downtime, washroom servicing cannot disrupt production. Previous providers attempted to service during the day shift — the busiest period — causing congestion and complaints from production line supervisors whose teams could not access washrooms during service visits.
  • HSE compliance requirements: The Health and Safety Executive mandates specific washroom provision standards for manufacturing environments, including adequate hand-washing facilities with suitable cleansing agents, paper towels (not just air dryers) in areas where workers handle chemicals, and proper first aid waste disposal. The site had received an HSE improvement notice relating to inadequate hand-washing provision in two production buildings.
  • Heavy-duty hand cleaning: Standard soap dispensers and office-grade soap products are inadequate for manufacturing workers who need to remove cutting oils, grease, and metallic residues from their hands multiple times per shift. The previous soap provision left workers with inadequately cleaned hands or resorting to industrial solvents that caused skin irritation.
  • Multiple building management: The campus comprises four production buildings, a main office block, a canteen, and two warehouse units — each with different washroom configurations and usage patterns. Previously, three separate providers serviced different buildings, resulting in inconsistent standards and three separate invoice streams.
  • Entrance contamination: Production workers moving between buildings tracked cutting oil residue, metal swarf, and outdoor debris through entrance areas, creating both slip hazards and floor damage. The canteen entrance was particularly problematic, with food safety implications.

The site's health and safety manager needed a single provider capable of delivering reliable, HSE-compliant washroom services across the entire campus without disrupting 24-hour production operations.

Our Solution

The Solution: Shift-Pattern Servicing with Industrial-Grade Products

Hygiene Solutions conducted a comprehensive campus audit, mapping every washroom facility, documenting usage patterns across all three shifts, and consulting with the health and safety manager, production supervisors, and employee representatives. The resulting service plan was specifically engineered for a 24-hour manufacturing environment.

Tailored manufacturing solution

  • Night-shift servicing schedule: All routine washroom servicing — bin exchanges, consumable refills, equipment checks — is performed between 22:00 and 05:00, coinciding with the lowest-headcount night shift. This eliminates disruption to the busier day and afternoon shifts whilst ensuring all facilities are fully operational and restocked for the start of each day.
  • Industrial hand-cleaning systems: We replaced standard soap dispensers with heavy-duty hand-cleaning stations dispensing industrial-grade cleansing paste that effectively removes cutting oils, grease, and metal particulates without causing skin irritation. These are supplemented with moisturising after-wash cream dispensers to protect workers' skin health during repeated hand-washing.
  • Paper towel provision in production areas: In compliance with HSE guidance, production building washrooms are equipped with paper towel dispensers rather than air dryers alone. Workers handling chemicals and industrial materials need to dry their hands with disposable paper to prevent recontamination — hand dryers alone do not meet HSE requirements in these environments.
  • Clinical waste management: First aid rooms in each production building generate clinical waste including used dressings, gloves, and sharps from minor injury treatment. We provide compliant sharps containers and clinical waste bins in all first aid stations, collected fortnightly with full consignment note documentation.
  • Sanitary bins across all buildings: Sanitary waste bins are serviced across all washroom facilities on the campus, ensuring consistent provision for all employees regardless of which building they work in.
  • Barrier matting at all entrances: Heavy-duty industrial barrier matting was installed at every building entrance and inter-building walkway. These mats are designed to trap oil, metal particles, and moisture, protecting internal flooring and — critically — preventing contamination at the canteen entrance.

The entire service is managed through a single contract with one monthly invoice, broken down by building for the client's internal cost allocation. A dedicated account manager conducts quarterly service reviews with the site's health and safety team.

The Results

The Results: HSE Compliance, Operational Continuity, and Consolidated Management

The Hygiene Solutions manufacturing washroom programme has delivered measurable improvements across compliance, employee satisfaction, and operational efficiency since implementation.

HSE compliance

  • Improvement notice resolved: The HSE improvement notice relating to inadequate hand-washing provision was formally closed within eight weeks of our appointment. The HSE inspector specifically noted the appropriateness of the industrial hand-cleaning products and the proper paper towel provision in production areas.
  • Full ongoing compliance: Subsequent HSE visits have confirmed full compliance with all washroom and welfare facility requirements. The site's health and safety manager now uses our quarterly compliance reports as part of the evidence pack for HSE inspections.

Operational benefits

  • Zero production disruption: Night-shift servicing has completely eliminated the washroom access complaints that were a regular source of friction between production supervisors and the facilities team. Washrooms are serviced and restocked before the day shift arrives.
  • Single invoice simplicity: Consolidating three separate provider contracts into one has eliminated invoice processing overhead and provided clear visibility of total washroom service costs. The site finance team processes one invoice per month instead of nine.
  • Employee satisfaction: The annual employee survey showed a significant improvement in washroom satisfaction scores, with particular appreciation for the industrial hand-cleaning products and consistent supply of consumables across all shifts.

Health and safety outcomes

  • Reduced dermatitis cases: Occupational health records show a 40% reduction in work-related contact dermatitis cases since the introduction of the industrial hand-cleaning system with moisturising after-wash cream. The previous practice of using solvents for hand cleaning had been a significant contributor to skin conditions.
  • Entrance safety: Slip incidents at building entrances have reduced by 65% since the barrier matting installation. The canteen entrance, previously the most problematic area, has had zero slip incidents since the matting was installed.

The site's managing director has described the washroom service consolidation as "a textbook example of how bringing services under one professional provider delivers better quality and lower costs simultaneously." The contract has since been extended to cover a new production building opened in 2024, with Hygiene Solutions involved from the design stage to ensure optimal washroom facility specification.

AM
Finding a washroom provider who genuinely understands manufacturing was a revelation. Hygiene Solutions did not try to fit a standard office solution into our factory — they designed a service specifically for our 24-hour operation, our industrial hand-cleaning needs, and our HSE requirements. The night-shift servicing model is brilliant, the industrial soap products are exactly what our workers need, and having one invoice instead of three has simplified our procurement enormously. They resolved our HSE improvement notice within weeks and we have been fully compliant ever since.
Andrew Metcalfe
Health & Safety Manager, Derbyshire Precision Manufacturing
ESPO Framework 239_20ISO 9001 CertifiedZero to Landfill
FAQs

Frequently Asked Questions

Common questions about our manufacturing washroom services

The HSE requires manufacturing sites to provide adequate washing facilities with hot and cold running water, suitable cleansing agents appropriate to the type of contaminants workers encounter, paper towels in areas where workers handle chemicals (air dryers alone are insufficient), and proper facilities for the disposal of clinical waste from first aid stations. Requirements are set out in the Workplace (Health, Safety and Welfare) Regulations 1992.
Yes. Hygiene Solutions offers night-shift servicing specifically designed for 24-hour operations. All routine washroom servicing — bin exchanges, consumable refills, and equipment maintenance — is performed during the lowest-headcount shift, typically between 22:00 and 05:00. This ensures all facilities are fully operational and restocked for the busier day and afternoon shifts.
Standard office soap is ineffective at removing cutting oils, grease, metal particulates, and industrial chemicals from workers' hands. Industrial hand-cleaning products use specialist formulations — often containing fine abrasive particles and degreasing agents — designed to remove these substances effectively without causing skin irritation. Proper hand cleaning reduces the risk of occupational dermatitis and cross-contamination.
HSE guidance specifies that workers who handle chemicals, oils, or other hazardous substances should dry their hands with disposable paper towels rather than air dryers. Air dryers do not remove residual contaminants from skin surfaces, and the blowing action can redistribute particles. Paper towels provide a physical wiping action that helps remove residual contamination and are then disposed of safely.
Manufacturing sites face specific entrance contamination challenges including cutting oil residue, metal swarf, and industrial debris tracked between buildings. Commercial barrier matting traps these contaminants, preventing slip hazards, protecting internal flooring, and — critically — preventing cross-contamination in areas like canteens where food safety standards apply. Matting is exchanged and deep-cleaned on a regular cycle.
Yes. We routinely provide consolidated monthly invoicing for multi-building manufacturing sites. Each invoice includes a detailed breakdown by individual building or cost centre, enabling the client to allocate costs accurately across departments. This replaces multiple provider contracts and invoice streams, significantly reducing procurement and finance administration.

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