Your worker’s full flour-dust day, before the limit drops.
FlourSafe is the Australian-specific exposure assessment tool for cafés and small bakeries — calibrated to the new 0.5 mg/m³ WEL and aligned with AIHA Bayesian Decision Analysis. Other sectors coming through 2027.
Run the assessment free. Pay only if you want the documented report.
A defensible exposure estimate before any sampling pump runs.
FlourSafe uses a structured visible-dust observation methodology to convert site-walkthrough evidence into quantitative exposure predictions. No measurement equipment required for the Stage 1 assessment.
Set the kitchen context
Facility type (café / artisan bakery / retail bake-off), shift length, throughput band. Three questions, under a minute.
Pick your operations from the tile menu
Select every flour-handling task your worker does in a shift — bag breaking, bench weighing, mixing, croissant lamination, sieving. Tiles calibrated to café and small-bakery reality.
Answer the per-task questions
Eight to fourteen visible-dust observation questions per task: cloud visibility, bag condition, surface accumulation, LEV state, batch size. Operationally meaningful, not technically esoteric.
Get your worker-day TWA and contribution chart
FlourSafe combines all tasks into the 8-hour TWA — the actual compliance metric. A contribution chart shows which operations drive the risk so you know where to act first.
A 20-fold reduction informed by baker’s asthma data.
The new Australian flour dust WEL replaces the legacy generic-particulate limit with a sensitiser-specific limit of 0.5 mg/m³ inhalable. Long-tenure exposure to flour dust is one of the most-documented occupational asthma risks; the new limit is calibrated to the science.
Sensitisation rate in long-tenure bakery workers
HSE bakery industry data documents flour-dust sensitisation in workers exposed across multi-year employment. Baker's asthma is among the highest-incidence occupational asthma conditions globally.
Flour-dust exposure is task-specific, not steady
A café kitchen worker's exposure is dominated by 2–3 high-dust tasks: bag breaking, dry sieving, bulk ingredient loading. The 8-hour TWA looks low — until you add them all up. FlourSafe shows which tasks drive the combined result.
Of due-diligence runway, narrowing.
Operators who establish baseline exposure profiles, design controls, and verify performance before the changeover demonstrate due diligence. Operators who wait until enforcement begins do not.
Built on the established frameworks of occupational hygiene.
FlourSafe is not a heuristic or a checklist. The exposure engine implements the canonical mathematical models that underpin occupational hygiene practice — adapted for Australian flour and grain operations and calibrated against four decades of peer-reviewed sector exposure research.
Two-zone near-field exposure modelling
The breathing-zone concentration is computed using the two-zone (near-field / far-field) mass balance — the foundation model for indoor airborne contaminant prediction in occupational hygiene practice. Implemented as a 100,000-iteration two-dimensional Monte Carlo simulation with parameter uncertainty propagated through to the result distribution.
AIHA Bayesian Decision Analysis
The exposure distribution is categorised against the applicable WEL using the AIHA Bayesian framework — the recognised approach for exposure decision-making with inherent variability. Output is an AIHA exposure category 1 through 4 with explicit posterior probability assignment, ready for the AIHA-aligned management plan.
Worker-day TWA from individual task contributions
Where a worker performs multiple flour-handling tasks in a shift, FlourSafe computes the time-weighted average exposure across all tasks — the actual compliance metric. Each task's contribution is shown individually so you know which operations drive the risk and where engineering controls will have the greatest effect.
Dust generation and deposition
Dust generation rates, particle settling velocity, deposition behaviour, and bimodal flour dust distributions are modelled using published particle physics — including material-specific deposition velocity tables for fine, coarse, and pre-treated flour. Visible-dust observations map to physically meaningful emission rate priors.
“FlourSafe applies the same mathematical and engineering frameworks used in canonical occupational hygiene exposure modelling — adapted to Australian flour and grain operations, calibrated to peer-reviewed sector data, and aligned with AIHA decision analysis.”
One tool family. Calibrated for each facility type.
An industrial bakery is not a feed mill, and a café kitchen is not a grain elevator. FlourSafe ships as a family of facility-specific tools so the calibration and unit operations match your operational reality.
Bag handling
Opening, cutting, and tipping 5–25 kg flour bags. The highest-dust task in most café kitchens — typically 3–15 mg/m³ active-task GM without controls.
Weighing & transfer
Bench weighing, scaling into bowls, recipe portioning from bulk containers. Exposure depends heavily on container design and pour height.
Bench work
Hand mixing, kneading, shaping, croissant lamination, dusting. Continuous low-level generation throughout the task — adds up over a long shift.
Mechanised
Dough hook loading, planetary mixer charging, bench proofer handling. Equipment configuration and enclosure state dominate the exposure estimate.
Try the assessment free. Pay only when you need the deliverables.
The free tier produces the AIHA category and a defensible three-number summary for each unit operation. The paid Full Report adds the detailed exposure characterisation, controls hierarchy, and sampling plan you would commission a CIH to produce.
Free Assessment
Run the tool on any unit operation. Get a defensible exposure estimate and AIHA category in under five minutes.
- ✓Active-task geometric mean concentration
- ✓95th percentile with uncertainty band
- ✓Multiple-of-WEL ratio
- ✓AIHA Bayesian exposure category (1–4)
- ✓Per-operation WEL (flour 0.5 / PNOS 10 mg/m³)
- ✓Combined worker-day TWA + per-task contribution chart
Full Report
Detailed exposure estimation, hierarchy of controls, and sampling plan — the deliverables a regulator and your insurer expect to see.
- ✓Detailed exposure estimation per unit operation
- ✓Hierarchy of engineering controls & recommendations
- ✓Sampling plan per AS 3640-2009
- ✓RPE selection guidance with assigned protection factors
Built on certified occupational hygiene practice.
FlourSafe is developed and maintained by OH Consultant Australia — the same team behind EHS Atlas, the OH Proposal Engine, and the OHConnect practitioner marketplace. Methodology, calibration, and ongoing validation are led by certified occupational hygienists with cross-sector experience across pharmaceutical, FMCG, oil & gas, and food manufacturing.
Know your café worker’s full flour-dust day — before the limit drops.
Run the assessment yourself in about 30 minutes. See where your bakery sits against the 0.5 mg/m³ WEL. Pay only if you want the documented, hygienist-reviewed report — no sales call, no obligation.
Start your assessment →Run the assessment free. Pay only if you want the documented report.
FlourSafe provides indicative exposure estimates based on a mathematical model. Results are not a substitute for professional occupational hygiene assessment or personal air monitoring conducted by a qualified hygienist. Outputs are intended for preliminary screening purposes only and should not be used as the sole basis for compliance decisions. Compliance determinations must be made in consultation with a Certified Industrial Hygienist or equivalent qualified professional. Applicable WEL reference: 0.5 mg/m³ inhalable flour dust (Safe Work Australia, effective 1 December 2026). OH Consultant Australia accepts no liability for actions taken solely in reliance on model outputs without professional verification.