How uvex and PJD solved a footwear challenge for a leading food services provider

A leading food services provider operates a busy manufacturing facility in Avonmouth, near Bristol. Employing around 200 workers of mixed gender and nationality, the site handles powders, pastes and aromatic ingredients such as curry powder and spices.

To maintain strict hygiene and safety standards, employees are equipped with comprehensive PPE including white uniforms, gloves, safety footwear, eyewear, and, in some areas, respiratory and hearing protection.

However, footwear had become a significant concern for both workers and management.

The site’s workforce endured long 12-hour shifts, often standing for extended periods. The safety shoes provided by another brand were causing problems:

• Incorrect fit: Many staff had never been professionally measured, leading to footwear that were the wrong size or width.
• Discomfort and health issues: Prolonged use of ill-fitting footwear resulted in fatigue, foot pain, and increased visits to occupational health.
• Low durability: A previous cost-cutting switch to cheaper footwear led to faster wear, forcing workers to use their own insoles for comfort.
• Limited supplier support: The site received little engagement or follow-up from the existing PPE provider.

The combination of discomfort, high replacement rates, and lack of supplier input prompted a search for a better, long-term solution.

The uvex specialist collaborated with the site manager and their PPE supplier, PJD, initially providing targeted assistance to employees experiencing medical concerns. Following the success of this pilot initiative, the programme was extended to encompass site-wide footwear solutions.

• Accurate sizing: Professional measurement for both length and width of each wearer’s feet.
• Education sessions: Guidance is provided regarding the replacement of insoles every 6 to 9 months, depending on usage. Additionally, the practice of “double-donning” insoles can affect the protective performance of safety footwear as well as being aware that replacing an insole in protective footwear is generally considered a modification under the PPE Regulation.
• On-site accessibility: Fitting clinics run across all shift patterns to ensure full participation.
• Product upgrade: Introduction of the uvex 65818 hygiene sport slip-on shoe, which meets food hygiene standards, delivers improved comfort, and withstands heavy use.

In total, 238 employees were individually measured and fitted with new footwear.

The new footwear was well received by the workforce and delivered measurable benefits:

• Greater comfort: Staff reported reduced fatigue and improved comfort throughout long shifts.
• Health improvements: Occupational health recorded fewer foot-related complaints.
• Cost efficiency: Reduced need for personal insoles and fewer footwear replacements.
• PPE compliance: Comfortable, well-fitted shoes encouraged consistent use of safety footwear.

The success of the footwear project prompted a review of other PPE categories at the site. Updated risk assessments, carried out following HSE inspections, have led to consideration of uvex eyewear, respiratory protection, and prescription safety glasses. The site’s partnership with both uvex and PJD has strengthened, with discussions underway about rolling out the same fitting programme to other facilities.

What began as a comfort and durability issue developed into a comprehensive PPE improvement programme. Through proper measurement, product selection, and on-site engagement, the site achieved lasting improvements in worker well-being, PPE compliance, and operational efficiency while building a stronger supplier relationship for the future.