Occupational exposure to BTEX compounds in paint manufacturing workers: a case study from Saudi Arabia

Volatile aromatic hydrocarbons, including benzene, toluene, ethylbenzene, and xylenes (BTEX), are widely used in paint manufacturing and can create occupational health hazards because of their toxicity and high volatility. This study assessed personal and exposure levels of BTEX compounds among workers in small- and medium-sized paint factories in Jeddah, Saudi Arabia. Air samples were collected using charcoal tubes and analyzed by gas chromatography with a flame ionization detector (GC-FID). Statistical analyses, including correlation and principal component analysis (PCA), were used to identify emission patterns and likely exposure sources. Benzene was not detected in any samples, whereas toluene, ethylbenzene, and xylenes were consistently present and frequently exceeded occupational exposure limits set by ACGIH and OSHA. The highest mean concentrations were found in mixing, grinding, and packaging operations, suggesting inadequate ventilation and direct solvent handling. Strong correlations between ethylbenzene and xylenes indicated shared emission sources from mixed solvent formulations. PCA showed that exposure variability was mainly process-related, with distinct components linked to blending and hardener-related activities. Chronic exposure to these levels may cause neurological, hepatic, and hematological effects, especially in workers with limited protection. The study highlights the need for engineering controls, worker training, and substitution with low-VOC or water-based products.