Abstract Scientists from the Health and Safety Executive visited a manufacturing workplace where coatings are prepared by loading powders, frit and water into various sized mills. The aim of the visit was to determine potential worker exposures to dust and respirable crystalline silica by static air monitoring and exhaled breath condensate. Low-cost particle monitors were deployed alongside more established scientific equipment. Airborne dust concentrations were measured at three site locations using two photometers, an optical particle counter (OPC) and a respirable cyclone. The size distribution was measured in real-time using a low-cost OPC and by offline analysis of a polycarbonate membrane filter housed inside an inhalable sampler. Pre and post shift samples of exhaled breath condensate were collected from 6 workers, with samples analysed by single particle inductively coupled plasma mass spectrometry to measure the number and size of silicon containing particles present. The real-time air monitoring data at all three locations showed peaks in airborne concentrations corresponding to the loading activities and indicating the tasks most likely to contribute to worker exposure. The average concentration of respirable dust measured closest to the process was 0.13 mg.m-3 for the 8-hour shift. The low-cost monitors provided good information about the changes in concentration over time relating to worker activities.