Case Study: A Cluster Model for Health Surveillance Across Irish Food Processing Plants

4 days ago

4 min read

Reviewed by Stephen Kelly, Advanced Nurse Practitioner (RANP), Precision Health

Precision Health cluster model for health surveillance across Irish food processing plants: four regional clusters, audiometry every 3 years, safety-critical medicals, pre-employment medicals, health checks, and follow-up with same-day action on urgent results

In short

In 2026 Precision Health delivered onsite health surveillance for one of Ireland's leading food processing groups at nine sites around the country. Instead of booking each plant separately, sites are grouped into four regional clusters, so one team can cover each region in a planned run of days. Our practitioners carry out hearing tests, safety-critical medicals, pre-employment medicals and health checks at the plant, and follow up any concerns through our occupational health team.

The challenge

Food processing is a demanding environment. Workers face noise, manual handling, cold, sharp tools and machinery, and many roles are safety-critical, such as forklift drivers, engineers and lone workers. The group needed health surveillance that met its legal duties, worked across plants hundreds of kilometres apart, fitted around production shifts, and kept up with a steady flow of new starters.

It also wanted to make better use of its existing occupational health spend, and to offer preventive health checks as a real benefit to staff.

The cluster model

Each plant is assigned to one of four regional clusters. Within a cluster, our team travels to each site in turn and runs hearing tests, medicals and health checks over planned days. Dates are agreed in advance as part of a rolling three-year programme, which matches the three-year cycle for repeat hearing tests. This gives the client predictable costs and gives every plant the same standard of service.

The same model can grow to include workplace vaccination, such as hepatitis A and B, tetanus and flu, and wellbeing initiatives like mobile cancer screening.

What we did

Took surveillance to the plants. Our practitioners and occupational health technicians worked on site at nine locations from August to October 2026, so employees didn't need to travel.
Ran hearing tests properly. Before each audiometry session, our technician checked that background noise in the test room was within the permitted limits, so results are reliable.
Delivered safety-critical medicals. Employees in safety-critical roles had hearing, lung function (spirometry) and movement assessments.
Supported recruitment. We carried out pre-employment medicals on site and reviewed health questionnaires, with remote consultations where suitable.
Avoided duplicate testing. When we found staff booked for a hearing test they had already had, we worked with the sites to tidy up the lists and prevent it happening again.
Acted quickly on urgent results. When a health check found a seriously high blood pressure reading, our practitioner escalated it the same day and the employee was sent for medical care that afternoon.
Followed up through occupational health. Results that needed review were passed to our occupational health team for follow-up consultations and reports to the employer, with medical details kept confidential.

What health surveillance covers

Audiometry (hearing tests) for noise-exposed workers, repeated every three years
Safety-critical medicals: hearing, spirometry and musculoskeletal (movement) checks
Pre-employment medicals and health questionnaire review
Health checks, including blood pressure, cholesterol, height, weight and BMI
Occupational health follow-up consultations and fitness-for-work reports
Optional workplace vaccination and wellbeing programmes

The results

Health surveillance delivered at nine plants across Ireland in a single programme.
Planned, locked-in dates in each cluster, with less disruption to production.
Reliable hearing-test results, checked against background noise limits at every session.
Serious health risks identified early and acted on the same day.
One provider and one standard for every site, under a rolling three-year plan.

Why this matters for employers

If you run several sites, separate bookings for each one quickly add up in cost, travel and admin. A cluster model plans surveillance by region, so you meet your legal duties under Irish health and safety law, keep production running and know your costs in advance. Precision Health has supported Irish employers since 2014 with occupational health, health surveillance, corporate wellness, health screening and flu vaccination. We work from clinics in Dublin 15 and Longford, and our mobile team delivers onsite anywhere in Ireland.

Frequently asked questions

What is health surveillance?

Health surveillance is a programme of regular health checks for workers exposed to risks such as noise, dust, fumes or vibration. It picks up early signs of work-related ill health so that action can be taken.

How often do employees need a hearing test?

For noise-exposed workers, audiometry is typically repeated every three years, and more often if results or exposure levels change.

What is a cluster model?

Sites close to each other are grouped into regional clusters. Our team covers each cluster in a planned run of days, which reduces travel, cost and disruption compared with booking each site separately.

Can you test employees at our site?

Yes. Our mobile team brings the equipment to your workplace and runs hearing tests, spirometry and medicals on site.

What is a safety-critical medical?

It is an assessment for employees whose health could affect their own safety or others', such as forklift drivers, engineers and lone workers. It usually includes hearing, lung function and movement checks.

Arrange health surveillance

To plan health surveillance across your sites, call +353 1 910 4024, email support@precisionhealth.ie or use our contact form.