The production and use of engineered nanomaterials and nano-enabled products is increasing, enabling innovations in many application areas, e.g., in the sector of food contact materials. However, nanosafety-relevant information for chemical risk assessment is still scarce, leading to a high level of uncertainty and making the early integration of safety to the innovation process indispensable. This study analyzed the strengths, weaknesses, and applicability of the nano-specific Safe-by-Design (SbD) concept using nanoclay-containing polymer coffee capsules as a theoretical case study. In addition, a material flow analysis was conducted to identify exposure pathways and potential risks, and a multi-stakeholder approach was applied to discursively discuss challenges when attempting to combine safety and innovation at an early stage. The results indicate that the SbD concept is generally welcomed by all stakeholders, but there is a lack of clear rules on the transfer of information between the actors involved. Furthermore, a voluntary, practical application usually requires in-depth knowledge of nanotechnology and often additional financial efforts. Therefore, incentives need to be created, as there is currently no obvious added value from a company’s point of view. The SbD concept should be further developed, standardized, and integrated into existing legal frameworks to be implemented effectively.

Nanomaterials and products containing such materials are already in widespread use because they exhibit technologically interesting, nano-specific features such as increased tensile strength, improved electrical conductivity, special optical characteristics or special medico-chemical properties. Nonetheless, the same features that make these substances so interesting technologically potentially harbor risks for those persons who handle them. This is because small particle size, coupled with increased reactivity due to special surface features, determines their biological activity and therefore toxicity. The increasing applications are exposing ever more employees – especially those working in research laboratories or in industrial production and processing – to nanosubstances. This makes occupational safety a major issue from a regulatory standpoint. Based on the available literature on occupational safety, the following nanomaterial-relevant topics have been identifi ed: health risks, adaptation of detection and measurement methods, actual exposure scenarios at the workplace, defi nition and compilation of existing worksites for nanomaterials, recommendations for worker safety by the authorities and by industry, as well as preventive occupational medical care.

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