Millions of workers are required to wear reusable respirators in several industries worldwide. Reusable respirators include filters that protect workers against harmful dust, smoke, gases, and vapors. These hazards may cause cancer, lung impairment, and diseases. Respiratory protection is prone to failure or misuse, such as wearing respirators with filters out of service life and employees wearing respirators loosely. Currently, there are no commercial systems capable of reliably alerting of misuse of respiratory protective equipment during the workday shifts or provide early information about dangerous clogging levels of filters. This paper proposes a low energy and non-obtrusive functional building block with embedded electronics that enable breathing monitoring inside an industrial reusable respirator. The embedded electronic device collects multidimensional data from an integrated pressure, temperature, and relative humidity sensor inside a reusable industrial respirator in real time and sends it wirelessly to an external platform for further processing. Here, the calculation of instantaneous breathing rate and estimation of the filter’s respirator fitting and clogging level is performed. The device was tested with ten healthy subjects in laboratory trials. The subjects were asked to wear industrial reusable respirator with the embedded electronic device attached inside. The signals measured with the system were compared with airflow signals measured with calibrated transducers for validation purposes. The correlation between the estimated breathing rates using pressure, temperature, and relative humidity with the reference signal (airflow) is 0.987, 0.988 and 0.989 respectively, showing that instantaneous breathing rate can be calculated accurately using the information from the embedded device. Moreover, respirator fitting (well-fitted or loose condition) and filter’s clogging levels (≤60%, 80% and 100% clogging) also can be estimated using features extracted from absolute pressure measurements combined to statistical analysis ANOVA models. These experimental outputs represent promising results for further development of data-driven prediction models using machine learning techniques to determine filters end-of-service life. Furthermore, the proposed system would collect relevant data for real-time monitoring of workers’ breathing conditions and respirator usage, helping to improve occupational safety and health in the workplace.