The National Institute for Occupational Safety and Health (NIOSH) has found that nearly all fraudulent respirator components sold through online marketplaces fail to meet federal performance standards, raising serious concerns for laboratories that rely on replacement filters and cartridges for worker protection. In a new pilot project, NIOSH tested P100 particulate filters, organic vapor chemical cartridges, and combination cartridges and found widespread failures in filtration efficiency, chemical protection, or both.
Fraudulent respirator components are replacement filters and cartridges that falsely claim to be NIOSH-approved even though they were never evaluated as part of a certified respirator configuration. These counterfeit parts often appear visually identical to genuine products, but they do not meet the federal performance standards required to protect workers from airborne particulates and chemical vapors.
NIOSH measured inhalation and exhalation resistance, filtration efficiency, and chemical breakthrough using the same standardized laboratory methods required for respirator approval under 42 CFR Part 84. The findings show that laboratories can unknowingly expose staff to hazardous aerosols and vapors if counterfeit replacement parts enter their supply chain, even when they believe they are using certified respirators.
How NIOSH respirator testing evaluated fraudulent respirator components
NIOSH’s National Personal Protective Technology Laboratory selected fraudulent respirator components that were widely advertised online, especially those labeled with high-protection markings such as P100 and NIOSH. Investigators targeted part numbers commonly associated with genuine respirators, including 3M models 2091, 2097, 6001, 6001CN, 60923, and 60926, because counterfeit sellers frequently copied these identifiers.
NIOSH purchased both fraudulent and genuine components for side-by-side testing and mounted them on elastomeric half-mask respirators to replicate real-world use in laboratories and industrial settings.
Test methods used
NIOSH evaluated performance using established standard testing procedures that measure:
- Filtration efficiency, or the percentage of particles that penetrate the filter
- Chemical service life, which indicates how long the cartridges block organic vapors
- Inhalation resistance, which reflects how hard it is to breathe in
- Exhalation resistance, which reflects how hard it is to breathe out
These tests replicate high-stress conditions that respirators face in laboratory environments, including elevated humidity and continuous exposure to aerosols or organic vapors.
What NIOSH respirator testing revealed about counterfeit respirator filters
Across all three product categories, counterfeit respirator components performed dramatically worse than genuine ones.
- P100 particulate filters: P100 filters are designed to block at least 99.97 percent of airborne particles. NIOSH found that 220 of 240 fraudulent P100 filters failed to meet this requirement, with many allowing more than one percent penetration and some exceeding four percent. Only one fraudulent product model passed all filtration tests.
- Combination cartridges: All 124 fraudulent combination cartridges failed filtration and chemical performance testing. Many allowed more than 50 percent of test particles to pass through immediately, and all failed the organic vapor service-life requirements.
- Chemical cartridges: Every fraudulent chemical cartridge tested experienced organic vapor breakthrough in less than five minutes, far below the 55 minimum required for NIOSH approval.
NIOSH summarized the results as follows:
“This finding highlights the possibility that fraudulent products may provide consumers with a false sense of confidence that they are receiving the same level of protection as filters and cartridges that are part of a NIOSH-approved respirator configuration provide.”
Why counterfeit respirator filters are complex to detect
Visual inspection alone cannot reliably identify fraudulent respirator components. The report shows that counterfeit cartridges and filters were often nearly indistinguishable from genuine products, even copying part numbers, colors, and labeling formats. In some cases, the only difference was the absence of the manufacturer’s name, even though the word “NIOSH” still appeared on the label.
Photographs in the report show fraudulent 6001 chemical cartridges that look almost identical to genuine models except for missing branding, making them difficult to detect during routine lab inventory checks.
What fraudulent respirator components mean for laboratory safety programs
Laboratories depend on respirators to protect staff from airborne chemicals, infectious aerosols, and particulate hazards. If counterfeit components enter the supply chain, respirators may no longer provide the level of protection required by the Occupational Safety and Health Administration (OSHA) respiratory protection programs.
NIOSH emphasizes that it approves only complete respirator configurations, not individual components. If labs replace filters or cartridges with parts not listed on the NIOSH approval label, the respirator is no longer considered approved for workplace use.
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To reduce risk, NIOSH advises laboratories to:
- Verify respirator components using the NIOSH Certified Equipment List
- Use only replacement parts listed on the respirator’s approval label
- Report suspected counterfeit products to NIOSH
For laboratory managers, the NIOSH findings highlight a growing compliance and safety threat. Even high-performance respirator systems can fail if laboratories unknowingly install fraudulent replacement components that do not meet federal performance standards.
This article was created with the assistance of Generative AI and has undergone editorial review before publishing.
