As the calendar year draws to a close, workplace safety teams across Australia are reviewing compliance obligations, updating policies, and preparing for the year ahead. For organisations using workplace breathalysers as part of their alcohol testing programs, there's one critical task that should be at the top of your year-end checklist: breathalyser calibration and maintenance.
Accurate alcohol testing isn't just about having the right devices, it's about ensuring those devices remain reliable, compliant, and legally defensible over time. This article provides a practical guide for WHS managers, fleet supervisors, and compliance teams on why calibration matters, what AS3547:2019 requires, and how to maintain your breathalysers for the year ahead.
Find out more about calibration through our Breathalyser Calibration FAQ page.
Why year-end is the ideal time for breathalyser servicing
End-of-year downtime offers a natural window to service workplace equipment without disrupting daily operations. For organisations running mandatory alcohol testing programs, this period allows you to send devices for calibration, assess their condition, and replace any units that are no longer fit for purpose, all before testing resumes in full swing in the new year.
There's also a compliance dimension. Many organisations align their calibration schedules with the financial year or calendar year to simplify record-keeping and ensure devices are serviced at regular, predictable intervals. Waiting until mid-year can lead to scheduling conflicts, testing gaps or worse, using devices that have drifted out of specification without your knowledge.
Year-end is also when many businesses conduct safety audits, review incident data, and plan budgets for the following year. Integrating breathalyser maintenance into this broader review ensures testing accuracy remains a priority rather than an afterthought.
Why calibration matters: sensor drift and testing accuracy
Breathalysers are precision instruments that rely on electrochemical fuel cell sensors or semiconductor sensors to detect alcohol in breath samples. Over time and with repeated use, these sensors naturally degrade. This is a process known as sensor drift.
Sensor drift occurs gradually and is influenced by factors including the number of tests performed, environmental conditions such as temperature and humidity, exposure to contaminants, and the age of the sensor itself. As drift occurs, the device may begin to produce readings that are either falsely high or falsely low, undermining the reliability of your testing program.
A falsely high reading can lead to unjust disciplinary action, damage employee trust, and expose your organisation to legal challenge. Conversely, a falsely low reading may allow an impaired worker to enter the workplace, creating serious safety risks and potential liability.
Calibration corrects for sensor drift by adjusting the device to a known standard, ensuring that readings remain accurate and within acceptable tolerance limits. This process isn't optional, it's a fundamental requirement for maintaining the integrity of workplace alcohol testing.
Understanding AS3547:2019 calibration requirements
The Australian Standard AS3547:2019 for breath alcohol testing devices sets out the performance requirements and testing protocols for breathalysers used in workplace settings. It is widely referenced as the benchmark for workplace devices, particularly those used for screening and compliance purposes.
AS3547:2019 specifies accuracy tolerances that devices must meet across a range of blood alcohol concentrations. To maintain compliance with this standard, devices must be calibrated regularly by trained technicians using certified reference standards.
The standard does not prescribe a single universal calibration interval—this varies depending on the device type, manufacturer recommendations, and usage intensity. However, most manufacturers and safety professionals recommend calibration at least every six to twelve months, or after a specified number of tests.
For organisations subject to regulatory oversight such as those in transport, mining or aviation, demonstrating compliance with AS3547:2019 through regular calibration is often a legal requirement. Even where it's not mandated, calibration provides defensibility in the event of a workplace incident, grievance, or legal dispute.
Calibration certificates issued by accredited service providers document the device's accuracy at the time of testing and confirm it has been adjusted to meet the required standard. These certificates form part of your compliance record and should be retained for audit purposes.
Year-end breathalyser maintenance checklist
To ensure your breathalysers remain accurate, compliant, and ready for use in the new year, follow this comprehensive maintenance checklist.
Review Your calibration schedule
Start by identifying which devices are due for calibration. Check manufacturer recommendations, service logs, and previous calibration certificates to determine when each unit was last serviced. If a device is approaching or has exceeded its recommended calibration interval, schedule servicing immediately.
For organisations with multiple devices, create a calibration register that tracks each unit's serial number, last calibration date, number of tests performed, and next service due date. This ensures no device falls through the cracks.
Inspect devices for physical damage
Examine each breathalyser for signs of wear, damage, or malfunction. Check for cracked screens, damaged mouthpieces, worn buttons, or loose components. If a device has been dropped, exposed to extreme conditions, or shows any physical defects, it may require repair or replacement in addition to calibration.
Pay attention to the condition of mouthpieces and ensure you have an adequate stock of unused, individually sealed mouthpieces for the year ahead. Contaminated or reused mouthpieces can affect test accuracy and hygiene.
Test device functionality
Before sending devices for calibration, perform basic functionality checks. Power on each unit, ensure the display is clear and responsive, and verify that the device completes its self-check sequence without error codes. If a device fails to power on or displays persistent error messages, note this when booking calibration so technicians can diagnose the issue.
Some devices include a sample simulator or test function. If available, use it to confirm the device is still producing readings within an expected range.
Clean and store devices properly
Breathalysers should be stored in clean, dry environments away from extreme temperatures, direct sunlight, and sources of contamination such as solvents, aerosols, or cleaning chemicals. Improper storage can accelerate sensor degradation and affect calibration stability.
Wipe down the exterior of each device with a soft, dry cloth. Avoid using alcohol-based cleaners or sprays near the sensor inlet, as these can interfere with sensor performance.
Review usage records and incident data
Take stock of how your breathalysers have been used over the past year. Review testing logs to identify any patterns such as frequent positive results from specific devices, unexplained error codes or user complaints about device performance. These may indicate calibration drift or operational issues requiring attention.
If your organisation has experienced any workplace incidents involving alcohol testing, revisit those cases to ensure the devices used were properly calibrated at the time. This is particularly important if the test result was used in disciplinary action or is subject to dispute.
Assess staff training and competency
Device accuracy depends not only on calibration but also on correct use. Review whether staff responsible for conducting tests have received appropriate training and whether refresher training is needed. Common operator errors—such as testing too soon after the subject has consumed food or drink, failing to follow warm-up procedures, or misinterpreting results—can undermine testing accuracy even when devices are properly calibrated.
Consider scheduling training sessions in the new year to ensure all operators are confident and competent in device use.
Check battery condition and accessories
Ensure batteries are charged or replaced as needed. Devices left unused for extended periods may experience battery degradation, which can affect performance. Check that you have spare batteries, chargers, and any other accessories required for uninterrupted testing.
Update policies and procedures
Year-end is an opportune time to review your alcohol testing policy and ensure it reflects current best practice, legal obligations, and any changes in your operational environment. Confirm that your policy addresses calibration requirements, record-keeping, operator training, and the consequences of non-compliance.
Booking calibration with a certified provider
Once you've completed your checklist, the next step is arranging professional calibration. Calibration should always be performed by qualified technicians using certified reference standards and equipment traceable to national or international measurement standards.
When booking calibration, provide your service provider with details including device make and model, serial numbers, last calibration date, and any known faults or performance issues. This allows technicians to prepare appropriately and ensures efficient turnaround times.
Most calibration services include sensor adjustment, accuracy verification across multiple alcohol concentrations, functional testing, and issuance of a calibration certificate documenting the results. Some providers also offer repair services, sensor replacement, and firmware updates where applicable.
Turnaround times vary depending on the provider and time of year. Year-end is a busy period for calibration services, so book early to avoid delays.
Andatech provides professional calibration services for workplace breathalysers, with technicians trained to service a wide range of AS3547-certified devices in their NATA accredited calibration centre in Melbourne.
Enter the New Year with confidence
Accurate alcohol testing is a cornerstone of workplace safety, particularly in industries where impairment poses serious risks to workers and the public. Regular calibration ensures your breathalysers remain reliable, your testing program maintains credibility, and your organisation meets its duty-of-care obligations.
By taking the time to service and maintain your devices at year-end you're not just ticking a compliance box, you're reinforcing a culture of safety, accountability, and professionalism.
Don't wait until a device failure or disputed test result forces your hand. Make breathalyser calibration a non-negotiable part of your annual safety review.
Ready to book Your calibration?
If your workplace breathalysers are due for servicing or you're unsure whether your devices are still compliant, now is the time to act.
Contact Andatech to book professional calibration, discuss your testing program requirements, or seek expert advice on maintaining AS3547-compliant devices. Start the new year with accurate, defensible alcohol testing that protects your people and your organisation.
