Dust consists of tiny solid particles carried by air currents. These particles are formed by many different processes. One of these processes is polymerization of inert plastic such as Polyvinyl Chloride production plant. According to the Occupational Health and Safety Assessment Series requirements, section 4.4.6, occupational health and safety risks must be defined and controlled where needed. This field study was conducted to evaluate the occupational exposure of packaging operators to airborne polyvinyl chloride dust in order to health risk assessment and recommend feasible controlling methods. The mass concentration of polyvinyl chloride particulate was measured in two fractions according to the particle size that expressed as total and respirable particulates. The Air Sampling Methods, Methods for the Determination of Hazardous Substances 14/3, of Health and Safety Executive were used as a standard sampling protocol. The average mass concentrations for respirable and total particulates were measured 3.54±0.3 mg/m³ and 11.89±0.8 mg/m³ respectively. Also health risks of studied condition were estimated as significant level, category one, therefore the risk must be reduced below the standard level. According to the work requirements to reduce the emission rate and mitigate the health risk exposure, a local exhaust ventilation system design was recommended for bag-filters of hopper tank.