Chemical risks (Pharmaceutical

industry).
By Manoj Kumar(HSE Professional,HSEGURU@YAHOO.IN/+91-8252771261,Aadhaar Number-
584186777088,Ex-Alstom,Permanent Address: Adarsh Nagar,Booty Road,PHED,PO-Bariatu,Ranchi-
834009,Jharkhand,India. Ancestral Home Address: Near Govt. School,Barhara-Ekwana Road,Paschim
Tola,PO+Village+Thana+Block-Barhara,Arrah,Bhojpur,Bihar,India).

Professional Journey(Till Date): Alstom India to Zetwerk(T&D/Railway Division).

Educational Cum Technical Qualifications: M.Sc.(Chemistry),B.Sc.(Chemistry),B.Sc.(Fire,Safety & Hazards

Management,DIS,DFS.First-Aid(DISH Approved,Govt. of Maharastra),IOSH Validated by The British
Institute of Safety,Member: IAC,NewYork,Life-Member: Sri Sri Krishna Balrama Mandir,Brindaban).

Pharmaceutical manufacturing is a complex process that involves the use of a wide

range of chemicals, including solvents, reagents, and active ingredients. While these
chemicals are essential for producing life-saving medications, they can also pose
significant risks to workers if proper safety measures are not in place.

Identifying Chemical Risks in Pharmaceutical

Industries.
Identifying chemical risks in a pharmaceutical plant is crucial for several reasons.
Firstly, it can significantly improve the safety and well-being of employees working in
the plant by reducing the likelihood of accidents or exposure to hazardous chemicals.
This in turn can lead to an increase in productivity among employees. Secondly,
minimizing chemical risks can reduce the potential for environmental contamination,
which is crucial for preserving the natural environment and avoiding any negative
impact on public health. Finally, it can help ensure that the pharmaceutical products
produced are of high quality and meet regulatory requirements, which is essential for
maintaining consumer trust and preventing costly recalls or legal issues.

Overall, minimizing chemical risks is essential for creating a safe and sustainable
pharmaceutical manufacturing environment.

1 – Manufacturing areas.
These areas are where the actual production of pharmaceutical products occurs.
Chemical risks in these areas can come from exposure to raw materials, solvents, and
reagents. For example, corrosive substances such as hydrochloric acid, sulfuric acid,
and nitric acid, and irritant substances such as acetone, ethanol, and sodium hydroxide
are commonly used in the manufacturing of pharmaceutical products. These products
can pose significant health hazards if not properly handled. For example, if a container
of a substance such as hydrochloric acid is mishandled or punctured, it can spill and
potentially cause harm to employees or damage to equipment. In the event of a
chemical spill, it is crucial to have an emergency response plan in place that includes
procedures for containing the spill, providing first aid to any affected employees, and
ensuring that the spilled material is properly disposed of.

2 – Laboratories.
Pharmaceutical companies often have extensive laboratory facilities for research and
development, testing, and quality control. These areas can be particularly hazardous
due to the large number of chemicals present. Chemicals used in laboratories can
include everything from acids and bases to highly reactive compounds that can pose
serious health and safety risks if not handled correctly. Here we will often have to deal
with smaller splashes in the event of an accident compared to the manufacturing area.
People working in the laboratory can be wearing their PPE equipment and by
mishandling an equipment they can received chemical splashes that goes underneath
their safety glasses or in between their clothes. In these cases, we will need to have a
quick response to ensure the health of the employee and as well the safety of the
environment of the workspace.

3 – Storage areas.
Chemicals used in pharmaceutical production must be stored safely to prevent
accidents, fires, and explosions. Improper storage of chemicals can also lead to
chemical spills and leaks, which can pose significant health and safety risks to
employees. All types of products will be found. Acids, bases, reducing agents, oxidizers,
chelating agents can be stored in designated areas with proper ventilation and safety
measures. It is also important to separate and create barriers between products that
can be dangerous if they are in contact with each other. Just like acids that should be
 stored somewhere far from basic products so that we make sure they never come in
contact with each other to create an exothermic reaction.

4 – Waste management.
Pharmaceuticals plants generate large quantities of waste, including hazardous waste
that must be properly managed. The wastewater treatment process that is often found
can be broken down into several main stages: inflow of effluent, pre-treatment
(screening, grit removal, degreasing and oil removal), treatment (physical-chemical
and/or biological, followed by clarification), disinfection, pH adjustment and sludge
treatment. At the various stages of the treatment process, the water and sludge are
monitored and analyzed to ensure compliance with local environmental standards. All
throughout the process of waste management we will find acids such as chlorohydric
acid or bases such as caustic soda.

5 – Maintenance.
The industrial risks of damage or dysfunction of the equipment lead pharmaceutical
companies to perform frequent maintenance operations of the installations. Accidents
may be observed during the operations of draining, cleaning, sanitation, and purging.
The main causes of accidents are the chemical splashes which can occur for instance
when a pipe or a tank burst under pressure or during disassembling operations of pipes
or valves.

Identifying chemical risks is the first step in protecting employees from chemical
exposure. Pharmaceutical companies should conduct thorough risk assessments to
identify potential hazards and implement appropriate safety measures to prevent
accidents and protect employees. This may include developing safety protocols,
providing safety training, and ensuring that employees have access to appropriate
personal protective equipment (PPE) to minimize their risk of exposure.

Protecting Employees from Chemical Risks in

Pharmaceutical Industries.
Once chemical risks have been identified, it is important to take steps to protect
employees from exposure. Here are some strategies that pharmaceutical companies
can use to protect their employees:

• Personal protective equipment (PPE): PPE, such as gloves, goggles, and respirators, can help
protect workers from exposure to chemicals. It is essential that employees are trained on how
to properly use and maintain PPE.
• Engineering controls: These include measures such as ventilation systems, air filtration, and
isolation of hazardous areas. Engineering controls can help minimize employee exposure to
chemical hazards.
• Administrative controls: Administrative controls refer to policies and procedures that help
reduce chemical risks, such as limiting employee exposure time, providing training on chemical
hazards, and establishing emergency response procedures.

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