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Why manufacturers must review their chemical safety protocols
Articles- Oct 31,23
Manufacturers of chemicals, as these are hazadous in nature, should take nessecary steps to improve workplace safety. By minimising injuries and illnesses, companies can save money by avoiding the direct and indirect costs of chemical exposures, says Suresh Tanwar.
India’s chemical manufacturing and processing industry is among the largest and most diverse sectors. Globally, India ranks among the top 6 largest producers of chemicals. The sector comprises petrochemicals, fertilisers, pesticides, pharmaceuticals, and paints, collectively accounting for over 70,000 commercial products that contain or are made from chemicals. Of these, several are hazardous chemicals. A media report states India produces and stores over 3,000 hazardous chemicals. Those involved in manufacturing, handling, or distributing these goods know the importance of good safety protocols. However, being aware is not enough. Companies that work in such sectors should also ensure that they review their chemical safety protocols periodically. Because not doing so can have severe consequences on workers’ health, communities, and the environment.
The National Disasters Management Authority (NDMA) estimates that 130 significant chemical accidents were reported in India in the last decade, causing 259 fatalities and injuring 563 people. The NDMA points to about 1861 Major Accident Hazard units across 301 districts, 25 states and 3 Union Territories. These numbers do not include thousands of hazardous factories and unorganised sectors that deal with hazardous materials that can pose severe and complex disaster risks.
The World Health Organization (WHO) estimates that two million people lost their lives due to exposure to hazardous chemicals in 2019, compared to 1.56 million in 2016, indicating a 29 per cent rise in fatalities due to chemical exposure. Another report from the UN Special Rapporteur on Human Rights and Hazardous Substances and Wastes states that one life is lost every 30 seconds due to toxic exposure at the workplace. With 2.78 million deaths per year attributable to unhealthy or unsafe workplaces, the report warned that women, children, migrant workers, and the poor are especially vulnerable to work-related fatalities, injuries and ill health. According to the WHO, most deaths from exposure to hazardous chemicals are preventable. The solutions to solve this global crisis of public occupational health require the participation of businesses, governments and not-for-profit organisations.
The impact of chemical cocktails on the environment also must be tackled. New research in the UK in 2023 showed the presence of harmful toxic chemical cocktails in over 1600 water bodies, including rivers, lakes, and groundwater sites. The alarming statistics call for a new approach focusing on a sustainable future. The strategy should focus on embedding stricter standards, stringent testing, more rigid controls, comprehensive monitoring, and research so we know what’s in our rivers and air and how it affects us, our environment, and our natural world.
There is a chemical safety law in the works in India. The country put together its fifth draft of Chemical Safety Rules in 2020. The draft is still in the proposal stage but is expected to close the gap between India’s limited chemical regulations and the more inclusive ones overseas. While the country awaits the new set of rules, manufacturers should do their bit to improve workplace safety. A chemical safety risk assessment is the first step in that direction. A safety audit will determine whether companies should be going back to the drawing board on their chemical safety protocols.
In the UK, COSHH (Control of Substances Hazardous to Health) is a set of regulations to protect workers at risk from working with hazardous chemicals. It defines the critical responsibilities of employers in key focus areas outlined below:
- Exposure: Employers must provide appropriate personal protective equipment (PPE) where applicable to prevent or control exposure to hazardous substances.
- Control measures: Employers must implement robust control measures around hazardous substances. The control systems must be properly maintained, clean, and in complete working order.
- Instruction: Employers must ensure workers are provided with information, instruction and training on working with hazardous substances
- Procedures: Employers must put in place procedures to deal with accidents and emergencies relating to hazardous substances
- Surveillance: Employers should ensure workers exposed to hazardous substances are under proper surveillance
- Risk assessments: Employers must undertake periodic COSHH risk assessments.
- Limits: Employers must ensure they don’t expose workers to hazardous materials beyond the Workplace Exposure Limit (WEL).
- Supervision: Supervisors must scrutinise if employees are carrying out tasks as per the protocol.
Similarly, employees must comply with the above guidelines to carry out the tasks safely without harming themselves or others. COSHH is not mandated by law in India yet; however, following the precepts may help organisations get a head-start when REACH/CMSR takes effect in India.
Organisations must strive for continuous improvement in safety
Continuous improvement entails assessing and enhancing safety processes and protocols to ensure their efficacy and relevance. Continuous improvement can be achieved through various strategies, such as utilising safety audits and establishing safety committees. Safety audits identify potential safety hazards within the manufacturing process, while safety committees facilitate the discovery and implementation of safety enhancements. Furthermore, manufacturers can employ safety metrics to monitor safety performance over time, like tracking the frequency of accidents and near misses and evaluating the effectiveness of safety controls.
By minimising injuries and illnesses, companies can save money by avoiding the direct and indirect costs of chemical exposures. An employee’s injury often leads to work absences and the need to hire or train replacement workers, resulting in decreased productivity. Incident investigations and corrective actions also consume time and effort, constituting further indirect costs. Direct costs include medical expenses related to chemical exposure incidents.
Adhering to best practices for chemical storage safety significantly reduces the risk of property damage. Proper segregation of incompatible chemicals helps prevent fires and explosions, which can otherwise result in substantial financial losses due to property damage. If a workplace facility is destroyed in a fire, manufacturing operations are halted, leading to significant revenue losses.
By prioritising chemical safety measures, organisations can safeguard the well-being of employees, reduce costs associated with injuries and property damage, and enhance overall productivity in the workplace. Therefore, chemical manufacturers and associated industries that deal with hazardous materials must prioritise safety and continually review their safety protocols and procedures to guarantee their continued effectiveness and alignment with current standards.
About the author:
Suresh Tanwar is the Head of Audit and Consultancy at British Safety Council – India. He has a rich experience in safety and health with hands on experience in the initial period of his career with companies like Johnson & Johnson, Tata Chemicals and BJ Services (now Baker Hughes, a GE company).
Suresh Tanwar
safey audit
British Safety Council
chemical sfaety
safety protocol
chemical manufacturing
Chemical Safety Rules
Policy
industrial safety
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