A leading pharmaceutical manufacturer in India, specializing in large-scale production of APIs (Active Pharmaceutical Ingredients), approached Sigma HSE. The plant handled high volumes of combustible powders daily in processes such as blending, drying, milling, and packaging.

During an internal safety audit, the client identified several red flags:

1. Combustible powder residues found in dryers and dust collectors.
2. Unknown explosibility data of powders being handled.
3. Potential ignition sources in mixing and packaging equipment.
4. Lack of dedicated explosion protection systems.

The management was concerned that a single spark could trigger a devastating dust explosion, risking lives, production, and compliance.

Our experts developed a systematic safety testing and risk mitigation strategy:

1. Dust Hazard Assessment (DHA)

a) Identified all powder-handling units (dryers, mills, transfer systems).

b) Assessed dust accumulation and ignition source risks

2. Process Safety Testing (in IIT Hyderabad Lab)

   Performed laboratory testing on client’s powders:

a) Minimum Ignition Energy (MIE) → Confirmed powders could ignite with <10 mJ energy.

b) Minimum Explosive Concentration (MEC) → Found explosion risk even at low concentrations.

c) Kst & Pmax Values → Classified powders as St-2 explosive dusts (high severity).

d) Minimum Ignition Temperature (MIT) → Highlighted risks in heated equipment.

3. Risk Evaluation

a) Dryer exhausts had insufficient explosion venting.

b) Powder transfer systems lacked proper grounding → risk of static discharge.

c) No isolation between dust collectors and main production lines → secondary explosion risk.

4. Recommendations & Implementation

a) Installed explosion vent panels on dust collectors.

b) Added spark detection & suppression systems.

c) Grounding and bonding for powder handling equipment.

d) Developed housekeeping & preventive maintenance protocols.

e) Conducted safety training workshops for plant operators.

Within 3 months, the client achieved:

1. 70% reduction in explosion risk through engineering and procedural controls.
2. Zero dust accumulation incidents after improved housekeeping measures.
3. Full compliance with OSHA & NFPA standards.
4. Boosted confidence of employees & stakeholders in plant safety.

A single spark from static electricity in the dryer could have ignited accumulated dust. This would have:

1. Caused a primary explosion inside the equipment.
2. Triggered a secondary explosion in connected units.
3. Resulted in massive financial loss, downtime, injuries, or fatalities.

Thanks to proactive process safety testing and preventive measures, the pharma plant successfully avoided a catastrophic incident.

1. Access to world-class process safety testing labs at IIT Hyderabad.
2. Data-driven risk analysis for dust, gas, and thermal hazards.
3. Tailored engineering + procedural solutions for Indian industries.
4. Proven expertise across pharma, chemical, oil & gas, and FMCG sectors.

This case demonstrates how scientific testing, expert analysis, and proactive safety culture can prevent disasters. By partnering with Sigma HSE, industries can ensure:

✅  Safety of employees
✅  Protection of assets
✅  Compliance with international standards
✅  Long-term business continuity

👉 Don’t wait for a disaster to remind you about safety. Contact Sigma HSE India today for process safety testing and risk mitigation.