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INDUSTRIAL HAZARDS DUE TO FIRE AND MECHANICAL EQUIPMENTSATYANARAYANA.V( M.Pharm I sem )

Department Of Pharmaceutical SciencesUNIVERSITY COLLEGE OF PHARMACEUTICAL SCIENCES, KAKATIYA UNIVERSITY,WARANGAL-500609.

CONTENTSINTODUCTIONTypes of hazards in a pharmaceutical industryFireClassification of firesClassification of hazardous areasPotential cause for a firePrevention of fire

Mechanical Hazards with equipmentSafety aspects in the pharma industryDisaster management planConclusionReferences

Introduction

HAZARD is a term associated with a substance that is likely to cause an injury in a given environment.

INDUSTRIAL HAZARD is any condition produced by industries that may cause: injury to a personnel, (or)One which may lead to loss of property, products etc; (or)A substance that might proove fatal to the personnel

TYPES OF HAZARDS IN AN INDUSTRYFire ChemicalsElectricalMechanicalMiscellanious Pharmaceutical BiologicalPersonnelEnvironmental

CHEMICAL HAZARDS

Volatility of solventsFlammabilityExplosivityStabilityCorrosivityReactivityRadioactivity ELECTRIC HAZARDS BASED over protective devices

Short circuit fault protectve device

Open circuit fault protective devices

Ratings and sizes of surge protective capacitorsMeasures to be takenUse of high quality electricalsElectrical equipment maintananceProper handling of chemicals

CHEMICAL SAFETY CARDSExpertsRetailer

CHEMICAL DATA SHEETA chemical safety data sheet provides the following basic information about the chemical: Identification : Name of the substance or preparation Name, address and telephone number of the company/supplier/undertaking Composition and information on ingredients Hazards identification First-aid measures Fire-fighting measures Spillage, accidental release measures Handling and storage Exposure controls and personal protection

Physical and chemical properties Stability and reactivity Toxicological information Ecological information Disposal considerations Transport information National regulations and references Other information

Chemical safety data sheets are published under several names such as: INTERNATIONAL CHEMICAL SAFETY CARD, ICSC CHEMICAL SAFETY CARD CHEMICAL INFO-SHEET MATERIAL SAFETY DATA SHEET, MSDS PRODUCT SAFETY DATA SHEET HEALTH AND SAFETY DATA SAFETY DATA SHEET.

Miscellaneous hazardsPharmaceutical

Biological

Personnel

EnvironmentalFIRE HAZARDSFire: The self-sustaining process of rapid oxidation of a fuel which produces heat and light

Fire is an exothermic chemical reaction between oxygen and fuel at certain temperature.

Three things essential for the combustion of fire are;Fuel (any combustible material)Oxygen (At concentrations above 23 % in air, the situation becomes dangerous due to the increased fire hazard)Temperature

Classification of firesMost fires that occur will fall into one or more of the following categories

Class A: Fires involving ordinary combustible materials, such as paper, wood, and textile fibers, where a cooling, blanketing, or wetting extinguishing agent is needed.

Class B: Fires involving flammable liquids such as gasoline, thinners, oil-based paints and greases. Extinguishers for this type of fire include carbon dioxide, dry chemical* and halogenated agent types.

Class C: Fires involving energized electrical equipment, where a nonconducting gaseous clean agent or smothering agent is needed. The most common type of extinguisher for this class is a carbon dioxide exinguisher

Class D: Fires involving combustible metals such as magnesium, sodium, potassium, titanium, and aluminum. Special dry powder* extinguishing agents are required for this class of fire, and must be tailored to the specific hazardous metal.

Class K: Fires involving commercial cooking appliances with vegetable oils, animal oils, or fats at high temperatures. A wet potassium acetate, low pH-based agent is used for this class of fire.

Classification of hazardous areasZone 0: an area in which a atmosphere is present continously or is present for long periods.

Zone 1: an area in which a flammable atmosphere is likely to be present periodically or occasionally during normal operations.

Zone 2: an area in which a flammable atmosphere is likely to be present peridically or occur in normal operations.POTENTIAL CAUSE FOR A FIREImproper design or layoutslack of proper work design processElectricityChemicalsHousekeepingImproper StorageFlammable LiquidsCombustible materialsEquipmentLack of proper ventilation Carelessness

Actions in the event of fireFire detectionRaising the alarmCalling the local fire brigadeFirst aid fire fighting practiceevacuationPREVENTION OF A FIREWell planned design and layoutProper ventilated systemsChemical data sheetsProper training of personnelProper maintenance of surroundingsuse of fire extinguishers, alarms ,sensors, detectorsFire fighting equipmentSprinkler systemsExtinguishment TheoryRemoving Heat Removing Fuel Reducing Oxygen

WILL

Inhibit Chemical Chain Reaction

FIRE EXTINGUISHERSThe fire extinguishing agents are classified into Water and water based agents portable extinguishers soda acid extinguishers antifreeze extinguishers foamDry chemical Carbon dioxideHalon1301( bromo tri fluoromethane)Vaporizing liquidDry powders for combustible metals

FIRE EXTINGUISHERS

Non-Magnetic stored pressure deionized water mist fire extinguisher

Halotron 1 Fire extiguisher.

ABC Dry chemical fire extinguisher

Carbon dioxide (CO2) Portable fire extinguisher

K Class Wet chemical extinguisher.Characteristics of extinguishers

Water extinguisher 30-40 ft. 60 sec.Dry chemical 5-20 ft. 8-25 sec.CO2 extinguisher 3-8 ft. 8-30 sec.

Quick-Check

Is It Ready To Use ?

Check the gauge. The pressure indicator should be in the green zone. (CO2 extinguishers do not have pressure gauges.)

The extinguisher should have a current inspection tag.

The pin and handle should be secured with a plastic tab seal.

4.The extinguisher and hose should be free of any visible damage.The P.A.S.S. Method

Pull the pin.

Aim the hose or nozzle.

Squeeze the lever.Sweep the agent.FIRE EXTINGUISHERS

Dry Chemical - Works on class A, B, and C fires (Multipurpose).Carbon Dioxide - Works on class B and C fires. Water - Works on class A fires.Foam - Works on class A and B fires.Halogenated - Works on class A, B, and C fires.Dry Powder - Works on class D fires.Wet Chemical - Works on class K fires. FIRE ALARMS

Smoke detectorFire sensorsSpinkler systems

Heat detectorsMechanical hazardsINTRODUCTION:

Mechanical hazards may occur due to the large numbers and different designs of equipment, crowded workplace conditions and frequent interaction between workers and equipment

Hazardous electrical, pneumatic and thermal energy must be released or controlled before working on active equipment and utilities

Workers are protected from sources of hazardous energy by

Implementing lock out / tag out procedures.Interlocked guards, control switches, emergency stop devices and operator training are important means of reducing mechanical hazards.HAZARDS WITH MECHANICAL EQUIPMENTWAREHOUSING

RAW MATERIAL WEIGHING

GRANULATE PREPARATION

SUPPOSITORY AND PESSARY PRODUCTION

OINTMENT PASTE CREAM GEL PRODUCTION

TABLET & CAPSULE PRODUCTION

SOLUTION PREPARATION

CONTAINER STERILIZATION

CONTAINER FILLING

INSPECTION

FREEZE DRYING

PACKAGING

PALLETIZATION

WAREHOUSING:FINISHED PRODUCTS

SHIPMENT

CONTAINER FILLING

WAREHOUSINGWORK PHASE DESCRIPTIONIncoming and out going goods store (raw materials, excipients, labels, printed information materials)

The raw materials and excipient store is generally located close to the production areas. Products are stored on multi-level racks and shelves. Manually operated trolleys and electrical pallet handlers are used to move boxes/containers.

EXPECTED INJURIESMuscular-skeletal complaints.Cutting injuries

Electronic and/or mechanical weighing scales

The pharmaceutical industry uses the classic single/twin platter mechanical scales. The more modern electronic scales are characterised by a metal box enclosing the apparatus and by a weighing system generally including a platter. Electronic scales are fitted with local powder/dust exhaust devices or laminar flow exhaust hoods.

RISK FACTORS: Exposure to dust

EXPECTED INJURIES: Allergic asthma, contact dermatitis

Work performed in the presence of moving machinery partsDESCRIPTIONManual cleaning of certain machine may entail the operator being snagged, dragged or crushed by the machines parts in motion. By way of an example, an operator may clean a mixer/blender by pouring the cleaning fluid in the vat and starting the machine in order to better clean the internal surfaces.Other operators may accidentally start the machine while staff is cleaning the machines internal parts.EXPECTED INJURIESLesions and bruises.PREVENTIVE MEASURES Hazardous zones must be shielded by fixed guards or fitted with interlocking safety devices to reduce the risk of operators being snagged and dragged. Machinery must be fitted with emergency shut down and accidental start-up lockout devices such as safety devices blocking machine start up when power is restored after a temporary blackout.

PROCESSING OF SEMI-SOLID PHARMACEUTICAL FORMS RISK FACTORS: Fatiguing tasks and work postures

DESCRIPTIONCareful cleaning of plant systems especially where processing of semi-solid pharmaceutical forms particularly rich in lubricating agents such as suppositories, ovules and ointments takes place, require manual operations involving fatiguing tasks and anomalous work postures.EXPECTED INJURIESMuscular-skeletal complaints.PREVENTIVE MEASURES - Consider the feasibility of employing built-in, closed-cycle automatic washing and/or sterilization systems (cleaning in place). - Accurate task organization and operator information and training.GRANULATE PREPARATION EQUIPMENT AND MACHINERY Miller/grindersCompactorTwin Whisk BlenderPlanetary or crown wheel Blender Rotating Tub BlenderFluid Bed Granulator-DryerDynamic Tunnel Dryer SystemDynamic Revolving Drum Dryer SystemVacuum DryersRISK FACTORS : Exposure to dust

DESCRIPTIONOperators may be exposed to dust during miller/grinder loading/unloading, compacting, blending and granulation operations. ESTIMATEField assays have yielded ambient air dust concentration levels ranging from 342 to 3.462 g/m3 in the blender shop, from 307 to 1.884 g/m3 in the granulator shop. EXPECTED INJURIESAllergic asthma, contact dermatitis. Specific pharmacological effects due to active principles.PREVENTIVE MEASURESUse of completely automated load/unload systems.Use of protective hoods fitted with absolute filters.EXPOSURE TO NOISE

DESCRIPTIONThe sources of noise in this work phase are: miller/grinders, compactors, blenders and granulators. Notwithstanding the use of sound dampening devices, noise levels may be quite high. EXPECTED INJURIESContinuous exposure to medium-high noise levels may cause hearing injuries (noise-induced hypoacusia) and extra-hearing complaints. Injuries and complaints may result also from exposure to noise levels lower than the thresholds for which legislation prescribes the use of specific preventive measures.In addition to communication and work performance-related complaints, the following disorders may also arise: cardiovascular effects (high blood pressure, etc.); psychic disorders (asthenia, irritability, depression, insomnia); digestive tract disorders.PREVENTIVE MEASURESPreventive measures established in cases of employee noise exposure exceeding 80 dB(A). Decrease the exposure time MANUAL LOAD HANDLING

DESCRIPTIONMachine hopper loading operations in this phase may be performed manually.EXPECTED INJURIESMuscular-skeletal complaints PREVENTIVE MEASURESUse of mechanical/electrical handling devices or automated loading systems.Two operator handling of heavy loads.Manual load handling is permitted for loads up to 30 kgs.(males) and 25kgs.(females). Handling of loads exceeding these limits shall be performed using appropriate devices and/or shall be performed by two operators.Operator information and training.OINTMENT, PASTE, CREAM AND GEL PRODUCTION EQUIPMENT AND MACHINES Turbo-emulsifier (blender-homogeniser) Manually operated trolleysBulk storage tanks

Risk factors: Exposure to dust

DESCRIPTIONLoading active principles into the emulsifiers is typically performed manually. Operators insert a suction nozzle connected to the emulsifier into the bins containing the active principles or excipients.

ESTIMATE: Field data typically reports that an operator performs approximately two active principle and excipient emulsifier loading cycles per 8 hour working shift. Loading operations total 90 minutes resulting in 0,76 mg/m3. mean operator dust exposure levels.TLV-TWA threshold values reported by firms are 0.5 mg/m3 for active principles and 10 mg/m3 for gelling excipients.EXPECTED INJURIESActive principle-specific induced injuries.PREVENTIVE MEASURES- Use of automated loading systems

Container Filling And Packaging EQUIPMENT AND MACHINES Manually operated trolleysPlastic stopper vibrator Tube FillerPackaging machineLabelling machinesBoxing machines

Risk factors: Manual load handling

ESTIMATE: Load handling data furnished by a drug company may be broken down as follows: - empty tube feed: package weight 5 kgs, feed frequency 3/min.;- filled tube transfer: weight 10.8 kgs, frequency 2/min.;- labeller feed: weight 7 kgs, frequency 1/min.EXPECTED INJURIES: Muscular-skeletal complaints.PREVENTIVE MEASURESUse of electric powered or mechanical devices or automated systems.Manual load handling operations are limited to loads up to 30kgs for men and 25 kgs for women.Heavier loads shall be handled employing appropriate means and/or shall be performed by two operators.

ContdSAFETY ASPECTS IN THE PHARMA INDUSTRYStandard operating proceduresHandling of hazardous materialsWater supply and drainageFloors and floor coveringsEmergency exitsBack up plan if anything goes wrongSpecially trained personnel Health polices and insuranceWritten proceduresSafety auditsRisk analysisAppropriate training and education to employeeRegular monitoring of workplaceWritten documentation of policiesCreate awareness of the environmentInvolvement of the personnelContingency plan DISASTER MANAGEMENT PLANDisaster management plan is essential as it:

Reduces the amount of thinking time required after the incident occurredContains the incident and minimizes the extent of the damage to the resources and business.Reduces the conduct of disaster to a set of predetermined rules and a system of orderly procedure to make orderly and rational

The success in disaster management depends on :

Reliable early detectionCareful planningEfficient personnelProper training of all personnel concernedProblem free communication

CONCLUSIONFrom the previous discussion it is clear that the safety aspects must be considered by the pharmaceutical industry not only in the interest of the employees or property but also in terms of the neighboring environment as well.

The source of possible hazards , risk analysis, control procedures ,preventive measures &contingency plan are the main five essentials for ensuring a complete work atmosphere in the industryREFERENCESG.D.Muir,Hazards in Chemical Industries, 2nd edition.Reigels Handbook of Industrial Chemistry, 9th edition.James Sward Brick, James C.Boylan, Encyclopedia of Pharmaceutical Technology,volume-4.www.fda.govwww.friesnoop.comwww.pubmed.comwww.agricum.comwww.teoma.comwww.altavista.com

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