Celebrated annually on the first Friday of October, National Manufacturing Day recognizes the United States' manufacturing expertise and innovation. In the chemical manufacturing industry, the holiday is a reminder of the ongoing shift towards safety, sustainability, and efficiency.
Working with chemicals is inherently risky, but initiatives ranging from the 1972 Clean Water Act to the 2024 updates to the OSHA Hazard Communication Standard (HCS) have led to safer, more environmentally friendly procedures and products.
The Advancements in Chemical Manufacturing
Chemicals are critical to a range of essential industries, including healthcare, energy, and apparel. However, certain substances involved in chemical manufacturing can be harmful to the environment and the population. To ensure safety and sustainability while continuing production, companies across the sector are dedicated to finding innovative solutions to longstanding challenges, including environmental impact, employee protection, and regulatory pressures.
Green Chemistry
Green chemistry — an approach to products and processes that reduces dangerous substances — is one way that companies are increasing safety and sustainability in the design, manufacturing, and application of chemicals. This approach is a departure from traditional remediation; it aims to reduce hazards at the source by:
- Preventing waste. Green chemistry aims to reduce or eliminate waste at every stage of production. Tactics include recycling substances including carbon dioxide, using enzymatic reactions for synthesis, reusing catalysts, and designing manufacturing processes that reduce wasted inputs.
- Using safer auxiliary substances. When processes require solvents or separation agents, companies are striving to use bio-based products that use renewable sources, reduce toxicity, and minimize environmental impact.
- Employing process intensification (PI). PI uses new and innovative equipment, techniques, and methods to develop more efficient and compact chemical production processes.
Digital Transformation
The expansion of artificial intelligence (AI) and machine learning (ML) could transform the chemical manufacturing industry — particularly when it comes to drug discovery and design. Research suggests that powerful AI tools can analyze vast data collections to identify drug targets for specific diseases, suggest chemical compounds, and predict interactions. They can also optimize research processes by predicting efficacy and toxicity, optimizing reaction conditions, and streamlining quality control.
Chemical companies are already using AI and ML tools to automate process control systems, optimize yields, and lower energy consumption. AI programs can also monitor a facility's Internet of Things (IoT) devices to identify and notify employees of potential hazards.
Material Innovations
Some companies in the chemical industry are developing innovative materials to boost safety and sustainability. New high-performance polymers offer impressive resistance to chemicals, temperature, and pressure in the oil and gas industry. In food packaging companies, biopolymer-based nanocomposites could increase the shelf life of food, reduce waste, and boost food safety.
New nanomaterials are poised to play a transformative role in catalysis for chemical manufacturers. Certain types of nanoparticles increase stability and precision in additive manufacturing, also known as 3D printing. Devices printed using additive manufacturing processes could lead to more efficient and sustainable catalytic processes, as well as enhanced features including heat dissipation and mechanical energy absorption. For example, 3D-printed catalysts can be tailored to specific reactions, optimizing heat dissipation and minimizing the risk of overheating or mechanical failure.
Adjusting Safety Procedures for Increased Lab Safety
Chemical manufacturing comes with inherent risks, including fires, explosions, and chemical exposure. To prevent accidents and protect people, chemical manufacturers invest heavily in their safety programs and practices.
Recent Safety Protocol Updates
Recently, government organizations have released updates to safety regulations and standards at the national and international levels. The Occupational Safety and Health Administration (OSHA) published new hazard communication guidelines in 2024. They included updates to hazard classifications and labeling requirements, as well as steps to help companies align with DOT and EPA procedures.
Technology's Role in Safety
Technology is playing an increasingly important role in enhancing safety within chemical manufacturing facilities. While new chemistry continues to contribute to safer processes and materials, it is advancements in technology — from digital transformation to automation — that are driving significant improvements in workplace safety.
For example:
Smart personal protective equipment (PPE): PPEs like connected helmets and wearable devices are improving worker safety. Equipped with sensors that monitor environmental conditions, these devices offer real-time alerts on air quality, gas leaks, or temperature changes, allowing workers in chemical plants to take preventive action before a situation escalates.
Sophisticated monitoring systems: Powered by the Internet of Things (IoT), sensors, and even aerial surveillance drones are enabling chemical manufacturers to detect gas leaks, temperature anomalies, or equipment malfunctions in real-time. These technologies help to identify and address potential safety hazards faster than traditional methods, significantly reducing the risk of accidents.
Automated shutdown systems: These systems can quickly respond to emergencies, such as chemical spills or equipment failures, minimizing human exposure to dangerous conditions and preventing further escalation.
Sophisticated monitoring systems:
- Automated shutdown systems: These systems can quickly respond to emergencies, such as chemical spills or equipment failures, minimizing human exposure to dangerous conditions and preventing further escalation.
The Future of Safety in Chemical Manufacturing
National Manufacturing Day is an opportunity to celebrate safety and sustainability initiatives in the chemical manufacturing industry. With new materials, procedures, and processes, companies are well-positioned to deliver a steady supply of chemicals. Emerging developments in AI and technology promise to bring further transformation to the industry, making it safer for the population and the planet.
No matter your chemical manufacturing needs, Ascensus Specialties is here to engineer the best formula for you. Reach out to our team today.