A soap and detergent manufacturer in Chambersburg, Pennsylvania, faces $161,310 in federal penalties after an Occupational Safety and Health Administration (OSHA) investigation into chemical gas releases in July 2024 sent a dozen workers to the hospital.
OSHA opened an inspection on July 11 after being notified by the Pennsylvania Emergency Management Agency and AFCO, the plant's operator, of a nitrogen dioxide gas release incident. The release occurred when chemicals reacted during processing by AFCO employees. AFCO, a manufacturing subsidiary of Zep, is based in Atlanta and specializes in maintenance, cleaning and plumbing solutions.
OSHA inspectors found that the company did not immediately assess the impact of the release and did not quickly evacuate workers from the building as a precaution. Inspectors said they found workers were exposed to nitrogen dioxide gas levels above the chemical's limit, leading to 12 employees being examined at a local hospital, with two of them requiring hospitalization.
Additionally, inspectors found that the company had no emergency response plan and that its respiratory protection and hazard communication programs did not meet federal requirements. OSHA cited AFCO for one repeat violation, nine serious violations and two non-serious violations.
The company has 15 business days to comply, request an informal conference with OSHA's area director, or appeal the findings before OSHA's review board.
“AFCO’s lack of urgency in addressing the hazardous conditions puts employees at serious risk,” said Kevin T. Chambers, OSHA area manager in Harrisburg, Pennsylvania. “Employers have a legal obligation to recognize hazards in the workplace and take immediate action to protect their employees from harm.”
Since 2022, OSHA has cited Zep for four failures to protect employees from hazardous chemicals at its Emerson, Georgia, plant.
Founded in 1937, Zep serves industrial, institutional, retail, and food and beverage customers on six continents.
Source: OSHA
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