Securing confined spaces in a chemical-pharmaceutical company
Products:
Genesi SCTY – Genesi SC6NW
Cosma is a company of the CFM Group. In addition to supporting major global players in the pharmaceutical sector, Cosma has also established itself in the animal health industry, with a production capacity of more than 130,000 liters and an annual output of over 300 tonnes of active pharmaceutical ingredients (APIs). Today, it represents the group’s largest production site.
Within such a complex and production-intensive environment, ensuring the safety of internal and external operators working in confined spaces is a high priority.
One of the most critical situations concerned stainless steel reactors used for mixing cosmetic products, which were characterised by high risks for maintenance and inspection.
The challenges of chemical reactors
During the inspection, Genesi technical team identified several issues:
- Confined spaces: the inside of reactors is classified as a confined space, with all the associated risks (lack of oxygen, difficulty of access and evacuation, etc.).
- Reactors in series: critical issues occurred in 18 plants, which required a replicable and standardised solution.
- Limited operating space and interference: the area around the silos did not allow the use of bulky equipment and fixed arrangements.
In an environment characterised by high technological density and tight production rhythms, a safe, ergonomic, compact, easy and quick-to-install solution was essential; one that could adapt seamlessly to the plant’s structural features.
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Chemical reactor safety intervention plan
Given the complexity of the context, Genesi Protection intervention consisted of four phases:
1. Site inspection, survey, risk analysis and assessment of client needs
2. Design of technical solutions and on-site testing
Access to the reactors is provided through a manhole just above the almond plate floor, fixed on steel beams. Genesi leveraged this structure to install threaded floor inserts, enabling a safe and reversible anchoring system.
3. Supply and installation of Genesi Protection safety systems
The solutions implemented were as follows:
- Genesis SCTY in T configuration: a solution that provides stability and flexibility. The rear crossbar of the system has been fixed directly to the threaded inserts, eliminating the need for non-invasive external structures.
- Genesi SC6NW in anodised aluminium: light and quick to install on the Genesis SCTY base. Supports up to 2 retractable devices with crank handles, for fall arrest during access/egress and controlled rescue in case of emergency.
4. On-site training with Genesi Academy trainers
The benefits of chemical reactor intervention
The intervention generated positive and immediate impacts:
- Reduced risk of falls inside reactors.
- Complete securing of confined spaces, with rapid rescue capability in case of emergency.
- Standardised systems across all plants, simplifying training and operational procedures.
Today, the staff of Cosma and the contracting companies can operate with greater safety and autonomy, thanks to unified procedures that reduce the margin of error and increase efficiency.
Are you an RSPP or ASPP in a pharmaceutical or chemical company?
Your safety is our priority. Rely on Genesi Protection to protect your team, without compromising productivity.
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