Why safety in laboratory operations?

A pharmaceutical laboratory is an integral part of a pharma organization to check and assure quality in the production life cycle. It provides facilities to test raw materials, products at various production stages, and final finished products for distribution to the market. 

The test process in a pharma laboratory uses various chemicals, instruments, and tools for conducting tests on various samples. The test process, various tools, and their associated components can become hazardous if improper and safely handled. It can damage buildings and tools and can even cause human casualties.

Safety is critical for safe routine laboratory operations. Safety in the laboratory ensures that 

• All the processes are carried out according to acceptable procedures.

• Personnel performing laboratory operations are trained and are capable of managing any hazardous situation.

The laboratory has adequate resources, systems, and procedures to deal with accidents.

What are the common hazards in pharmaceutical laboratory?

Depending on the production process in a pharma organization, there can be many hazards in a pharma laboratory. Classification and determination of hazards in the laboratory are necessary for developing an effective safety system. Otherwise, it could lead to unnecessary and ineffective safety systems.

Hazards are classified according to Hazardous Substance Ordinance, which classifies hazards in pharmaceutical laboratories into

• Physical Hazards

• Health Hazards

• Environmental Hazards

Let’s briefly discuss each of these

Physical Hazards

Physical hazards are activities and items that pose a danger to a person's physical safety. This hazard is common in every industry, including pharma laboratory operations, and in some cases, it is unavoidable.

A hazard is classified as physical if it contains the following properties.

• Explosive substances

• Flammable

• Oxidising agents

• Inflammable

• Highly Inflammable

• Highly toxic

• Toxic

Health Hazards

Hazards that harm our long-term and short-term health are classified as Health Hazards. They affect the human body when touched, inhaled, or ingested. If these hazards are not treated promptly and appropriately, they can seriously affect the human body, resulting in adverse consequences and even becoming fatal.  

Health hazards include one or all of the following properties.

• Harmful to health

• Corrosive

• Irritant

• Sensitizing

• Carcinogenic

• Toxic to reproduction

• Mutagenic

Environmental Hazards

Environmental hazards are activities or events that affect the environmental characteristics badly, which in turn have bad consequences on human health and other living beings. These hazards drifts appropriate environmental parameters out of standard value.

For example, a hazards can increase or decrease the concentration of certain chemicals or substance from standard values, which in turn can become hazardous for personnel and pharma process being carried out.

How to implement safety in pharma lab

Safety in the pharma lab is implemented through various means. It requires responsible human behavior, adequate tools, and updated procedures—these efforts when combined, result in safety in all processes of a pharma lab.

Let’s discuss some ways to implement safety in pharmaceutical laboratories.

Safety from the beginning

Always ensure safety from the beginning of the process, test, or any procedure in a laboratory environment. Follow safety instructions, use adequate resources, and apply safety procedures from the start of your activity. It helps to complete the desired activity successfully without any hazards to personnel and the environment.

If safety is not applied from the beginning, it will become difficult to implement in between the process or at the end because a testing process cannot be stopped in the middle to apply safety. Otherwise, the test will have to repeat.

No drinks and food in the lab

Drinks and Food are prohibited in the laboratory environment in any form and for any purpose. Personnel must not eat or drink in the laboratory, nor can they store these items on any shelf or cabinet. Additionally, refrigerators are not allowed to store any eatables, especially those previously used to store any chemicals in them.

If Food and drink enter the laboratory area, it can be a major source of contamination for chemicals stored in these areas. Chemicals can also be exposed to food items if stored near chemicals, and food items can become hazardous for personnel consumption. So to prevent contamination of chemicals and preventing inhalation by humans, keep all sorts of foods and drinks outside of the laboratory.

Use PPE when handling chemicals and routine testing

Personal Protective Equipment – PPE is specially designed body wearables that protect personnel from various hazards, such as chemical, radiological, physical, electrical, and mechanical. Example of PPE includes glasses, helmet, and safety shoes.

PPEs must be used during the entire testing process and procedures. It must also be worn during the entire time spent in the laboratory. PPE must be maintained and kept in working condition for use in any emergency. The laboratory supervisor is responsible for maintaining the PPE in working condition. They must contact the relevant department if PPE needs maintenance or replacement.

Many types PPEs are designed for a specific hazard and activity> it must be selected accordingly, depending upon the hazard. Some questions to ask before selecting a PPE can be as follows.

• What is the nature of hazard and for what task or process, personnel are involved?

• Are there any chemicals being used? If yes, what are its concentration and quantity?

• What is the state of chemicals i.e. liquid, gaseous or solid? It determines to analyze the possibilities of chemical to affect a human body

• Is the material of PPE faces degradation? If yes, for how much time it is safe to use such PPE.

Store chemicals and Hazardous substances with proper storage

Use proper storage for storing chemicals in the pharma laboratory. Otherwise, chemicals will react with other chemicals, and personnel can be easily exposed to them.

Some properties of a good chemical storage include the following

• Storage containers must be labeled with the details of hazardous chemical and warning.

• Use a single storage container for one type and must be kept away from different chemicals.

• Flammable chemicals must be stored in approved and dedicated cabinet, capable of controlling fire in chemical, if occurred.

• Do not overcrowd a cabinet or storage, and must not be stored no higher than the eye level.

• Avoid floors for storing

• Liquid chemicals must be stored in un-breakable glass or container

• Volatile or strong odor chemicals must be stored in ventilated area

• Check for any unusual condition such as leaks, spillage, too hot or too cold area etc. etc.

Ensure proper ventilation in lab, by the use of appropriate HVAC system

Pharma laboratory must be properly ventilated to ensure adequate airflow in a lab. Additionally, the performance of ventilation components and systems must be properly maintained and checked for effective working.

Ventilation is achieved by ensuring proper airflow inside a laboratory so that polluted and contaminated flows out of the lab. The filter must be employed at the air inlet section to remove any external particles and contaminants from entering the lab area. Filters must also be used at air outlets to prevent any traces of chemicals and hazardous substances going outside the lab area. Doors must be closed at all times, as they can allow untreated air to enter the laboratory.

Dispose waste accordance with local and legal requirements. Chemical manufacturers also provide disposal guidelines

Dispose of waste according to the local and legal requirements as it will help a pharma laboratory protect itself from legal actions such as fines and shutting down operations. It will also help to create waste disposal procedures and policies.

Waste disposal activities are proper processes that include many sub-processes, such as collection, transport, and disposal.

Materials for which waste disposal activities are employed include the following

• Chemical waste

• Toxic items

• Used oil

• Biological

• Radioactive waste

• Sharps and broken glasses

An important strategy to deal with waste is to minimize waste. It involves practices where material can be used up to its maximum capacity to minimize waste. Some ways waste minimization can be implemented are as follows

• Limiting the amount of order by reviewing stocks and inventory levels

• Avoid duplication and excess material for keeping it in inventory levels.

• Make sure to use chemicals and other items before their expiry date to prevent discard.

Ensure presence of fire extinguishers at proper places

As the name suggests and is commonly known, fire extinguishers extinguish fire erupting in an enclosed area. The major advantage of using a fire extinguisher is that it is a handy tool that can easily carry.

Different types of fire extinguishers are available, each capable of extinguishing specific fires. For example, fire is caused by chemical and flammable substances. Personnel working in the area must be trained to use fire extinguishers and know the type of fire extinguisher for a particular fire.

Eyewash should be easily accessible

Eyewash stations are dedicated laboratory sections capable of washing eyes without making too much effort. These can be of varying designs but commonly contain a shower pointing toward a human eye and bursting water. Its pressure and drop-like design help to remove any chemicals, particles, and other contaminants.

Eyewash stations must be adequately installed and reachable, and its path must not be blocked. Like another safety system, -personnel working in the area must be trained to operate and know its location.

About the Author

Muhammad Asim Niazi has a vast experience of about 11 years in a Pharmaceutical company. During his tenure he worked in their different departments and had been part of many initiatives within the company. He now uses his experience and skill to write interested content for audiences at PharmaSources.com.