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SUSTAINABLE SOLUTIONS FOR CHEMICAL HANDLING AND WORKER SAFETY
**A Cleaning Chemical Manufacturing Case Study:**
Ridgway Industries, based in Pennsylvania, is a leading manufacturer of both industrial and household cleaning products. Their wide range of offerings includes everything from dishwashing detergents to floor strippers and power washing solutions—all of which are chemical-based. The company has long relied on traditional methods for handling these materials, but as their operations grew, so did the risks associated with manual processes.
Previously, workers had to manually tip and tap heavy 55-gallon drums of chemicals, often using leaky spigots to transfer the contents into open containers. This process involved threading brass fixtures into small bungs on the drum tops, attaching vents, and placing the drum on a roll-down fixture before tilting it horizontally for dispensing. While this method worked, it came with several challenges that affected both safety and efficiency.
One major issue was the tendency for spigots to clog, making them hard to remove and requiring significant effort to extract the remaining liquid. Controlling the flow rate was also difficult, and leaks were common, leading to inventory loss and environmental concerns. Additionally, the system didn’t allow for complete drainage of the drums, which meant extra labor was needed to ensure compliance with RCRA (Resource Conservation and Recovery Act) standards.
Brad Dagy, owner of Ridgway Industries, described the situation as “a chemical disaster waiting to happen.†He knew that even a small mistake could lead to serious consequences—both for his employees and the environment. With several close calls, he decided it was time to find a safer, more efficient way to handle chemicals.
Drawing on information from the EPA’s Process Hazard Analysis guidelines, Dagy and his safety manager conducted a thorough review of the facility’s equipment and processes. They identified key areas for improvement, particularly in the chemical transfer system. Their solution came in the form of a chemically compatible and environmentally compliant pump system.
The new system used a single shop air-line at 4 psi to power multiple pumps, allowing for safe and accurate transfer of fluids directly from the drum to the point of use. Each pump featured a spring-activated nozzle, enabling controlled dispensing at a rate of 4 gallons per minute. This not only improved efficiency but also eliminated the need for dangerous manual tipping and handling of open containers.
Another unexpected benefit was the ability of the pumps to empty drums completely, meeting RCRA compliance standards without additional effort. With proper maintenance, the pumps lasted up to 10 years, reducing waste and long-term costs.
Since implementing the new system in 2006, Ridgway has operated safely and efficiently, with no incidents reported. The company has made significant progress in sustainability by enhancing worker safety, improving chemical handling, reducing pollution, and lowering VOC emissions. These changes have also contributed positively to the company’s bottom line, proving that safety and efficiency can go hand in hand.