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SUSTAINABLE SOLUTIONS FOR CHEMICAL HANDLING AND WORKER SAFETY
**A Case Study in Cleaning Chemical Manufacturing: Ridgway Industries of Pennsylvania**
Ridgway Industries, based in Pennsylvania, is a leading manufacturer of both industrial and household cleaning products. Their product range 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 chemicals, but their process was far from efficient or safe.
Until recently, the manufacturing process involved workers manually tipping and tapping heavy 55-gallon drums of chemicals. They would then dispense the contents through leaky spigots into open transfer containers, often requiring additional handling to move the fluids to the point of use. This gravity-fed system required threading a brass fixture into the small bung on top of the drum, attaching a vent to the larger bung, and positioning the drum horizontally on a roll-down fixture for dispensing.
This method came with numerous challenges. The spigots were prone to clogging, making them hard to remove and increasing labor demands. Controlling the flow rate was difficult, and leaks were common, leading to inventory loss and environmental concerns. Plus, not all the fluid could be removed from the drums, meaning extra work was needed to make them RCRA-compliant.
As Brad Dagy, owner of Ridgway Industries, puts it, “A chemical disaster was always just one slip of the hand away.†He knew that the risks weren’t just about safety—they also impacted the environment and the company’s bottom line. A few close calls pushed him to find a better solution.
Drawing from the EPA’s Process Hazard Analysis guidelines, Dagy and his safety manager conducted a thorough review of their equipment and processes. They identified key areas for improvement, with the main solution being a chemically compatible and environmentally compliant transfer pump system. This system used a single shop air-line set at 4 psi to power multiple pumps, allowing for efficient and safe chemical transfer.
With the new system, Ridgway was able to directly transfer fluids from individual upright drums to the point of use, using a spring-activated nozzle for accurate dispensing. The system operated at 4 gallons per minute, significantly improving efficiency and eliminating the need for dangerous manual handling. Workers no longer had to tip, carry, or spill chemicals, reducing the risk of accidents and exposure.
An unexpected benefit was the system’s ability to completely empty drums to RCRA-compliant standards, minimizing waste and disposal costs. With proper maintenance, the pumps lasted up to 10 years, further enhancing cost-effectiveness and sustainability.
Since implementing this system in 2006, Ridgway has operated without incident, proving that safer, more efficient chemical handling can go hand-in-hand with environmental responsibility and business success. The company has made significant strides in worker safety, pollution prevention, and VOC reduction, all while boosting productivity and reducing operational costs.