OSHA cites detergent maker for safety failures in hazardous chemical release

A soap and detergent manufacturer faces $161,310 in penalties after an Occupational Safety and Health Administration investigation of a chemical gas release in Chambersburg, Pennsylvania, that sent a dozen workers to a hospital in July 2024, the agency announced Tuesday.

OSHA initiated an inspection of AFCO, the facility’s Atlanta-based operator that is owned by Zep Inc., after being notified of an incident involving a release of nitrogen dioxide gas. The release occurred when chemicals reacted during processing by AFCO employees. AFCO specializes in producing and distributing maintenance, cleaning and sanitation solutions.

OSHA inspectors determined the company had taken no action to assess the impact of the release immediately and did not swiftly evacuate workers from the building as a precaution. Inspectors discovered that workers were exposed to nitrogen dioxide gas levels exceeding the chemical’s ceiling limit, resulting in 12 employees being evaluated at a local hospital, with two of them requiring hospitalization.

Additionally, inspectors determined that the company had no emergency response plan in place, and that its respiratory protection and hazard communication programs failed to meet federal requirements. OSHA cited AFCO for one “repeat” violation, and nine “serious” and two “other-than-serious” violations. The company has 15 days to contest.