Our industry Solutions

Process safety solutions for the pharmaceutical industry

Our solutions for hazard assessment and process management play a crucial role in identifying and minimizing the potential risks associated with fire and explosion hazards across the entire operational lifecycle. From the initial stages of development and production through to commercial scale and sale, we actively identify, evaluate, and mitigate hazards. Supported by a diverse team of global engineers and technical experts, we specialize in delivering customized process safety consulting, testing, and training solutions specifically designed for the pharmaceutical industry.

Do these challenges sound familiar?

Accurately identifying chemically stable reagents, intermediates and mixtures

Chemicals, gas, solvents and excipients are prone to unique hazards and hazard reactions that pose serious risks. Testing is required if a material is filtered, crystallized, heated, purified, dried or milled as its chemical properties may change

Correctly implementing and maintaining a top down safety culture

A rigorous top down safety culture that includes the discovery, process chemistry and commercial teams must be implemented and managed to ensure process safety continuity

Quickly identify and mitigate threats while rapidly scaling production operations

You must quickly and cost-effectively identify and mitigate significant hazard risks connected to equipment and materials via a hazard assessment in order to prevent delays during the lab scale-up process

Safely integrate new technology and manufacturing equipment

If additional manufacturing or lab equipment must be purchased and quickly integrated, there must be stringent checks to ensure that they are fit for purpose and correctly classified for any potentially hazardous zones or areas


Sigma-HSE provides actionable process safety solutions to the pharmaceutical industry by eliminating the threat of fire and explosion throughout the entire operational lifecycle. 

Our team of global engineers and technical experts can implement a range of process safety consulting, testing and training solutions across your business. 

Protect your Supply Chain

Ensure that any material change to your process or basis of safety has been correctly managed. Process alterations require specialist risk assessments, material testing and operator training

Maximize Efficiency

Ensure that any material change to your process or basis of safety has been correctly managed. Process alterations require specialist risk assessments, material testing and operator training

Consolidate your safety skill gap

Ensure that every one of your qualified workplace operators understands the critical role that process safety plays in their daily tasks by optimizing your pharmaceutical process development productivity and organizational safety culture

Pivot stress free

From R&D to pipeline development and commercial drug expansion, make use of our insights and unmatched turnaround time to optimize any potential pivots in your processes

Common hazards associated with pharmaceuttical production

Inadequate dust containment and housekeeping at active pharmaceutical ingredients (APIs) handling units such as material charging, blending, granulation, fluid bed drying, vacuum drying, grinding, sieving, milling, compression, coating, dust collection, and micronization could present fire or flashfire hazards

Dust cloud formation during the transfer of active pharmaceutical ingredients (APIs) powder into bins which could present a fire or flashfire hazard in the presence of credible ignition sources such as unrated electrical equipment (electrical fixtures, motors) and electrostatic discharge from ungrounded equipment

Dust cloud formation inside dust collectors and bins which could present a deflagration hazard

Fire hazard inside dryers due to self-heating of material

Request a Quote

Sigma-HSE uses the contact information provided to contact you. You may unsubscribe from our communications via a link at the bottom of our emails at any time. Our privacy policy and our commitment to the protection of your privacy is outlined in our Privacy Statement.
We would like to share details of our work, webinars you can attend, insights, case studies and fact sheets with you. To do this, we need to hold some of your personal information, including your full name, job title, organization name and email address.

Your single process safety solution

Protect your vital assets and ensure supply continuity

Our dedicated global team of engineers, technical experts and specialist coaches provide pragmatic and effective solutions that work in harmony with your pharmaceutical manufacturing operations. 

Ensure continuity by optimizing your development pipelines against the risk of fire and explosions. Our actionable insights and data keep your employees, infrastructure and operational demands safe, allowing you to concentrate on providing your vital commercial services. 

Sigma-HSE’s approach to process safety in the pharmaceutical industry utilizes a range of holistic tools, methodologies, laboratory testing, engineering expertise and vast knowledge of standards and regulations to develop an approach that is unique to your business and the specific challenges you face. 

Are you visiting Sigma-HSE from outside your region? Visit your regional site for more relevant process safety solutions.