Hazardous chemical release sends 12 workers to the hospital, soap manufacturer fined $161K
An OSHA investigation has determined that AFCO, a manufacturing subsidiary of Zep Inc., failed to protect workers before, during, and after a chemical gas release. The incident occurred in July 2024 when chemicals reacted during processing by AFCO employees. Nitrogen dioxide gas was released, exposing employees to gas levels exceeding the chemical’s ceiling limit. Ultimately, 12 workers were sent to the hospital, with two employees requiring hospitalization.
During its investigation, OSHA determined that AFCO, which manufactures soap and detergent, failed to assess the impact of the release immediately and did not swiftly evacuate workers from the building as a precaution. The agency also found that AFCO had no emergency response plan in place, and that its respiratory protection and hazard communication programs failed to meet federal requirements. The company was cited for four serious violations and faces $161,310 in federal penalties.
What people are saying
In a recent quote, OSHA Area Director Kevin T. Chambers said, “AFCO’s lack of urgency in addressing the hazardous conditions put employees at serious risk. Employers have a legal responsibility to identify workplace hazards and take immediate action to protect their employees from harm.”
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About the Author
Alexis GajewskiAlexis Gajewski
Senior Content Strategist
Alexis Gajewski is a manufacturing writer and editor with nearly 20 years of experience covering the people, practices, and technologies that keep industrial facilities running. For more than a decade, she served as Senior Content Strategist for Plant Services, creating content for plant managers, engineers, and maintenance professionals on a variety of industrial topics.
During her tenure, Alexis worked to develop the brand’s digital strategy and helped launch and produce Great Question: A Manufacturing Podcast. She also created The Lighter Side of Manufacturing, a weekly blog that explored the inventive and sometimes humorous side of the industry.
Alexis co-founded Influential Women in Manufacturing, a recognition program that honored 49 women in its first two years, earned an industry award for Best Product Launch, and received a proclamation from Illinois Governor JB Pritzker and a commendation from U.S. Senator Tammy Duckworth.
She also led newsroom operations and development at a large media company where she set editorial standards, developed training curriculum, and helped support AI adoption for more than 150 editors across 80+ brands spanning manufacturing, industrial processing, automation, and more.
Additionally, Alexis works as a freelance writer and editor, and her areas of interest include continuous improvement, the skilled workforce, and the role of emerging technology on the plant floor.
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