'No further inspection was done after Sigachi's self-compliance report': Safety violations included lack of fire systems, PPE, and emergency exits

Time of India

2 days ago

HYDERABAD: A damning report just months ahead of the deadly explosion at Sigachi Industries exposed several glaring safety lapses at the factory.
Among the key findings of the Dec 2024 inspection report were the absence of an inert gas suppression system in panel boards, battery rooms, and UPS setups.
The factory also failed to install automatic fire extinguishing appliances and fire-resistant dampers, which should have been interlocked with heat or smoke detectors.
Deficiencies in emergency preparedness, such as insufficient fire exits from machinery halls, inadequate firefighting equipment, untrained workers, and a complete lack of personal protective gear such as safety belts, shoes, gloves or goggles, were also identified.
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Loosely laid electrical wiring, with no rubber mats or insulating stands at panels, posed a direct danger to the workforce.
Self-Compliance,
Without Follow-Up
Deputy chief inspector of factories, Sangareddy, K Gowri Shankar told TOI that the inspection, which usually occurs in Dec every year, was carried out by Nehru under the practice of cross-district assignments. "The inspection identified violations, but no show-cause notice was issued," he said, adding, "in such cases, companies submit a self-compliance report online, and no further inspection is done."
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Regarding the blast, Gowri Shankar said the probe was on.
Another official of the department said that "dirt stuck in a spray dryer might have ignited, leading to a dust explosion, and other multiple aspects, like overheating and faulty electric lines, are being looked into." Importantly, Sigachi Industries did not submit its annual return at the time of inspection - a statutory requirement under the Factories Act.
However, Sigachi claimed: "The self compliance report of revised good manufacturing practices (GMP) schedule M was filed as per CDSCO." "There was no overcrowding of equipment and adequate space was provided to facilitate our material flow and ergonomic working conditions," Sigachi said.
Combustible dust,
risks ignored
K Babu Rao, former chief scientist at Indian Institute of Chemical Technology (IICT), reviewed the inspection report and raised concerns over the culture of compliance followed by factory inspections.
"The inspections are based on a compliance-box-checking culture, not a risk-sensitive, enforcement-oriented regulatory regime," he said.
Babu Rao pointed to systemic failures, including the absence of fire exits, PPE, safety training, and unsafe wiring, as well as the omission of combustible dust hazards, despite MCC powder being a highly flammable material. "This isn't a loophole. This is regulatory neglect," he said.
He also noted the absence of any recorded follow-up action. "A facility handling flammable powder cannot be deemed compliant when it lacks basic firefighting measures and protective gear," he added.