A soap and detergent manufacturer in Chambersburg, Pennsylvania, is facing $161,310 in federal penalties following an investigation by the U.S. Department of Labor into a chemical gas release incident. The incident, which occurred in July 2024, resulted in a dozen workers being hospitalized.
The Occupational Safety and Health Administration (OSHA) began its inspection on July 11 after receiving notifications from the Pennsylvania Emergency Management Agency and AFCO, the facility's operator. The incident involved a release of nitrogen dioxide gas during processing by AFCO employees. AFCO is a manufacturing subsidiary of Zep Inc., based in Atlanta, specializing in maintenance, cleaning, and sanitation solutions.
OSHA inspectors found that the company did not assess the impact of the release immediately nor evacuated workers promptly as a precautionary measure. Workers were exposed to nitrogen dioxide gas levels above the permissible ceiling limit, leading to 12 employees being evaluated at a local hospital; two required hospitalization.
Further inspections revealed that AFCO lacked an emergency response plan and had inadequate respiratory protection and hazard communication programs that did not meet federal standards. As a result, OSHA cited AFCO for one repeat violation and nine serious violations along with two other-than-serious violations.
"AFCO’s lack of urgency in addressing the hazardous conditions put employees at serious risk," stated OSHA Area Director Kevin T. Chambers from Harrisburg, Pennsylvania. "Employers have a legal responsibility to identify workplace hazards and take immediate action to protect their employees from harm."
Since 2022, OSHA has cited Zep for four serious violations related to protecting employees from hazardous chemicals at its Emerson, Georgia facility.
Zep Inc., founded in 1937, serves customers across industrial, institutional, retail sectors as well as food and beverage industries on six continents.
The company has 15 business days from receipt of its citations and penalties to comply with them or contest the findings before the independent Occupational Safety and Health Review Commission or request an informal conference with OSHA’s area director.
For more information on developing workplace safety programs or compliance assistance resources offered by OSHA, employers are encouraged to visit OSHA's website.
