Pharmaceuticals
Pharmaceutical DSEAR risk assessment expertise
We have provided DSEAR risk assessments for pharmaceutical manufacturers, laboratory environments and healthcare product facilities across the UK.
These environments often involve the storage, handling and use of flammable liquids, gases and fine materials within controlled processes. Our work focuses on identifying where hazardous atmospheres may arise, particularly during process changes, and ensuring appropriate controls are in place to support safe and compliant operations.
Medica Packaging
The challengeMedica Packaging Limited specialise in the production of high quality printed cartons and leaflets for clients primarily in the pharmaceutical and healthcare sectors. The site in Cheshire visited incorporated typical print infrastructure and packaging …
Advanced Medical Solutions
The challengeA visit was made to Advanced Medical Solutions in the South West, in August 2015 to consider compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). It was found that routine laboratory …
Advanced Medical Solutions – Winsford
The challengeAdvanced Medical Solutions (AMS) is located at Winsford in Cheshire. The site develops and manufactures a range of wound care and wound closure products, some of which entail the receipt, storage and handling of …
Baxter Healthcare
The challengeA visit was made to Baxter Healthcare Limited site at Thetford, Norfolk, on 1st October 2015 to consider compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). They are the manufacturer of …
Public Health England
The challengeA visit was made to the Public Health England site at Porton Down to consider compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR) around the site’s utility, storage and facilities management …
DSEAR risk assessments for pharmaceutical manufacturing and laboratory environments
Pharmaceutical and healthcare manufacturing environments typically involve tightly controlled processes, but still present DSEAR risks due to the use of flammable substances and the potential for vapour or dust release during normal operations.
Typical risk areas include:
- Laboratory use of flammable solvents and chemicals
- Storage and handling of highly flammable liquids
- Mixing, dispensing and transfer of substances
- Production and packaging processes
- Ventilation and extraction systems
- Maintenance activities and utility areas
- Process changes and new equipment installations
A key consideration in this sector is that hazardous substances are often used in relatively controlled quantities, but may still generate flammable vapours or atmospheres under certain conditions. Vapours from solvents and chemicals can be heavier than air, allowing them to accumulate at low levels or travel to ignition sources if not adequately controlled.
Process change is another important factor. Modifications to production lines, materials or equipment can alter the way hazardous substances are used and introduce new risks that must be properly assessed under DSEAR.
Our DSEAR assessments review how substances are stored, handled and used in practice, including ventilation, containment, ignition source control, maintenance systems and operational procedures. Where required, hazardous area classification is applied and supported with clear zoning drawings and explanations.
The result is a structured, practical report that helps pharmaceutical and healthcare businesses understand their risks, prioritise improvements and maintain compliance with DSEAR.
Frequently asked questions
Yes. Where flammable liquids, gases or combustible materials are used, DSEAR applies and a suitable risk assessment is required.
Yes. Laboratory activities involving flammable solvents or gases can create fire and explosion risks that must be assessed and controlled.
Changes to processes, equipment or materials can introduce new hazards or alter existing risks, so they should always be reviewed to ensure continued compliance.
It includes review of hazardous substances, laboratory and production processes, storage arrangements, ventilation, hazardous area classification and a prioritised action plan.