Overcoming the challenges of fire safety in the pharmaceutical industry

Offices, facilities for clinical trials and other research and development, plus scientific and medical archives, might not pose a huge fire risk on their own. However, they are typically located on the same site as production and storage areas containing large quantities of combustible products, making them vulnerable. Medical journals and office paperwork are classic kindling items, and dust poses further risks of a fire spreading.

Solutions:
AVENAR panels and “all-in-one” 4000 signalling devices that can be combined with the AVENAR fire detectors from Bosch provide reliable fire detection with both visual and audible alert signalling. Up to 125 devices can be installed in one loop and they are easy to fit and maintain. AVENAR systems are backwards compatible to ensure full coverage between any legacy and new systems. Rapid, reliable heat and smoke detection provides dual protection for administrative spaces.

The chemical cocktail of combustible powdered substances and flammable liquids, plus electrical devices, amounts to massive fire risks on formulation facilities. Machinery and personnel working to produce end pharmaceutical products can exacerbate hazards with movement, which stirs up dust and generates static and heat.

Solutions:
Bosch AVENAR 4000 fire detectors are quick to respond to any such risks. They are superior to many other fire detection units

AVENAR 4000 detectors comprise dual-ray LED technology. This facilitates detection by visibly indicating the difference between disturbance values, such as a red light to indicate the presence of smoke or a blue light to indicate the presence of steam. Also, their chamber maid plug and dust-repellent labyrinth-and-cap construction makes them easy to clean and maintain.

Many pharmaceutical plants experience frequent false alarms. One key reason for this is electromagnetic disturbance values which hinder operations – and therefore the productivity and overall performance of the plant.

Solutions:
The unique eSmog feature of the AVENAR 4000 detectors enhances stability and detection performance by constantly measuring the electromagnetic exposure of each detector and calculating mid- and long-term averages. These are used to predict the exceeding of threshold values even before possible false alarms can occur. Operators can see the current EMC values and averages on the user interface of the fire panel and hence avoid false alarms. Moreover, the eSmog feature supplies the installer with information about critical environmental disturbances at the installation site, allowing maintenance staff to change the location of the source of disturbance quickly.

R&D and quality control of pharmaceutical products involving valuable, high-cost equipment must adhere to strict GMP regulations for hygiene and cleanliness. Dust and dirt must not accumulate in any pharmaceutical clean rooms (for instance, where ampoules and bottles are opened or filled) and research areas so as not to contaminate any substances to be trialed or distributed as approved products. These areas, however, also require reliable protection from fire.

Solutions:
The series of discreet “invisible fire detectors” by Bosch are ultra-slim with smooth surfaces. This makes them easy to clean and their slender design means they avoid gathering an excess of dust. They are thus perfect for environments like labs, clean rooms and quality-control areas. Clean rooms with high ceilings can be covered by AVIOTEC video-based flame and smoke detection. Smart AI algorithms instantly recognize real signs of fire at any level, such as the rise of smoldering vapor, or sparks – and this triggers an alert within seconds.

Large demand from health service customers like hospitals and pharmacies drive the need for the pharma industry to produce stockpiles of many medicinal drugs. Smart, complex manufacturing facilities can produce vast quantities of products daily – but this means any surplus, or stocks waiting to be distributed, must be stored in huge warehouses. A mix of different products, each with differing levels of fire risk and volatility, are placed on shelves from the ground upwards. Regular smoke alarms fitted to ceilings would take too long to respond to smoldering or ignition.

Solutions:
Bosch has a range of aspirating smoke detectors in its portfolio. The solutions include special applications, like spaces with high ceilings, and they monitor the air flow, precisely detecting any obstructions, for instance, due to fumes or smoke. They connect to the local security network directly, making them highly reliable. Beam detectors are also a great solution for spacious areas as they offer extended monitoring fields where point-type detectors are not so effective. Alternatively, AVIOTEC video-based fire detection functions perfectly in such areas. It detects flames and smoke – including light sparks and smoldering – within seconds, at any shelving level. The low rate of false alarms ensures business continuity in the storage and distribution areas in pharmaceutical production.

Packaged prescription and over-the-counter drugs are often stacked under semi-covered outdoor constructions adjacent to main production buildings. This makes them vulnerable to arson, vandalism, theft – as well as strong sunlight by day and any motion of high winds – all in a wide, sprawling area which is difficult to monitor efficiently around the clock.

Solutions:
Smart algorithms, coupled with Bosch fire panels in AVIOTEC video-based solutions, pick up any glow of real fire or source of smoldering even in low-light conditions outside and at night, thanks to infrared lighting. The video camera can be integrated with existing surveillance cameras, meaning it provides a highly reliable fire safety and security solution.

Some processing and storage areas on pharmaceutical production plants are particularly at risk of explosions occurring during normal operations, or for short periods. This is due to the presence of dust, gases, mists or vapors. These areas are thus classified as hazardous zones 0, 1, 2, 21 or 22. If an explosion occurs, however, classic smoke alarms or fire alarm panels could shatter on impact. The risk here is that no alert would be raised for emergency services to respond to, and a resulting fire from the explosion could tear through valuable pharmaceutical assets and premises. If any staff are on site, they too would be at risk, from fire, smoke and any harmful gases released.

Solutions:
ATEX and IECEx-certified flame detectors by Bosch are explosion proof and remain intact if combustion occurs in zones 0, 1, 2, 21 and 22. They are also highly resistance to contamination and humidity. These devices function effectively in the presence of smokeless liquids and gases or any flames not visible to the naked eye. Additional safety measures can be taken on such sites with manual call points by Bosch Building Technologies which function efficiently even in challenging industrial environments.

Some areas of pharmaceutical manufacturing may require detectors which have been developed for specific scenarios, including the presence of hazardous gases or chemical dusts which can ignite or combust.

Solutions:
Specialized gas detectors or intrinsically safe detectors can easily be integrated into Bosch fire detection systems. Therefore, besides detection of fire and smoke, oxygen and process gases as well as other hazardous gases can also be detected rapidly. This helps keep workers safe and protects premises and other valuable business assets.