FSAI Urges Telangana Pharma Units to Adopt Predictive Safety Systems

Pharmaceutical manufacturing companies in Hyderabad and across Telangana must move beyond basic regulatory compliance and implement predictive safety systems to prevent industrial fires and explosions, Fire and Security Association of India (FSAI) Hyderabad chapter president Manoj Wahi said.

Speaking at the FESA conference in Hyderabad, Wahi emphasised that fire safety within pharmaceutical plants cannot be viewed in isolation. He noted that fire hazards are closely tied to electrical safety, security, automation, and overall industrial processes. FSAI launched its integrated initiative to address these overlapping safety risks across industrial sectors under a combined framework of fire safety, electrical safety, security, and automation.

Wahi referenced an industrial incident at Pashamylaram last year, stating that it underlined the severe hazards associated with increasingly complex pharmaceutical manufacturing operations, especially the risks posed by combustible dust. He explained that the incident demonstrated why companies need to invest in technologies and systems designed to proactively prevent fires rather than simply reacting after an emergency occurs.

According to Wahi, the industry requires a predictive model rather than a mere compliance model, urging companies to look beyond standard regulatory frameworks. He pointed out that human error and poor maintenance remain among the most critical safety vulnerabilities in pharmaceutical facilities. While safety mechanisms often exist on paper, their real-world efficacy depends on regular maintenance, operational readiness, timely activation, and comprehensive employee awareness.

Highlighting the importance of vigilance, Wahi stated that last-mile human error presents a major challenge, noting that workers must remain consistently alert to potential workplace hazards rather than responding only when a crisis unfolds. He recommended that pharmaceutical units take immediate steps to evaluate the health and functional readiness of all existing safety equipment and systems.

Telangana fire services director G.V. Narayana Rao also addressed the gathering, calling for a zero-accident approach across the State’s pharmaceutical sector. Rao stressed the necessity of rigorous process-safety audits, thorough hazard assessments, and the deployment of advanced fire detection systems. The FESA conference brought together industrial leaders, safety professionals, and technology providers to examine fire, electrical, process, security, and automation risks.