to all staff and contractors working in the warehouse, raw material storage, solvent storage, and production areas where chemicals are received, handled, or processed. It includes actions for minor, moderate, and major spills involving powders, liquids, or hazardous materials.

3. Responsibilities

• Warehouse & Production Staff: Immediately report and contain the spill using spill kits.
• Shift Supervisor: Coordinate spill response and notify the EHS team.
• EHS Officer: Assess spill severity, initiate cleanup, and record the incident.
• QA Representative: Evaluate product impact and ensure compliance with GMP documentation.

4. Accountability

The EHS Manager is accountable for ensuring proper availability of spill kits, training, cleanup materials, and timely closure of incident reports and CAPAs related to chemical spills.

5. Procedure

5.1 Classification of Spills

1. Minor Spill: Less than 100 ml or 100 grams; non-hazardous material, easily contained.
2. Moderate Spill: Up to 5 liters/kilograms of flammable or irritant substances.
3. Major Spill: More than 5 liters/kilograms, or spills involving corrosive, toxic, or reactive chemicals.

5.2 Initial Response

1. Alert personnel in the area and restrict access.
2. Evacuate affected area if the material is hazardous or releasing vapors.
3. Use signage or barricades to secure the zone (refer Annexure-1).

5.3 Personal Protective Equipment (PPE)

1. All responders must wear:
   • Chemical-resistant gloves
   • Goggles and face shields
   • Splash-proof apron or chemical suit
   • Respirator (if volatile fumes or powders are involved)
2. All PPE shall be available in the designated Spill Response Cabinet.

5.4 Spill Containment and Neutralization

1. Use absorbent pads or spill pillows around the edges to prevent spread.
2. For liquid spills, use inert absorbents like vermiculite or spill powder to soak material.
3. For acidic/alkaline materials, neutralize using approved neutralizing agents as per SDS.
4. For solid spills, gently sweep using a HEPA-filtered vacuum or wet mop depending on dustiness.

5.5 Collection and Disposal

1. Transfer the collected waste into leak-proof, labeled containers (see Annexure-2 for labels).
2. Place filled bags into the designated chemical waste bin in the hazardous storage area.
3. Disposal to be performed via ETP or authorized vendor as per the Waste Disposal SOP.

5.6 Incident Documentation

1. Record the event in the Chemical Spill Incident Log (Annexure-3).
2. Prepare a Chemical Spill Investigation Form (Annexure-4) and submit to QA and EHS.
3. Attach photos (if available), time of incident, response time, and cleanup completion time.

5.7 Preventive Actions

1. Root Cause Analysis (RCA) must be conducted by EHS for major and repeated spills.
2. Implement CAPA, such as container reinforcement, procedure revision, or training refreshers.
3. CAPA to be tracked in the Spill CAPA Tracker (Annexure-5).

5.8 Training and Awareness

1. Conduct quarterly spill response training drills for warehouse and production teams.
2. All new joiners must undergo spill management training as part of EHS induction.
3. Training records shall be maintained by HR and reviewed by EHS annually.

6. Abbreviations

• SOP: Standard Operating Procedure
• EHS: Environment, Health & Safety
• PPE: Personal Protective Equipment
• SDS: Safety Data Sheet
• CAPA: Corrective and Preventive Action

7. Documents

1. Spill Area Signage Template – Annexure-1
2. Chemical Waste Label Format – Annexure-2
3. Chemical Spill Incident Log – Annexure-3
4. Chemical Spill Investigation Form – Annexure-4
5. Spill CAPA Tracker – Annexure-5

8. References

• OSHA Hazard Communication Standard 29 CFR 1910.1200
• WHO GMP Guidelines for Environmental Safety
• Company SDS Library
• Pollution Control Board Guidelines for Hazardous Waste Management

9. SOP Version

Version: 2.0

10. Approval Section

	Prepared By	Checked By	Approved By
Signature
Date
Name
Designation
Department

11. Annexures

Annexure-1: Spill Area Signage Template

Text: “CAUTION – CHEMICAL SPILL AREA – ENTRY RESTRICTED”
Color: Yellow background with black font
Size: A3

Annexure-2: Chemical Waste Label Format

Label Field	Example
Contents	Acetone Spill Cleanup Waste
Date	13/04/2025
Hazard Class	Flammable
Disposed By	Sunita Reddy

Annexure-3: Chemical Spill Incident Log

Date	Location	Material	Quantity	Severity	Cleaned By
12/04/2025	Solvent Store	Methanol	3 L	Moderate	Rajesh Kumar

Annexure-4: Chemical Spill Investigation Form

Spill ID	Description	Root Cause	Preventive Action
SP-025	Container dropped during transfer	Slippery floor	Install non-slip matting

Annexure-5: Spill CAPA Tracker

CAPA No.	Action	Owner	Status	Closure Date
CAPA-SP-008	Retrain handlers on spill SOP	EHS Team	Closed	13/04/2025

Revision History:

Revision Date	Revision No.	Details	Reason	Approved By
01/01/2022	1.0	Initial Issue	New SOP	QA Head
14/04/2025	2.0	Added spill classification, signage, and annexures	Audit Recommendation	QA Head