Standard Operating Procedure for Secure Storage of Flammable and Explosive Raw Materials

1. Purpose

This Standard Operating Procedure (SOP) outlines the guidelines for the secure storage of flammable and explosive raw materials to ensure safety, prevent accidents, and maintain compliance with Good Manufacturing Practices (GMP) and safety regulations.

2. Scope

This SOP applies to all warehouse, safety, and quality assurance (QA) personnel involved in the handling, storage, and monitoring of flammable and explosive raw materials within the facility.

3. Responsibilities

• Warehouse Personnel: Ensure proper storage and handling of flammable and explosive materials.
• Safety Officer: Conduct safety checks and ensure compliance with fire and explosion prevention protocols.
• Quality Assurance (QA) Team: Verify storage conditions and document compliance.

4. Accountability

The Safety Manager is accountable for ensuring compliance with safety protocols, while the Warehouse Manager is responsible for proper storage. The QA Manager is responsible for periodic audits and documentation.

5. Procedure

5.1 Preparation and Storage Requirements

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Material Identification:

• Identify flammable and explosive materials based on Safety Data Sheets (SDS).
• Ensure materials are labeled correctly, and details are logged in the Flammable Material Identification Log (Annexure-1).

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Storage Area Setup:

• Store materials in explosion-proof, ventilated storage cabinets located in designated flammable storage areas.
• Document storage conditions in the Flammable Material Storage Condition Log (Annexure-2).

5.2 Storage Conditions and Monitoring

1. Temperature and Humidity Control:
   • Maintain storage temperature as per SDS guidelines (typically between 15°C and 25°C) and humidity below 60%.
   • Log readings in the Temperature and Humidity Monitoring Log (Annexure-3).
2. Fire Safety Measures:
   • Install fire suppression systems and ensure fire extinguishers are accessible and inspected regularly.
   • Record fire safety equipment status in the Fire Safety Equipment Inspection Log (Annexure-4).

5.3 Handling and Movement of Flammable Materials

1. Material Handling Procedures:
   • Handle materials using spark-proof tools and anti-static clothing.
   • Document movements in the Flammable Material Movement Log (Annexure-5).
2. Emergency Handling Protocols:
   • Follow emergency protocols in case of spills or fire, and document incidents in the Emergency Incident Log (Annexure-6).

5.4 Training and Compliance

1. Employee Training:
   • Provide regular training on flammable material handling and emergency procedures.
   • Document training sessions in the Flammable Material Handling Training Log (Annexure-7).
2. Inspection and Audit:
   • Conduct monthly inspections and annual audits to ensure compliance with storage protocols.
   • Document findings in the Storage Inspection and Audit Log (Annexure-8).

5.5 Non-Conformance and Corrective Actions

1. Identifying Non-Conformance:
   • Log any non-conformances in the Flammable Material Non-Conformance Log (Annexure-9).
2. Corrective Actions:
   • Implement corrective actions and document them in the non-conformance log, ensuring follow-up for resolution.

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6. Abbreviations

• SOP: Standard Operating Procedure
• GMP: Good Manufacturing Practice
• QA: Quality Assurance
• SDS: Safety Data Sheet

7. Documents

1. Flammable Material Identification Log (Annexure-1)
2. Flammable Material Storage Condition Log (Annexure-2)
3. Temperature and Humidity Monitoring Log (Annexure-3)
4. Fire Safety Equipment Inspection Log (Annexure-4)
5. Flammable Material Movement Log (Annexure-5)
6. Emergency Incident Log (Annexure-6)
7. Flammable Material Handling Training Log (Annexure-7)
8. Storage Inspection and Audit Log (Annexure-8)
9. Flammable Material Non-Conformance Log (Annexure-9)

8. References

• 21 CFR Part 211 – Current Good Manufacturing Practice for Finished Pharmaceuticals
• OSHA Standards for Hazardous Materials
• WHO Guidelines on Good Storage Practices
• NFPA (National Fire Protection Association) Guidelines

9. SOP Version

Version: 2.0

10. Approval Section

	Prepared By	Checked By	Approved By
Signature
Date
Name
Designation
Department

Annexure-1: Flammable Material Identification Log

Date	Material Name	Batch Number	Hazard Classification	Identified By
10/04/2025	Solvent A	Batch 00123	Flammable	Ravi Kumar

Annexure-2: Flammable Material Storage Condition Log

Date	Material Name	Storage Temperature (°C)	Humidity (%)	Inspected By
10/04/2025	Solvent A	20°C	55%	Neha Verma

Annexure-3: Temperature and Humidity Monitoring Log

Date	Area	Temperature (°C)	Humidity (%)	Checked By
10/04/2025	Flammable Storage Room	18°C	50%	Amit Joshi

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Annexure-4: Fire Safety Equipment Inspection Log

Date	Equipment Type	Inspection Status	Inspected By	Remarks
10/04/2025	Fire Extinguisher	Functional	Priya Singh	No Issues

Annexure-5: Flammable Material Movement Log

Date	Material Name	Batch Number	Moved From	Moved To	Moved By
10/04/2025	Solvent A	Batch 00123	Flammable Storage Room	Processing Area	Kiran Patel

Annexure-6: Emergency Incident Log

Date	Incident Description	Response Taken	Handled By	Remarks
10/04/2025	Minor Spill	Contained and Cleaned	Ajay Sharma	No Injury

Annexure-7: Flammable Material Handling Training Log

Date	Employee Name	Training Topic	Trainer	Remarks
10/04/2025	Sanjay Mehta	Flammable Material Handling	QA Manager	Successfully Completed

Annexure-8: Storage Inspection and Audit Log

Date	Inspector Name	Findings	Corrective Actions
10/04/2025	QA Supervisor	Temperature Slightly High	Adjusted Cooling System

Annexure-9: Flammable Material Non-Conformance Log

Date	Non-Conformance Description	Corrective Action	Handled By	Status
10/04/2025	Improper Labeling	Relabeled Correctly	Neha Verma	Closed

Revision History:

Revision Date	Revision No.	Revision Details	Reason for Revision	Approved By
01/01/2024	1.0	Initial Version	New SOP Implementation	QA Head
10/04/2025	2.0	Updated storage monitoring procedures and added emergency response protocols.	Regulatory Update	QA Head