📢 Maharashtra Factories (1st Amendment) Rules, 2025: Reactor Safety Regulations Notified

On May 14, 2025, the Government of Maharashtra officially notified the Maharashtra Factories (1st Amendment) Rules, 2025, introducing comprehensive safety guidelines for reactors used in exothermic chemical reactions. These amendments are issued by the Industries, Energy, Labour, and Mining Department and modify the Maharashtra Factories Rules, 1963, under the Factories Act, 1948.

This critical amendment aims to mitigate the serious hazards associated with chemical manufacturing processes, especially those involving exothermic reactions, by enforcing predictive, preventive, and protective safety protocols.

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🔍 What’s New Under Rule 73-ZC?

The amendment introduces Rule 73-ZC, which outlines mandatory safety practices for all reactors used in exothermic chemical reactions across factories in Maharashtra.

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✅ Applicability

This rule applies to all factories in Maharashtra that operate reactors for exothermic chemical processes — covering both batch and continuous systems.

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🔬 Predictive Safety Measures

Before beginning any process, factories must conduct thorough scientific assessments:

• Compatibility testing of reactants and reactor construction materials

• Heat of reaction, decomposition energy, and adiabatic temperature rise evaluations

• Runaway reaction predictions and cooling system adequacy checks

• Failure risk analysis of agitators, pumps, and other key components

• Control protocols for reactant feeding sequence and speed

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🛠️ Preventive Safety Protocols

To reduce the likelihood of accidents, factories are required to implement:

• Engineering and administrative controls (preferably over reliance on PPE)

• Use of alternative reactor designs like semi-batch or flow reactors

• Mandatory certification from manufacturers on pressure/temperature handling

• Proper documentation for Management of Change (MoC) with approval logs

• Regular HAZOP studies and implementation of all recommendations

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🛡 Protective Controls Mandated

For emergency handling and response:

• Automatic shutdown mechanisms, interlocked with feed/heating systems

• Safety valves, rupture discs, and venting systems for pressure surges

• Audio-visual alarms for any process breach or malfunction

• Provisions for emergency quenching, depressurization, or safe dumping

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🧪 Testing & Inspections

To ensure ongoing safety compliance:

• External inspection: Every 6 months

• Internal inspection: Annually

• Hydraulic testing: Every 2 years or Non-Destructive Testing (NDT) where applicable

• Test results must be certified using Form 13-C, maintained for 5 years

• No reactor should be used post-inspection unless fully compliant

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🚨 Emergency Preparedness

Factories must improve emergency response systems:

• Emergency instructions must be prominently displayed in local languages

• Workers should be trained, with mock drills conducted every 6 months

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👨‍🔧 Personnel Qualification Requirements

Supervisors:

• Degree in Chemical Engineering + 3 years of experience
  OR

• Diploma + 5 years of hands-on reactor experience

Operators:

• Degree/Diploma/Certificate in Chemistry or Chemical Engineering

• Must undergo certified training on reactor operation and chemical handling

• Refresher training every 3 years is mandatory

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📋 General Operational Requirements

• Display names of authorized operators and supervisors near each reactor

• Maintain shift-wise logbooks for a minimum of 3 months

• Each reactor must have a corrosion-resistant nameplate showing:

  • Serial number

  • Material of construction

  • Design code

  • Pressure/Temperature ratings

  • Type of process

  • Manufacturer

  • Last testing date

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🧾 Access the Official Notification

The official Gazette Notification is available through the Maharashtra Labour Department website or your regional Factory Inspector’s office.

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📌 Final Thoughts

The Maharashtra Factories (1st Amendment) Rules, 2025 are a significant step toward enhancing industrial safety, especially in sectors dealing with hazardous chemicals. Factory owners, compliance officers, and plant heads must act swiftly to adopt these protocols and train their teams accordingly.

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👉 Need help with compliance implementation or training?
📧 Contact us at boardhr@gmail.com or comment below.

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Link - Maharashtra Factories 1st Amendment Rules 2025