Essex County Perfume Factory Cited For 'Explosion Hazards'

An Essex County perfume and cosmetics manufacturing company is facing $50,000 of possible sanctions and fines for “serious” violations of OSHA standards, including fire and explosion hazards.

Contract Filling, Inc., located on Cliffside Drive in Cedar Grove, manufactures perfume and cologne using denatured alcohol, a flammable liquid, according to OSHA documents.

Manufacturing processes at the facility include routine pumping and mixing/agitation of 14,000 pounds of flammable liquids.

The facility is about 1,000 feet away from a youth batting cage center and the West Essex Trail, and is within a few miles of multiple residential neighborhoods, Passaic Valley High School, Montclair State University, the Cedar Grove Elks Lodge, the Cedar Grove Community Park and the Cedar Grove Reservoir.

According to the company’s website, the 150,000 square foot facility is solar-powered and air conditioned, and is “equipped with explosion proof batching rooms.”

In addition, the company is registered with the EPA, DEP, ATF and FDA (Voluntary Cosmetic Registration).

ALLEGED VIOLATIONS

During an OSHA-conducted Process Safety Management inspection on July 22, observed violations included:

• “The employer had no written plan of action for employee participation in process safety management.” - $6,300 proposed penalty
• “The employer did not develop process safety information pertaining to the technology of the processes used by employees in the manufacture of perfume/cologne, including the safe upper and lower limits for the transfer meter pump’s flow rate.” - $6,300 proposed penalty
• “The employer did not evaluate the consequences of deviation during transfer of flammable liquids from storage tanks to process vessels. Deviation during transfer could include overflow of process vessels.” – No proposed penalty
• “The employer did not have the required P&IDs for the process equipment.” - $6,300 proposed penalty
• “The employer did not perform an initial process hazard analysis on the covered process used by employees in the manufacture of perfume/cologne, including but limited to pumping and mixing/agitation of flammable liquids.” - $6,300 proposed penalty
• “The employer did not develop and implement written operating procedures, including but not limited to emergency shut down, temporary operations, and start up after emergency shutdown.” - $6,300 proposed penalty
• “Employees manufactured perfume/cologne 11sing alcohol, a flammable liquid, without receiving training in the general requirements of the process safety standard.” - $6,300 proposed penalty
• “The employer did not establish and implement written mechanical integrity procedures for employees responsible for maintenance of process equipment, including but not limited to conservation vent/flame arrestor, as part of the safety system.” - $6,300 proposed penalty
• “Employees were repairing main drive of Line #10 motor without locking out energy sources.” - $6,300 proposed penalty (corrected during inspection)

The company has until Sept. 8 to abate the alleged violations.

See the full list of citations here.

“The numerous safety hazards found at Contract Filling’s facility exposed employees to the dangers of potentially fatal fires, which is unacceptable,” stated Kris Hoffman, OSHA’s area director in Parsippany. “This company must strengthen and improve its chemical safeguards to prevent a life-threatening incident.”

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