Worker Safety In Solvent Handling: A Checklist For Small Batch Coatings Plants

In small batch coatings plants, where custom formulas and flexibility are the norms, handling solvents is part of daily operations. Solvents pose significant health and safety risks, however, from flammability and chemical exposure to long-term environmental impacts. For coatings industry professionals and plant operators, ensuring worker safety in these environments is not just about compliance — it’s about fostering a culture of accountability and protection.

Small batch facilities can reduce risks and improve solvent-handling safety by following key best practices, ranging from proper equipment use and chemical storage to comprehensive employee training.

1. Personal Protective Equipment (PPE): Standardize and Enforce Use

Proper PPE is the first line of defense against solvent exposure. All workers handling or working near solvents should be equipped with:

• Chemical-resistant gloves (e.g., nitrile or neoprene)
• Splash-proof goggles or face shields
• Flame-resistant lab coats or coveralls
• Respirators, where required, especially in poorly ventilated areas

Ensure PPE is stored accessibly, checked regularly for integrity, and replaced when worn. Supervisors should conduct routine audits to verify compliance and correct usage.


2. Ventilation and Air Quality Control

Many solvents release volatile organic compounds (VOCs), which can pose respiratory hazards. Install and maintain adequate ventilation systems in all solvent-handling areas, such as fume hoods, local exhaust ventilation, and air purifiers with activated carbon filters.

Use continuous air quality monitoring tools to detect VOC levels and respond to any alerts promptly. Good air flow not only protects workers but also reduces the likelihood of flammable vapor buildup.

3. Safe Transfer and Mixing Procedures

Solvent transfers and mixing should be done using closed systems whenever possible to limit exposure. Use chemical-resistant pumps and containers, and always ground equipment to prevent static discharge, which can ignite flammable vapors.

Establish standard operating procedures (SOPs) for:

• Opening and sealing solvent containers
• Measuring and mixing components
• Cleaning spills or equipment

All SOPs should be documented, easily accessible, and updated regularly.



4. Proper Chemical Storage Practices

Correct storage is essential for minimizing risk, particularly in compact facilities with limited space. Every solvent should be labeled clearly and stored in approved containers, such as a chemical storage tote made specifically for hazardous materials. Follow best practices:

• Store solvents in cool, dry, well-ventilated areas
• Segregate incompatible substances (e.g., acids and bases)
• Use fire-resistant storage cabinets for flammable liquids
• Keep emergency spill kits nearby

Investing in high-quality storage totes with secure lids and labeling features can prevent accidental exposures and simplify inventory management.



5. Training and Emergency Preparedness

Even the most sophisticated equipment is only as safe as the people using it. Ongoing training is essential, not just for new hires, but as part of a continuing education program. Topics should include:

• Solvent identification and hazard communication
• Proper PPE use
• Fire safety and extinguisher operation
• First aid and emergency response procedures

Conduct regular drills so workers know how to respond to chemical spills, exposure incidents, or fires. Every employee should know the location of safety showers, eyewash stations, and emergency exits.

6. Record-Keeping and Compliance

Maintaining accurate records is key to meeting OSHA, EPA, and local regulatory requirements. Keep detailed logs of:

• Solvent inventory and usage
• PPE inspections
• Training sessions
• Air quality monitoring results
• Incident reports and corrective action

This documentation not only ensures compliance but also helps identify patterns that could point to underlying safety risks.

Sealing Safety Into Every Batch: Making Solvent Handling Second Nature

Worker safety in solvent handling is a shared responsibility that requires vigilance, training, and investment in the right tools. From choosing the correct chemical storage tote to reinforcing safety protocols during transfers, every step contributes to a healthier work environment.

By proactively managing these risks, small batch coatings plants not only protect their employees but also improve operational consistency, reduce downtime, and reinforce their reputation as responsible, compliant businesses within the coatings industry.

Smart safety is smart business—and it begins with clear, actionable steps that protect both workers and operations.



Author bio: Mike Lange is Vice President of Sales for SolvChem, a large independent chemical distributor. He has 25 years of commercial and executive leadership experience in the distribution industry. Lange is responsible for strategic direction and commercial execution of SolvChem’s account management team.