In a catastrophic industrial accident, a massive reactor explosion rocked the Sigachi Industries pharma manufacturing facility in Pashamylaram, Telangana, on Monday morning, resulting in the deaths of 12 workers and serious injuries to over 30 others. The incident has reignited longstanding concerns about industrial safety practices in India’s expanding pharmaceutical sector.

Blast Details

According to eyewitnesses and local authorities, the explosion occurred around 9:30 a.m. in the plant’s spray drying unit—a high-temperature component of the chemical production process. Within minutes, the blast escalated into a raging fire, with thick black smoke visible for kilometers.

Emergency response teams rushed to the site, with 10 fire tenders, ambulances, and National Disaster Response Force (NDRF) units battling the blaze and assisting with rescues. The charred remains of 10 workers were recovered from the site, while two others succumbed to critical injuries at the hospital.

“The explosion was deafening. We heard screams and then saw smoke everywhere,” said Raju, a contract worker from a neighboring unit.

About the Company

Sigachi Industries is a well-known manufacturer of pharmaceutical excipients and active ingredients, with plants across Telangana and Andhra Pradesh. The Pashamylaram unit, where the accident occurred, is known for producing microcrystalline cellulose—a crucial ingredient in tablets.

Following the incident, the company’s stock plummeted by 15% on the Bombay Stock Exchange, reflecting growing investor concern over liability, operational disruption, and potential lawsuits.

Preliminary Investigation

Initial reports suggest that the blast was likely triggered by a pressure build-up or malfunction in the spray dryer unit, which operates at extremely high temperatures to process chemical powders. An internal safety audit conducted in 2023 had highlighted the need for upgraded ventilation and pressure controls, but it remains unclear whether the recommendations were implemented.

A senior police official said, “We suspect overheating led to the reactor failure. A detailed forensic and mechanical audit is underway.”

The Telangana government has ordered a judicial probe, and the Telangana State Pollution Control Board has sealed the facility pending inspection.

Victims and Relief

Among the deceased were daily wage workers, technicians, and junior plant operators. At least eight of the victims were migrants from Odisha and Bihar, highlighting the vulnerability of contract workers in high-risk industries.

Prime Minister Narendra Modi expressed condolences and announced an ex-gratia of ₹2 lakh for families of the deceased and ₹50,000 for the injured from the Prime Minister’s National Relief Fund.

Chief Minister A. Revanth Reddy visited the injured at a local hospital and stated, “The state will take strong action. Lives lost due to negligence are unacceptable.”

Pattern of Negligence

This isn’t the first industrial mishap in the region. Telangana, home to one of the country’s densest pharma manufacturing corridors, has witnessed over 50 factory accidents since 2020—many due to lapses in safety practices, improper waste handling, or boiler malfunctions.

A former factory inspector, speaking anonymously, stated: “Regulatory oversight is often weak. Factory owners cut costs on safety mechanisms, and enforcement bodies lack manpower.”

In 2024, a similar accident at SB Organics led to six deaths. Despite outcry and temporary enforcement crackdowns, meaningful reforms have lagged.

Industry Impact

India is one of the largest suppliers of generic medicines globally, and Telangana contributes a significant share of the pharmaceutical output. Accidents like this not only threaten worker safety but may dent the country’s reputation as a reliable drug manufacturing hub.

“This is a wake-up call. Pharma safety has to go beyond compliance paperwork. It needs daily vigilance,” said Dr. Renuka Rao, a Hyderabad-based chemical safety consultant.

What’s Next

Authorities have formed a multi-agency team comprising the police, the Directorate of Factories, and industrial safety experts to assess the cause. Meanwhile, the families of victims are calling for legal accountability and long-term compensation beyond immediate ex-gratia payouts.

This tragedy may spur new regulations or stricter audits, but unless they are enforced consistently, safety will remain precarious for the thousands employed in India’s booming but risky pharma manufacturing sector.