Early Monday morning, a thunderous blast rocked the Sigachi Industries facility in Pashamylaram, Telangana’s Sangareddy district, about 50 km from Hyderabad. The explosion occurred inside the spray dryer unit of the microcrystalline cellulose (MCC) plant. It completely destroyed a three-storey structure and triggered a massive fire. Emergency crews acted fast, deploying National Disaster Response Force (NDRF) teams, HYDRAA units, and local fire departments to put out the fire and search for survivors.
How Many Lives Were Lost and Injured?
As of July 1, 42 people have been confirmed dead, with the toll expected to rise as rescue teams continue clearing the debris. Initial reports started with 12 deaths, which quickly rose to 34 by Tuesday morning and eventually reached 42. Around 34 to 40 workers have also been reported injured, many with severe burns and lung damage due to toxic fumes.
Who Were the Workers Affected?
At the time of the blast, around 90 to 140 workers were present inside the plant. While many managed to escape, a significant number were caught in the explosion and the subsequent collapse. Some were reportedly thrown up to 100 meters away due to the force of the blast, worsening their injuries.
Investigating the Cause
Initial investigations suggest a pressure surge or uncontrolled chemical reaction inside the spray dryer or reactor unit. Overheated airflow—possibly reaching 700 to 800 °C—might have caused a dangerous pressure buildup, leading to the explosion. A five-member panel led by Telangana’s Chief Secretary K. Ramakrishna Rao has been formed to conduct a thorough investigation.
The Aftermath: Plant Closure & Financial Impact
Sigachi Industries has shut down its Telangana unit for 90 days to assess and repair damage. This plant is responsible for over 25% of the company's total MCC production capacity of 21,700 MTPA. Following the incident, the company's share price dropped nearly 15%—the sharpest two-day fall in its history.
Rescue & Relief Efforts
Rescue teams and firefighters have been working tirelessly to remove rubble and find survivors. Hospitals such as Pranaam in Miyapur and Dhruva in Patancheru have admitted several severely burned victims, with some suffering burns over 40–80% of their bodies. Many of the deceased were charred beyond recognition, requiring DNA tests for identification.
Government Response and Compensation
Prime Minister Narendra Modi announced ₹2 lakh as compensation for the families of the deceased and ₹50,000 for the injured. Bihar Chief Minister Nitish Kumar extended similar support to affected workers from his state. Telangana Chief Minister A. Revanth Reddy ordered safety audits in all chemical plants across the state.
Safety Lapses: A Recurring Risk
This is not an isolated incident. Telangana has witnessed 10 industrial blasts in the past 30 months. Most were linked to outdated equipment and weak safety practices. Although this particular plant passed a safety inspection in December, poor maintenance and undertrained staff are believed to have played a role in the disaster.
Ripple Effects on Industry & Supply Chains
Sigachi Industries supplies MCC to key sectors like pharmaceuticals, food, cosmetics, and specialty chemicals across countries like the USA and Australia. This disruption may delay production in related industries, especially pharmaceutical tablets, food additives, and cosmetic items.
What Happens Next?
The investigation committee is expected to submit recommendations soon. These will likely include better maintenance protocols, frequent inspections, automation for control systems, and improved staff training. The plant will only reopen once all safety measures are implemented. Meanwhile, affected families continue to wait for support, and the incident highlights the urgent need for reforms—especially as similar tragedies like Sivakasi's fire underline the risks.
FAQs (Frequently Asked Questions)
Q1. Why did the reactor explode?
Investigators believe a pressure buildup in the spray dryer unit or reactor pushed internal temperatures to unsafe levels, causing a powerful and deadly explosion.
Q2. How many workers were inside during the blast?
Official estimates indicate between 90 and 140 workers were inside the plant when the explosion happened.
Q3. What compensation has been offered?
The central government offered ₹2 lakh to families of the deceased and ₹50,000 to the injured. State governments like Telangana and Bihar have matched this support.
Q4. How severe were the injuries?
Most victims suffered extreme burns—some over 80% of their body. Others experienced serious respiratory injuries due to inhaling toxic gases.
Q5. Will the plant resume operations soon?
No. The plant is shut down for at least 90 days. It will only reopen after thorough audits, structural repairs, and safety upgrades are completed.
Conclusion
The Sigachi reactor blast in Telangana is one of the worst industrial accidents in recent history—claiming 42 lives and exposing deep-rooted safety failures. As rescue operations wind down, the focus must shift to reforms. Mandatory safety enforcement, modern equipment, and trained personnel are crucial. This tragedy reminds us that in the race for industrial growth, human safety must never be compromised.
Report by Toofan Express