A theme of the recent election was to bring good jobs back to the U. S. One type of job that many regard as good is manufacturing: the work is usually steady, often no advanced degree is required of most manufacturing employees, and anything from a factory in the U. S. can be labeled "Made in the U. S. A." Combine such jobs with the all-natural theme that has run through so much of Western history—the notion that natural ingredients are better than artificial ones—and you would think that employees of the Givaudan Sense Color factory in Louisville, Kentucky, which made natural caramel coloring for a variety of foods and beverages, were some of the most favored in the country.
And perhaps some of them were, until an explosion at the plant last Tuesday, Nov. 12, killed two of them, injured 11 more, and wrecked a good part of the factory.
This is the second fatal accident at the plant in the last three decades. In April of 2003, an ammonia tank which was moved from another facility without its safety pressure-relief valve exploded, killing one person and releasing 26,000 pounds of ammonia solution, according to the Wikipedia page on D. D. Williamson, which company owned the plant until it was sold to the Swiss multinational corporation Givaudan in 2021. Investigators are still looking into last week's explosion, which apparently did not release significant quantities of hazardous chemicals.
The D. D. Williamson firm dates to 1865 and specialized in caramel coloring for malt liquor, soft drinks (think Coca-Cola and Dr Pepper), and other food products. Anyone who has burned cookies in a stove has encountered the process that turns sugar brown. To control the process and end up with a water-soluble product, one must start with a sugar solution and add acids or alkalis. The alkali favored by the Williamson plant was evidently aqua ammonia, a solution of ammonia gas in water. Nearby residents complained of odors from the plant ranging from a burnt-sugar smell to an ammonia smell, all of which stands to reason.
So until the plant blew up, except for the minor odor nuisance it seemed to be a good place to work. But any time heat and pressure are applied to materials at an industrial scale, there are hazards, and the price of freedom from such hazards is eternal vigilance. Such vigilance requires a culture of safety and a kind of rigor that is not easy to sustain these days. But it was evidently sustained adequately at the Givaudan plant until last week, when something went horribly wrong.
Such accidents are one reason that many average citizens do not favor the idea of a manufacturing plant being built in their own neighborhood. This is the famous NIMBY problem ("not in my back yard"), which not only makes it hard for new manufacturing plants to be built anywhere there are people, but leads to building and zoning laws that essentially put huge swathes of the U. S. off limits for certain types of manufacturing.
Of course, some types of manufacturing are nicer than others, at least in the public eye. Here in Central Texas, we have hosted the construction of several huge new manufacturing facilities in the last decade. The developers of the so-called Tesla Gigafactory in southwest Austin broke ground in 2020 and began making cars in it only a year later. I drive by it every time we take the eastern turnpike around downtown Austin, and there's new construction at the site all the time. Northeast of Austin, Samsung is building a clone of one of their giant Korean semiconductor plants, which is expected to be completed soon.
Neither one of these plants was in anybody's back yard, as they were sited in semi-rural areas, but close enough to Austin and its suburbs so that commutes from populated areas are not too arduous. And if history is any guide, residential communities will spring up nearer the plants, which compared to a factory using a 100-year-old caramelization process are pretty clean and modern.
I'm not aware of any major accidents involving either car manufacturing or semiconductor manufacturing, but I'm sure there have been some. There are plenty of materials in any semiconductor plant that would kill dozens of people really fast if they got loose. But the fanatically fussy nature of semiconductor manufacturing—the "seven-nines" (99.99999%) type of purities required, the exacting care every step requires—more or less bakes in safety procedures as well, or at least it should.
The other major manufacturing enterprise that Texas is known for is oil production and refining, and for insurance reasons refineries have to be fanatical about safety. Such efforts are not always successful, and the factory town of Deer Park outside Houston has suffered two fatal accidents just this fall, as referred to in this blog. An oil refinery is something that my adult self would hesitate to invite into my neighborhood, although I confess to a youthful industrial-romantic phase in which I thought the sight of giant flares illuminating the mudflats of Houston for miles around was beautiful. Then I found out how much cancer and other chronic diseases show up in people who live their lives near chemical plants, and that took some of the bloom off the rose.
As long as people still want new stuff, someone is going to have to make it, and I see no reason that we in the U. S. shouldn't be able to make our fair share of stuff and sell it both here and abroad. But the visions of so-called autarky, in which a country becomes completely self-sufficient, are either harmless fantasies that have no chance of being realized, or cruel malignant visitations on the citizenry of a dictator who actually tries to put it into practice, as Castro did in Cuba and as Kim Jong Un still does in North Korea.
The Givaudan caramel factory in Louisville may be rebuilt, or its new owner may conclude that the effort isn't worth it and close it down, as a 100-year-old wax plant in Barnsdall, Oklahoma was closed last summer after being wrecked by a tornado. But if the Givaudan plant closes, Kentuckians can hope for someone to come along and build a new factory making cleaner-smelling stuff more safely. It's happened in Texas, and it can happen there too.
Sources: I referred to an article on the Dayton Daily News website at https://www.daytondailynews.com/nation-world/2-dead-in-explosion-at-kentucky-factory-that-also-damaged-surrounding-neighborhood/ZCCWLCJIBJGDFHRPPX4VAKVIRA/. I also referred to the Wikipedia pages on D. D. Williamson, caramel color, and Tesla's gigafactory. My blogs on the Deer Park accidents are at https://engineeringethicsblog.blogspot.com/2024/09/deer-park-pipeline-fire-raises-questions.html and https://engineeringethicsblog.blogspot.com/2024/10/deadly-hydrogen-sulfide-accident-puts.html.
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