Color Codes for the Gas Cylinders in Pharmaceuticals | ISO and BIS Color Codes

Gas cylinders are widely used for various purposes in pharmaceutical industry from sterile operations and laboratory testing to manufacturing and packaging. The gases in the cylinders are stored at high pressure, so these must be handled carefully.

It is important to know the colour codes of the same because most of the gas cylinders don’t have any written information about their contents. Colour codes are given for safety purposes and to prevent mix-ups in handling.

The colour codes for the gas cylinders are not just a matter of regulatory compliance but it is a critical safety requirement. The incorrect identification of the gas can cause serious problems and hazards because colour codes are specific to different gases.

Gas cylinders may be coloured with one or more colours according to gas filled in them. Upper curved part of the cylinder is known as shoulder and the lower as the body.

Different colour combinations of shoulder and body are used for different gases. Colour codes of gas cylinders may differ from country to country.

Importance of Color Coding in Gas Cylinders

Color coding is a visual identification system for gases where more than one gases are restored or used in a facility, then it becomes essential to differentiate them instantly to prevent their wrong use.

The purpose of color coding includes:
Safety: Color coding prevents accidental connection or use of wrong gas.
Compliance: Color coding ensures compliance with national and international standards such as ISO 32, BS EN 1089-3 and IS 3933.
Efficiency: Color coding enables quick identification during operation and emergency use.
Quality Assurance: Color coding helps to avoid contamination by ensuring the use of correct gas in critical manufacturing and testing purposes.

Each gas cylinder has a specific color combination of their and shoulder that it easy to identify gas even from a distance.

International Standards for Gas Cylinder Color Coding

Pharmaceutical industry always follows globally recognized standards to maintain uniformity and safety. The ISO 32 and BS EN 1089-3 standards are widely used in the pharmaceutical industry for nonflammable, flammable and toxic gases.

In India Bureau of Indian Standards BIS has issued is IS3933:1966 for color identification of gas cylinders. Most of the pharmaceutical industries follow a combination BIS and ISO standards depending upon their regulatory requirements.

General Color Coding System

There may be some differences in color coding in different regions but the overall concept of gas cylinder color coding remains consistent worldwide.

The colour of the gas cylinder indicates the hazard but not the filled gas. Poisonous and corrosive gas cylinders have a yellow colour, while red coloured cylinders indicate the inflammable gas in them. Oxidizing gas cylinders are light blue in colour and inert gas cylinders are bright green.

Following table shows the general concept for the coding-

S. No.	Gas Cylinder	Color
		Shoulder	Body
1.	Air	Grey	Grey
2.	Ammonia	Red	Yellow & Black
3.	Carbon Dioxide	Silver	Black
4.	Chlorine	Yellow	Yellow
5.	Helium	Brown	Brown
6.	Hydrogen	Red	Red
7.	Nitrogen	Black	Grey
8.	Oxygen	White	Black

Note: Valves of oxygen gas cylinders should not be lubricated using oil and grease.

Gas Cylinders Commonly Used in Pharmaceuticals

In pharmaceutical industry different glasses are used for various purposes.

Sterilization and Purging

• Nitrogen is used to displace oxygen and moisture in sterile areas and during filling.
• Compressed air is used in pneumatic systems and filtration processes.

Analytical Testing

• Helium and hydrogen are used in gas chromatography.
• Nitrogen is used as a carrier gas in HPLC systems.

Production Support

Oxygen and carbon dioxide are used in fermentation and bioreactor operations.

Packaging and Preservation

Nitrogen is used to maintain inner atmosphere in the packing lines that extend product shelf life.

Reading Gas Cylinder Labels and Markings

Color coding is used to provide a visual identification of cylinders but labels and markings are the most reliable source of identification. Every gas cylinder must have following details.

• Gas name and chemical formula
• Supplier name
• Cylinder serial number
• Test date and due date
• Pressure rating
• Net and tare weight
• Hazard classification (as per GHS)

You should never rely completely on the colour especially when labels are missing, faded or tampered.

Handling and Storage Guidelines for Gas Cylinders

Proper handling and storage of gas cylinders are important to prevent accidents. Following are some important GMP points to follow during handling and storage of gas cylinders.

1. Storage

• Always store cylinders in upright positions and fastened with chains or clamps.
• Keep cylinders separate on the basis of the gas type like flammable, nonflammable and oxidizing gases must be stored in different regions.
• Storage area should be properly ventilated.
• Keep gas cylinders away from direct heat, electrical panels or sunlight.
• Cylinder storage area must have restricted access.

2. Handling

• Used trolleys or cylinder cards for transport and never roll cylinders.
• Always check color codes, labels and valve tags before connecting the cylinders.
• Always ensure that pressure regulators are in good conditions.
• Never interchange regulators between different gases.
• Open cylinder valves slowly and avoid forcing them after connection.

3. Maintenance

• Periodically check the cylinders for leakage using soap solution.
• Never use damaged or expired cylinder and return it to the supplier immediately.
• Keep proper records of gas usage, refills and inspection dates because it is a part of GMP documentation.

GMP and Regulatory Expectations

Gas cylinder handling in pharmaceuticals is a part of GMP compliance. Following are some regulatory requirements for gas cylinders used in pharmaceutical industry.

According to WHO GMP, EU GMP, and Schedule M (India):

• All materials including gas cylinders must be clearly labeled and segregated.
• Storage areas should prevent mixups and contamination.
• Gases used in calibration or manufacturing should be traceable with their COAs.
• Cylinders must be inspected periodically and maintained according to safety standards.

During regulatory inspections, auditors often check cylinder labeling, segregation and SOPs related to gas cylinder handling and maintenance.

Common Mistakes in Gas Cylinder Handling and How to Avoid Them

Even trained personnel sometimes overlook small things that can lead to major safety incidents. Common errors during gas cylinder handling include.
1. Assuming gas type based on cylinder color only: Always verify the label to know the actual gas in the cylinder.
2. Using wrong regulator: It leads to leaks or breast hazards.
3. Improper storage: Placing oxidizing cylinders near flammable gas cylinders.
4. Neglecting expiry or inspection dates: Expired cylinders are unsafe and can cause serious hazards.
5. Ignoring leakage signs: Even a small leakage can lead to fire.

Proper training of operators regularly and maintaining updated SOPs can prevent most of issues like above.

Best Practices for Pharmaceutical Facilities

To maintain safety and compliance with regulatory standards pharmaceutical companies should implement following points.

1. Color coding charts should be displayed near storage and usage points.
2. Dedicated storage areas with separation barriers should be there.
3. There should be barcode tracking for gas cylinders
4. Staff should be periodically trained for gas identification and emergency handling.
5. Gas cylinder coding, storage and maintenance should be included in internal audits.

Documentation of every cylinder’s moment, inspection and usage is an essential part of a GMP facility.

Color coding of gas cylinders seems simple but it is a powerful safety major in pharmaceutical manufacturing facilities. When color coding is combined with proper labeling, training and maintenance it can prevent accidents ensure quality and maintain regulatory compliance.

Pharmaceutical professionals must be fully aware of these color codes and follow them strictly. A small error in gas identification or handling can lead to system failure or even life threatening incidents. By maintaining clear color coding, proper labeling and handling, pharmaceutical companies can achieve a safer and more efficient work environment.

Frequently Asked Questions on Gas Cylinder Color Codes

Q1. Why are gas cylinders color coded in pharmaceutical plants?

Answer: Color coding of gas cylinders helps in quick visual identification of different types of gases used in pharmaceutical manufacturing facility. It reduces the chances of using the wrong gas.

Q2. Which color is used for nitrogen gas cylinders in pharmaceuticals?

Answer: Nitrogen gas cylinders have a gray body with black shoulder and it is used for purging to create inert atmosphere and packaging.

Q3. What is the color code for oxygen cylinders used in the pharmaceutical industry?

Answer: Oxygen gas cylinders usually have a black body with white shoulder and these are used in cleaning room systems and oxidation processes.

Q4. Is color coding the same for all countries?

Answer: No, but the basic concept is similar worldwide. A specific color code can vary by country or region depending on local regulations.

Q5. How should gas cylinders be stored in a pharmaceutical facility?

Answer: Gas cylinder should be stored in upright position and secured with chains or clamps. They should be stored separately on the basis of gas types and described in article above.

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