The Real Cost of Inadequate Process Safety
Process safety failures have devastating consequences for people, assets and business continuity. These figures represent the ongoing global reality of preventable industrial incidents.
Major process safety incidents occur globally every year, predominantly in chemical, petrochemical and energy sectors.
Global economic losses from process safety failures - property damage, business interruption and liability claims.
Research consistently shows the majority of major industrial incidents could have been prevented with adequate risk management.
Every R1 invested in robust process safety management typically returns R10 in avoided losses - a compelling business case.
Don't leave process safety to chance.
Nexis Process Safety provides the specialist expertise to identify hazards, assess risks, implement controls and build a durable safety culture - before an incident occurs.
Talk to Our SpecialistsAfrica's Process Safety Specialists
Founded to embed a culture of process safety excellence across African industry.
Nexis Process Safety (Pty) Ltd is a specialist consulting firm based in Centurion, Gauteng, delivering technically rigorous, compliance-driven process safety and management systems solutions to industry across Africa.
We understand that in hazardous industries the difference between a near-miss and a catastrophe is robust process safety management. Our team brings deep technical expertise, a practical approach, and genuine passion for protecting people and preserving assets.
2026 Centurion, Gauteng
Comprehensive Process Safety Solutions
From frontline hazard assessments to full ISO management systems - we cover the complete process safety lifecycle.
Process Safety Engineering
HAZOP, LOPA, SIL, ATEX hazardous area classification, dust hazard analysis, machine safety and consequence modelling - technically rigorous, practically delivered.
Learn morePSM Programmes
Design, development, implementation, monitoring and independent auditing of PSM programmes aligned to CCPS frameworks and industry best practice.
Learn moreISO Management Systems
ISO 9001:2015, 45001:2018, 14001:2015, 22000:2018 and 27001:2022 - gap analysis, system development, documentation and certification readiness.
Learn moreQuantitative Risk Assessment
Flash fire, reactive chemical hazards, electrostatic hazard studies, thermal instability, energetic materials evaluation and quantitative risk modelling.
Learn moreHazardous Area Classification
SANS 10108 and IEC 60079 zone classification, EI 15 methodology, NCOP 2022 compliance and DSEAR 2002 assessments for flammable atmospheres.
Learn moreTechnical Advisory
Flammability studies, reaction hazard evaluation, regulatory classification, dangerous goods advisory per ADR/SANS 10228 and turnkey project management.
Learn moreTrack Record in Numbers
Delivering measurable process safety outcomes across African industry.
Process Safety Studies Delivered
ISO Standards Covered
High-Hazard Industries Served
Client-First Approach
Why Partner With Nexis PS?
Specialist Focus
Dedicated exclusively to process safety - our entire intellectual capital is focused on keeping your people safe.
Africa-Focused
Deep understanding of African regulatory frameworks, operational environments and industry cultures. Solutions designed to work in context.
Practical Solutions
We produce actionable safety improvements, not theoretical reports. Every recommendation is implementable, proportionate and prioritised by risk.
Full Lifecycle
We support your process safety journey from assessment and design through implementation and continual improvement.
Safety Culture
We build lasting safety culture and competence alongside your teams - the value remains long after our formal engagement concludes.
Passion for Life
Every engagement is driven by genuine conviction that no one should be harmed by a preventable industrial incident.
"Process safety is not merely a regulatory requirement - it is a moral obligation to every worker who walks through your facility gates."
Process Safety in Action
Real-world examples of how Nexis PS has helped organisations achieve measurable process safety improvements.
HAZOP Study & Risk Reduction for Reactor Section
A South African chemical manufacturer required an independent HAZOP study for their exothermic reactor section following a near-miss incident and upcoming regulatory inspection.
Key Outcomes
- Identified 23 credible hazardous scenarios
- Recommended 17 risk reduction measures
- Facilitated regulatory compliance documentation
- Zero findings at subsequent regulatory inspection
ISO 45001:2018 Certification Readiness
A large food processing group needed to achieve ISO 45001:2018 certification across three facilities within a 12-month timeline to satisfy a key export customer requirement.
Key Outcomes
- Achieved full certification at all three facilities
- Delivered within 10-month accelerated timeline
- Zero major non-conformances at certification audit
- Management system framework retained in-house
Hazardous Area Classification - Gas Compressor Station
A natural gas utility required an updated hazardous area classification study for an ageing compressor station ahead of a major electrical installation upgrade.
Key Outcomes
- Reclassified 8 areas per current SANS 10108
- Identified equipment non-compliance in Zone 1 areas
- Full GA drawings and ATEX equipment schedule delivered
- Electrical upgrade completed without safety incidents
Industries We Serve
We bring specialist process safety expertise to high-hazard industries across Africa.
Manufacturing
Chemical, petrochemical, pharmaceutical and general manufacturing.
Energy & Utilities
Power generation, gas processing, renewable energy and utilities.
Food Processing
Combustible dust, refrigeration hazards and food safety systems.
Chemical & Petrochem
Flammable liquids, reactive chemicals and high-consequence operations.
Mining & Heavy Industry
Explosive atmospheres, dust management and process plant safety.
Process Safety Across Africa
Based in Centurion, Nexis Process Safety is positioned to serve clients across Sub-Saharan Africa. We understand the challenges that African operations face - regulatory variability, infrastructure constraints, supply chain complexity and the dual pressure of meeting international standards while operating in local realities.
Our consultants are experienced in cross-border project delivery and bring practical solutions developed specifically for the African industrial context.
Our Four-Stage Engagement Model
A structured methodology delivering thorough, compliant and practically implementable process safety outcomes every time.
Assess
Comprehensive hazard identification and risk assessment - HAZOP, LOPA, Bow-Tie, risk matrix, gap analysis and regulatory benchmarking tailored to your specific operation.
Design
Develop tailored PSM frameworks, ISO management systems and safety programmes aligned to your operations, regulatory context and business objectives.
Implement
Hands-on implementation - documentation, procedure development, training facilitation, team coaching, roll-out management and system integration support.
Monitor
Independent auditing, KPI monitoring, benchmarking against international standards and corrective action planning to drive continual performance improvement.
Standards & Frameworks We Work With
Our consultants work across a comprehensive range of international and South African standards.
Professional Affiliations & Standards Bodies
Our work is aligned to globally recognised process safety standards and bodies.
Process Safety Knowledge Hub
Access our growing library of process safety guides, checklists, standards summaries and technical articles - curated by our specialists to help you navigate the complex world of industrial process safety.
- HAZOP methodology guides and templates
- ISO management system implementation roadmaps
- SANS 10108 hazardous area classification overview
- PSM element implementation checklists
- Process safety FAQs for SHEQ professionals
What Our Clients Say
Trusted by process safety and SHEQ professionals across Africa.
Nexis PS delivered a comprehensive HAZOP study for our chemical plant within challenging timelines. Their technical depth and practical approach set them apart from other consultants we have worked with.
The ISO 45001 implementation support provided by Nexis PS was exceptional. We achieved certification on first attempt - a direct result of their thorough preparation and documentation.
Their hazardous area classification work was technically rigorous, well-documented, and fully compliant with SANS 10108. Highly recommended for any energy sector project.