Automation as a Lifeline: How AI and IoT Can Avert Hazardous Industrial Accidents Like Goregaon Leak

A massive ammonia leak at the Mahananda Dairy facility in Goregaon caused widespread alarm, waking Mumbai to panic. The leak, which was caused by a suspected malfunction in the refrigeration system of the cold storage unit, sent hazardous vapors drifting across the surrounding region, causing emergency evacuations and stopping operations, albeit thankfully no injuries were reported. The event is a loud siren blaring across India's industrial landscape, not just a health concern. In 2025, manual oversight in dangerous industrial processes is still a ticking time bomb in a city that takes pride in being the country's commercial center.

This is the point at which industrial automation becomes essential—not a luxury. Ammonia is a harsh gas, even though it works well for industrial refrigeration. Its leaks can result in blindness, serious respiratory harm, or even death. According to early reports, there was a delay in identifying pressure anomalies in the pipeline system in the Mahananda Dairy case, a delay that automation could have avoided. Such hazards can be reduced before they become catastrophes with the use of automatic emergency shutdown valves, real-time IoT sensors, and predictive AI algorithms.

Think about this: before human operators were on the site, an AI-integrated ammonia handling system might have activated automated alarms, turned off compressors, and even released neutralizing chemicals. In addition to event management, digital twins could be used to prescribe maintenance regimens and model stressful situations, guaranteeing that system integrity is never left to chance. With its intricate cold chain infrastructure, India's food and dairy processing sector is at a turning point. Even as the industry grows, its safety protocols frequently fall short of international norms. The Mahananda incident serves as a clear reminder to hasten the deployment of automation in the management of hazardous materials.

The industrial community in Mumbai needs to clear its conscience as it literally cleans the air. Nowadays, safety is not a checkbox item. It is a necessity of technology. Also, it is best to take action before the next leak occurs rather than after.