DGFASLI, Mumbai, Ministry of Labour, Govt. of India carried out a detailed survey in 20 pesticide factories during 1998 - 2001 to assess the process safety, occupational health and work environment conditions prevailing in the units manufacturing technical pesticides and their formulation products. Common methodology was adopted for collection of information from the units, sampling and analysis of air-borne contaminants and medical examination of workers. The pesticides covered in this study are : phorate, DDVP, monocrotophos, malathion, cypermethrin, ethion, lindane, DDT, dimethoate, carbofuran acephate, mancozeb, carbandazim, 2,4-D, endosulfan, fenvelarate, profensophos, dicofol and their formulations namely, Dusting Powder (DP), Wettable Dispersing Powder (EDP), Emulsifiable Concentrate (EC) and Coated Granules (CG). The report gives a detailed account of safety and health hazards associated with different processes and operations, work practices adopted, the existence and effectiveness of hazard control measures, recommended measures for control of process safety hazards and personal exposure to pesticides. Data on air-borne levels of pesticides and allied chemicals with their Permissible Exposure Limits (PEL) are contained in the report. Medical examination of workers included cholinestease level in blood, lung function test, ECG, Urinalysis, etc. The report contains 193 recommendations to improve process safety, industrial hygiene and occupational health of workers engaged in pesticide industry.