In this work, the safety analysis of a new production line in a pesticide factory in Northern Italy is presented. The analysis was based on four different methods in a way that every part of the new line was investigated. The eventual incidents identified by this analysis were further examined with regard to their consequences using three different simulation models for the release and dispersion of the resultant toxic cloud. This analysis has proven that the risk level for the personnel of the factory and the surroundings is acceptable. (C) 2003 Elsevier Science Ltd. All rights reserved.