AbstractCompetition in commodity centered chemicals, in the Chemical Process Industry (CPI), has led many chemical companies to consider cost reduction in every facet of their businesses. Once the obvious fixed cost control measures are achieved, the invention, development, and commercialization of new and existing products is questioned for cost reduction opportunities. The challenge is to bring the product line to market with sufficient volume and quality at a lower cost than any competitors. Short term and long term profitability, per capita of the corporation, must continue upward or at least break‐even in the low end of the chemical business cycle. Consideration of the principles of chemistry and physics early in the development and throughout the life of a chemical product can eliminate the need for instrumentation or administrative controls that add significant cost to the product over its lifetime. This paper examines opportunities to use inherent safety principles to improve lifetime cost, while reducing or eliminating hazards.