Allergy Relief at Scale: Plant Design for Diphenhydramine Hydrochloride; Just Pop An Aspirin: An Analysis On The Perceived Safety of Over-The Counter Pain Medications in America

This thesis portfolio encompasses two distinct projects related to over-the-counter medications, though from different perspectives. The technical component presents the design of a manufacturing plant for diphenhydramine hydrochloride, a common antihistamine found in allergy medications. This project explores a novel, environmentally conscious synthesis route that eliminates bromine usage while maintaining pharmaceutical-grade product quality. The second component, a Science, Technology, and Society (STS) research paper, investigates the gap between perceived and actual safety of over-the-counter pain medications in America. While these projects approach different aspects of pharmaceuticals, both contribute to understanding how technical innovations and societal factors shape our experiences with medications that millions consume daily. The technical project focuses on improving production methods for a medication we often take without consideration, while the STS research examines how our cultural assumptions about common medications may not align with their actual risk profiles. Together, these works offer complementary examinations of the pharmaceutical field that consumers navigate when seeking relief from common ailments. Though not directly connected in subject matter, both projects reflect an interest in improving pharmaceutical safety and accessibility through different yet equally important avenues of inquiry.
The technical project details the design of a batch manufacturing facility for diphenhydramine hydrochloride, an antihistamine used to relieve allergy symptoms with an annual market value exceeding $1 billion. Located in Ponca City, Oklahoma, this plant employs an innovative solvent-free synthesis that eliminates bromine, a corrosive and environmentally hazardous substance traditionally used in production. This approach significantly reduces environmental impact and workplace safety concerns while maintaining product purity above 98%, meeting pharmaceutical standards. The facility operates 313 days annually with a 24-hour schedule, producing 457,320 kg of product per year through 1,833 batches. The process consists of four primary blocks: reduction of benzophenone to benzhydrol, chlorination of benzhydrol, nucleophilic substitution to form diphenhydramine, and final purification to pharmaceutical quality. Each batch generates 249.46 kg of product, contributing to the plant's substantial production capacity. Economic analysis shows remarkable profitability with an estimated annual revenue of $1.5 billion and net profit of $638 million. Beyond demonstrating commercial viability, this design provides a model for how pharmaceutical manufacturing can incorporate environmental considerations without sacrificing economic performance or product quality.

The STS research examines whether Americans perceive over-the-counter pain medications as safer than their actual risk profiles warrant. Through analysis of FDA regulatory processes, pharmaceutical marketing strategies, consumer behavior patterns, and medical literature on active ingredients, the research reveals a substantial gap between perception and reality. The investigation found concerning limitations in FDA oversight, with the agency acknowledging its OTC review system as "slow and antiquated" and allocating approximately 40 times more resources to prescription drugs than OTC medications. Pharmaceutical companies contribute to misconceptions through marketing that emphasizes benefits while minimizing risks. Consumer research reveals widespread misunderstandings about medication safety and concerning patterns of overuse. Medical literature confirms that both aspirin and acetaminophen carry significant risks that contradict popular perceptions of safety, with consequences ranging from gastrointestinal bleeding to liver failure. The findings indicate a complex system where ineffective regulations, marketing, cultural normalization, and psychological tendencies that all contribute to a distorted public perception of OTC medication safety. The cultural acceptance of "just popping an aspirin" fails to recognize the genuine risks these common medications pose when used improperly or without adequate understanding of their potential effects.
Both projects demonstrate how technical and social factors shape our experiences with over-the-counter medications. The manufacturing design project shows how innovative chemical engineering can improve production processes to reduce environmental impact while maintaining effectiveness and profitability. Meanwhile, the STS research reveals how regulatory systems, corporate practices, and consumer psychology interact to create potentially dangerous disconnects between perceived and actual medication risks. As the pharmaceutical industry continues to evolve, this portfolio suggests that progress requires not only technical innovation but also critical examination of the social systems that influence how medications are regulated, marketed, and consumed. Whether designing manufacturing processes or analyzing safety perceptions, a comprehensive approach that considers both technical effectiveness and societal context is essential for improving public health outcomes related to over-the-counter medications. The combined insights from these projects point toward opportunities for creating safer, more environmentally responsible pharmaceutical products while also fostering more accurate public understanding of medication risks and benefits, ultimately promoting more informed consumer choices and better health outcomes.

School of Engineering and Applied Science

Bachelor of Science in Chemical Engineering

Technical Advisor: Eric Anderson

STS Advisor: Kent Wayland

Technical Team Members: Sabrina Linskey, Abigail Janiga, Justin Kim, Yusra Babar