Powder companies have been in business for many years and thoroughly understand the chemistry and processes involved in making powder. The roots of Goex go all the way back to the first Du Pont powder mill on the Brandywine in 1802. After Du Pont gained too much control of the explosives business the Sherman Anti Trust act broke the company up in 1912. The Hercules Powder company was one of the spinoffs of the break up. Hercules eventually changed its name to Alliant, which makes Unique and many other Smokeless powders today, and Goex was spun off to continue making Black Powder. These guys have over two hundred years of cumulative experience making Black Powder.
To suggest that the home hobbyist is somehow safer making Black Powder than the professionals is ludicrous. The pros have all the controls in place, and even so, every once in a while a powder mill goes up in smoke. The latest explosion at Goex, which happened last June, was caused by foreign material getting into the corning mill. Corning is probably the most dangerous part of making Black Powder. The three ingredients are mixed together into a past with water. Most of the water is driven out, and the resulting cake is ground down to granular size in the corning mill. These days it is always a remote operation, nobody is in the corning mill when it is operating. That's why nobody was killed this last time around.
My Dad was a chemist. He worked for Hercules Powder Company in Kansas during WWII. He was a foreman on a line producing rocket fuel for bazookas. The fuel was extruded into sticks through a hole in a large steel plate in a large press. One day that building blew up. Everybody inside was killed. Luckily my Dad was somewhere else that day. Powder mills are usually constructed with separate buildings housing separate operations, so that if an explosion occurs in one operation, the entire facility is not destroyed. This facility had multiple buildings each with a blow away wall facing out onto the prairie. When the rocket fuel extrusion building blew, that steel plate was found about a mile away on the prairie.
A few miles from where I live the United States Cartridge Company did business in Lowell Mass from shortly after the Civil War until about 1929. In 1903 an explosion in one of the company's powder magazines leveled a neighborhood, killing 22 employees and residents of the nearby neighborhood.
My Dad told me how to make gunpowder when I was about 15 years old. He told me the ingredients and the correct proportions so that I would not experiment on my own. Then he cautioned me not to even think of trying to make it on my own.
My point is the powder companies have been doing this for hundreds of years, they have all the safety precautions in place, including dust control, keeping the correct moisture level in the powder cake, doing the most dangerous operations remotely, and still they have the occasional mishap. In 1986 the president of Goex and a worker were killed in a lab explosion. If the professionals still experience explosions, it is arrogant and foolhardy to think the hobbyist can do it safely. Even just making a pound or two of powder at a time, have you ever seen what happens when a pound of Black Powder explodes?
As for the Mario Andretti analogy, you are talking apples and oranges. Mario Andretti getting in a car accident does not mean the rest of us should not drive. It means the rest of us should not get into a race car and compete with other professionals.
And making powder is not at all like reloading. Reloading is much safer than trying to make powder at home.
Leave the dangerous stuff to the professionals who have been doing it for years and have the proper equipment to do it right.