Engineering an Operator-First Custom Solution for Containment & Powder Control

Discover how Hosokawa Micron Limited designed a custom Downflow Booth for the manufacturing of aerosol products under strict containment conditions.

When an international biopharmaceutical manufacturer needed to implement safe, controlled methods for handling powders to generate aerosols, they chose Hosokawa. In turn, Hosokawa designed a custom Downflow Booth engineered to provide protection against occupational health risks and maintain strict temperature conditions. This collaborative approach turned a significant safety challenge into a future-proof solution that is capable of supporting ongoing manufacturing growth.

The customer forms part of one of the world’s leading manufacturing networks, serving consumer product markets across multiple regions. The customer’s facility forms part of a wider international operation with stringent requirements for product quality, operator safety, and environmental control.

The facility was facing challenges, such as materials exhibiting sensitising characteristics similar to industrial enzymes, where airborne exposure creates occupational health risks. With this in mind, the client needed a safe and controlled method of handling powders that can generate dust or aerosols during weighing, sieving, and dispensing operations.

A Made-to-Measure Solution — Why Non-Custom Wouldn’t Work

Our team began by reviewing the process requirements, facility layout, and operating procedures to identify how they could solve the client’s challenges.

The primary challenge was protecting operators while maintaining process efficiency. A standard, off-the-shelf solution wouldn’t cater to strict regulations such as meeting occupational exposure targets below 50μg/m³.

Put simply, without adequate containment and environmental control, operators could be exposed to airborne dusts and aerosols, increasing the risk of occupational health concerns, which in turn compromises business workflows and product integrity.

Operators’ ergonomic requirements also needed to be accounted for, so operators could use the equipment comfortably.

A Collaborative Partnership

Hosokawa is the customer’s preferred containment partner, and the relationship continues to develop through long-term collaboration.

But why does the client keep choosing Hosokawa? Because Hosokawa demonstrates a strong understanding of containment technology, powder handling, and operator protection.

The engineering process began with the Hosokawa team reviewing the process requirements, facility layout, and current operating procedures.

From there, the engineering team was brought into the technical consultations. After detailed engineering reviews, the team was able to provide a clearly defined delivery programme within an agreed timeframe, followed by FAT, installation supervision, commissioning, and operator training.

The Solution

The agreed solution was a custom-designed Downflow Booth, engineered and manufactured at Hosokawa’s UK facility.

The 3.5m-wide Downflow Booth delivers vertical laminar airflow at approximately 0.5m/s with 14,000 m³/h recirculating airflow. Its H13 HEPA filtration allows the booth to work in ATEX-rated operating zones, providing humidity reduction capabilities from 80% RH to approximately 30% RH at 25°C.

Together, these features deliver operator protection, product containment, and stable environmental conditions for weighing, sieving, and dispensing activities.

“This project demonstrates how effective containment is about far more than simply capturing dust. By combining Hosokawa’s proven Downflow Booth technology with advanced humidity and environmental control, we delivered a solution that protects operators, supports product quality, and provides a stable manufacturing environment.”– Carl Emsley, Sales Manager at Hosokawa Micron Limited.

 

Discuss Your Process

Hosokawa has been designing and delivering bespoke pharmaceutical containment solutions for over six decades. Our support spans initial consultation, engineering, factory acceptance testing, installation, and long-term aftercare.

Every project is built around the specific operational reality of the customer’s site. To discuss how Hosokawa can support your next pharmaceutical containment project, contact our team by filling out the below form: