Collect material evidence before choosing equipment
Obtain the supplier’s safety data and relevant process information, then describe particle-size distribution, bulk density, moisture, aeration, flowability, tendency to cake, dust release and any known combustion or explosion data. The competent risk assessor may require specialist testing where existing evidence is insufficient.
Product name alone is not enough. Different grades, particle sizes, additives and handling methods can behave differently.
Map every point where dust can be released
Review bag opening, tipping, vacuum transfer, hopper refill, agitation, auger venting, forming tube, seal area, reject handling, extraction discharge and cleaning. Identify both routine and foreseeable non-routine releases, including blockages, damaged film, overfill and maintenance.
Containment or extraction must be designed around the real source and must not destabilise product feed or draw powder into the seal area.
Define the machine and installation boundary
The powder dosing unit, sachet former, electrical controls, sensors, drives, extraction, ductwork, earthing/bonding arrangements, collection equipment and room environment form one risk system. Equipment selection cannot be separated from hazardous-area classification or the site’s protective measures where those are required.
Do not advertise or accept an ATEX or DSEAR suitability claim without documentation for the final approved machine and complete installation.
Plan cleaning and housekeeping as production controls
Define safe isolation, access, approved vacuum or cleaning equipment, waste handling, cleaning verification and release back to production. Avoid methods that simply disperse deposited dust into the room. Separate allergen, contamination and exposure controls from fire/explosion controls while ensuring they work together.
Wear parts, seals, filters, flexible connections and extraction components should be included in the inspection and maintenance plan.
Make the trial represent the production powder feed
- Use representative product with its normal storage and temperature history.
- Reproduce the intended transfer and hopper-refill method.
- Test lowest, normal and highest doses and relevant pack sizes.
- Observe dust at fill, seal and discharge points through steady running and refill.
- Sample dose and seal performance across time, not only immediately after setup.
- Record extraction state, settings, rejects, cleaning and any operator intervention.
- Do not use the machinery trial as a substitute for the employer’s competent DSEAR assessment.
Powder and dust project brief
| Area | Information required |
|---|
| Material | Safety data, grade, particle size, bulk density, moisture, flow, aeration, dust and relevant hazard evidence |
| Process | Delivery, opening, transfer, hopper refill, agitation, dose, reject, cleaning and waste method |
| Pack | Dose range, sachet dimensions, film, seal, code, cut and accepted-output requirement |
| Environment | Room, ventilation/extraction, zoning assessment where relevant, temperature, humidity and adjacent operations |
| Safety | Competent risk assessment, protective measures, isolation, inspection, maintenance and emergency arrangements |
| Evidence | Representative samples, trial plan, dose/seal methods, dust observations and acceptance criteria |
