Packaging operations handle fine powders that can become airborne at transfer points, counters, and sachet lines. Uncontrolled dust risks cross-contamination, operator exposure, and GMP deviations. The goal is reliable containment, cleanable surfaces, and fast, verifiable changeovers.

Define zones and pressure strategy

Keep primary packaging rooms at defined pressure relative to adjacent spaces, and enclose the dusty step. Use local exhaust ventilation (LEV) on hoppers, de-dusters, and tablet counters so dust is captured under local negative while the room maintains its qualified pressurisation.

Capture at source

Fit close-coupled hoods or collars to transfer chutes and feeders. Minimise drop heights and use slower feed rates to reduce puffing. For small interventions, use glove ports or temporary soft enclosures connecting to LEV to avoid open handling.

Control in the air

Specify room HEPA final filters to H14 where fine or potent powders are present and verify airflow under load, accounting for filter loading. During maintenance or non-critical support activities, a mobile air scrubber can reduce background particulate; for example, the MAXVAC Dustblocker may be deployed in ancillary areas without disturbing validated airflow patterns.

Housekeeping and changeover

Avoid dry sweeping. Use H-Class industrial vacuums with HEPA filtration, then wipe with approved lint-free materials. Follow validated cleaning SOPs, including top-down sequence and disassembly points. Use visual checks and swabbing as specified by QA, and document all steps.

Monitoring and people

Use smoke tests to demonstrate LEV capture and a particulate monitor for trend checks during high-risk tasks. Train operators on set-up, cleaning limits, and PPE selection (e.g., FFP3 for potent dusts per risk assessment).

Practical takeaways

• Enclose and extract at transfer points; keep rooms in qualified pressure regimes.
• Minimise drop height and feed rates to reduce puffing.
• Use H14 filtration and consider supplementary scrubbing in support areas.
• Vacuum with H-Class units; no sweeping or compressed air.
• Prove capture with smoke tests and record every clean.

By prioritising source capture, verifiable airflow, and disciplined cleaning, packaging suites stay compliant and changeovers remain swift without compromising product or people.