Case Studies Archives | Custom Powder Systems

We Don’t Just Build Equipment

June 5, 2025

by custompowd2stg Blending Case Studies Containers/IBC/Bins Downflow Booth Isolators Lift/Manipulators White Papers

At Custom Powder Systems, we believe manufacturing equipment should do more than function. It should solve problems. Whether you’re navigating strict containment requirements, managing complex material handling workflows, or launching a new line of high-potency APIs, we don’t just deliver stainless steel and schematics—we deliver peace of mind.

As a domestic supplier, Custom Powder Systems proudly designs, fabricates, and supports all of our systems in the United States. This gives our clients faster lead times, direct access to engineering support, and confidence in American-made quality and compliance.

Because at the end of the day, you don’t need equipment.
You need a solution.

From Problem to Process: Our Engineering-First Approach

Most equipment vendors ask, “What do you need us to build?”
We start by asking, “What problem are you trying to solve?”

Our engineering process begins with understanding your product, your process, and your compliance demands. Then, we design and fabricate systems that are purpose-built for your environment. This often means integrating containment, automation, ergonomic access, and cleaning protocols into one seamless solution.

Examples of our solution-first thinking:

Turning a crowded, multi-vendor process into a compact, CIP-ready production line
Designing a modular downflow booth that adapts to new product launches
Engineering IBC transfer systems that achieve sub-microgram OEL compliance

It’s Not Just What You Build. It’s How You Build It.

Our expertise spans a range of systems—including:

Downflow Booths
Designed with airflow precision and operator access in mind, our booths meet ISO classifications and OEL targets for safe powder handling.
Isolators & Containment
Custom-built for cytotoxic, hormonal, and sterile applications—designed to be ergonomic, cleanable, and easily integrated with upstream/downstream equipment.
IBC Blending and Transfer Systems
Built for accuracy and hygiene, our IBCs and blending stations are configured to reduce dust, eliminate manual handling, and maximize space.
Custom Lifts & Manipulators
Engineered to move heavy materials with ease and safety—tailored to facility layouts and operator workflows.

Every weld, every interface, and every component is built for performance, compliance, and reliability. We don’t do off-the-shelf. We do on-the-mark.

Compliance Isn’t Optional. And Neither is Ingenuity.

In regulated industries, there’s no margin for error. Whether you’re preparing for an FDA audit, scaling up high-potency production, or upgrading for ATEX compliance, our systems are designed to exceed expectations—because you can’t afford downtime, cross-contamination, or guesswork.

We engineer for:

21 CFR Part 11 compliance
cGMP environments
Hazardous material zones
High-containment OEB 4–6 environments

And we back it all with documentation, validation support, and a collaborative engineering process that puts your team in the driver’s seat.

Your Partner in Innovation

We’re not a fabricator with a catalog. We’re an engineering partner who listens first, designs second, and builds third. Whether you’re in pharmaceuticals, nutraceuticals, specialty chemicals, or food processing—Custom Powder Systems is here to help you transform your challenges into high-performing, compliant solutions.

We build it right because we build it for you.

Containment 101: How to Keep Your Facility Compliant and Safe

June 5, 2025

by custompowd2stg Case Studies Downflow Booth Integrated Containment Systems White Papers

Understanding Downflow Booths, Isolators, and Custom Containment Solutions—And How to Meet OEL Challenges Head-On

In high-stakes industries like pharmaceutical, biotech, and chemical manufacturing, managing the risks of potent compound exposure is essential. Custom Powder Systems specializes in the design and engineering of containment solutions that help clients meet strict Occupational Exposure Limits (OELs) while maintaining productivity and compliance.

As a domestic supplier, Custom Powder Systems proudly designs, fabricates, and supports all solutions in the United States—offering faster communication, responsive service, and complete control over quality and timelines.

We also collaborate closely with our sister company, Integrated Containment Systems (ICS), to deliver complete, end-to-end solutions for high-containment environments. ICS enhances our capabilities by focusing on the development of isolators, gloveboxes, and specialty enclosures tailored to critical applications.

This guide breaks down three core technologies—downflow booths, isolators, and custom systems—and how they address common challenges in regulated environments.

Downflow Booths: Flexible and Effective Containment

Custom Powder Systems’ downflow booths are ideal for handling dust-generating processes such as weighing, dispensing, or sampling APIs. These booths use unidirectional (laminar) airflow, HEPA filtration, and low-level extraction to protect both the operator and the surrounding environment.

Key Features:

Modular stainless-steel construction with powder-coated interiors
HEPA or ULPA filtration for particle capture
Airflow design maintains ISO Class 5–8 conditions
Available with integrated weighing stations and ergonomic work surfaces

Best suited for:
OEL targets down to 1 µg/m³, suitable for non-sterile operations that require open access.

Advantage:
Compared to full enclosures, downflow booths offer operational flexibility, faster access, and lower capital expenditure—all while achieving excellent containment performance for medium-potency compounds.

Isolators: Maximum Protection for Highly Potent Compounds

When dealing with HPAPIs (highly potent active pharmaceutical ingredients) or cytotoxic materials, isolators are the gold standard. Custom Powder Systems designs both negative and positive pressure isolators depending on the containment or sterility requirement.

Design Attributes:

Fully sealed environments with glove ports
Integrated decon systems for aseptic cleaning
Internal pressure differential controls
Optional vaporized hydrogen peroxide (VHP) sterilization

Typical Applications:

Final weighing of HPAPIs
Sterile material transfer
Aseptic sampling or QC labs

With containment capability <1 µg/m³, isolators are engineered to protect both personnel and product without compromise.

Custom Systems: Engineered for Specific Process Demands

Every process is different. That’s why Custom Powder Systems offers engineered solutions tailored to individual client needs—from transfer systems to lift-and-seal devices, and IBC blending enclosures.

Every process is different. That’s why Custom Powder Systems offers engineered containment solutions tailored to individual client needs—from transfer systems to lift-and-seal devices, and IBC blending enclosures.

Examples include:

Split Butterfly Valve (SBV) charging systems
Contained drum-to-IBC transfers
Lift-assist isolator integrations
Contained tablet dedusters or blenders

Process-specific benefits:

Seamless containment during powder charging/discharging
CIP/SIP compatibility for hygiene-critical operations
Compact footprints designed to retrofit existing facilities

How We Solve Common OEL Compliance Challenges

1. Inconsistent Airflow or HEPA Efficiency
We integrate real-time airflow monitoring and redundant HEPA filtration to ensure consistent negative pressure and ISO classification—even during high-traffic operation.

2. Difficult-to-Clean Surfaces
All containment systems are designed with cleanability in mind: smooth welds, sloped surfaces, and CIP-ready connections minimize risk and downtime.

3. Cross-Contamination Risks
Our closed transfer systems—like IBC charging stations with vacuum conveying or split-valve containment—prevent powder breach during critical transfer points.

4. Operator Fatigue or Workflow Disruption
Human factors are considered in every design, from ergonomically placed glove ports to adjustable-height work surfaces—reducing strain while increasing precision.

A Partnership for Compliance and Confidence

And because we’re a U.S.-based partner, we provide unmatched access to engineering teams, faster service turnarounds, and ongoing domestic support—without navigating international delays.

Together with Integrated Containment Systems, we offer a unified approach to containment that’s both technically sound and tailored to your operation’s needs.

Let’s Design a Safer, Smarter Process
Explore our downflow booths, isolators, and engineered containment systems at custom-powder.com, or contact our team to start your compliance roadmap today.

How Proven Technology Can Benefit New Battery Manufacturing

May 4, 2025

by custompowd2stg with No Comment Case Studies NEWS White Papers

The race to develop and scale up battery manufacturing has never been more critical. With the rapid adoption of electric vehicles (EVs), renewable energy storage, and portable electronics, battery production is under increasing pressure to deliver quality, consistency, and efficiency. While new breakthroughs push the boundaries of performance, proven manufacturing technologies—many refined over decades—are quietly powering this revolution.

At Custom Powder Systems, we believe innovation and experience go hand in hand. By adapting trusted manufacturing methods for modern applications, we’re helping battery manufacturers scale smarter, safer, and faster.

The Role of Established Manufacturing Techniques

Many traditional manufacturing methods—originally developed in industries like pharmaceuticals, food processing, and industrial powders—are now proving indispensable to battery production. Processes such as powder handling, blending, and containment can be seamlessly integrated into battery manufacturing environments.

Custom Powder Systems brings deep expertise in these areas, offering solutions that are both field-tested and future-focused.

Proven Powder Handling Solutions

Advanced batteries rely on highly specific formulations of powdered materials, including lithium, cobalt, and nickel. These materials must be handled with precision and care to maintain consistency and prevent contamination.

Technologies such as vacuum transfer systems, containment booths, and automated bulk-handling solutions provide clean, efficient material flow—ensuring process integrity while meeting the highest quality standards.

Efficient Mixing and Blending Techniques

Battery cathodes and anodes require uniform mixtures of active materials to perform reliably. Proven blending technologies—like tumble blenders and high-shear mixers—originally developed for the pharmaceutical and chemical industries, now enable manufacturers to achieve homogeneity at production scale.

These solutions offer a repeatable, scalable way to deliver the consistency today’s battery applications demand.

Containment and Safety Practices

Lithium-ion battery materials are sensitive and often reactive, requiring rigorous safety measures. Long-established containment techniques such as isolators, gloveboxes, and downflow booths help create controlled production environments that safeguard both workers and product integrity.

Custom Powder Systems specializes in modular containment systems that meet strict regulatory and environmental safety requirements—without compromising productivity.

Cost-Effective Scaling for the Future

Adapting well-established technologies isn’t just practical—it’s strategic. Instead of starting from scratch, manufacturers can integrate proven systems that already meet performance, compliance, and safety standards. This approach reduces costs, accelerates time to market, and minimizes the risks often associated with untested solutions.

Legacy systems also benefit from existing supply chains and operator familiarity, which further streamlines adoption and scale-up across production facilities.

Custom Powder Systems: Bridging the Gap Between Old and New

At Custom Powder Systems, we specialize in upgrading and adapting time-tested powder handling and processing technologies for modern battery manufacturing. Our solutions integrate with existing production infrastructure while enhancing automation, efficiency, and output.

We offer:

Modular containment and transfer systems that retrofit easily into current lines
Automated bulk powder handling for greater precision and reduced human error
Custom-engineered blending and material handling solutions designed to meet evolving performance needs

Whether you’re building a new facility or optimizing an existing one, our systems support scale-up without sacrificing the reliability of the tools that have always worked.

Meeting the Moment with Innovation and Experience

Battery manufacturers who embrace both emerging technologies and established best practices will be best positioned to lead in a competitive, fast-moving industry. At Custom Powder Systems, we deliver solutions that connect the reliability of the past with the demands of the future.

Contact us today to discover how our industry-proven technologies can support your next generation of battery production.

International Adventures: Qatar

June 1, 2021

by jackie Case Studies

We were asked to design, build, and install a two-part gas-to-liquid catalyst dispensing system in 2008. We created, set up, and tested it entirely at the CPS factory in Missouri, before packing and shipping it to Ras Laffan, Qatar.

A country with fewer residents than expatriates, the State of Qatar sits on the western shore of Saudi Arabia. Although it’s half the size of Lake Erie, Qatar has the third-largest GDP per capita in the world. It was a modest fishing and pearl hunting country until the discovery of oil in 1940. In short order, the citizen’s way of life improved vastly and this tiny nation proudly boasts an unemployment rate of 0.1%.

Ras Laffan and Mysterious Mangroves

Sitting near the tip of Qatar, our customer was in an area commissioned as an “industrial city” in the 90s. It’s home to many petrochemical companies processing liquified natural gas and gas-to-liquid. It’s situated perfectly near the North Field, the world’s largest natural gas field.

To accommodate a large number of shipping exports, Ras Laffan built the world’s largest artificial harbor. But just 45 minutes to the south sits an equally amazing display of nature: The Al Thakira Mangroves. A boggling forest of mangrove trees, crusted with sea salt, that supports life both above and below the water. Tourists often kayak through this water forest almost unaware of the large industrial centers a few miles away.

Where Cars Go to Die?

Another mysterious find is a scrapyard of over 20,000 vehicles. We’re talking everything from convertibles to cement mixers. Cars live at the Al Wukair Scrapyard for about four or five months while the owner is tracked down. After that, they are put into the compactor and recycled.

This odd state-run junkyard is about 12-miles from the Qatar capital of Doha, but judging by the look of the cars, it may as well be in the middle of nowhere. But in a place with few natural resources (outside of oil and pearls), these scraps are often recycled into usable steel for construction.

Doha and Beyond

You’re not likely to get to Qatar without going through its capital city of Doha. Nearly half the population of the country lives in this modern city. Almost half the year is spent above 100 degrees Fahrenheit (over 38 Celsius), and you’ll find creative ways to keep buildings cool. You’ll find structures built to cast shadows, highly sophisticated (and costly) cooling systems, and using white-colored building materials to reduce heat absorption. When visiting, you’ll see something else unexpected: Blue roads! In an attempt to help cool the city, a road downtown was painted with blue-colored heat reflective paint. It’s an innovative test in hotter climates around the world to see if city temperatures can be lowered, as the world around it gets hotter.

A Journey We’ll Never Forget

If you have the opportunity, Qatar is an amazing place to visit. Atlas Obscura, the internet’s guide to hidden wonders everywhere, has a collection of must-see places if you ever have the opportunity to stop in this tiny, but wealthy, nation.

It’s one of the many places we’ve been fortunate enough to visit and help a customer. To this day, if you drive through Ras Laffan, there’s a 65-foot system that was custom made to help convert gas to liquid in one of the many refineries in the industrial city.

We love creative discoveries like blue roads and hidden mangroves, and nothing excites us more than creative inventions custom-made for our customers worldwide.

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IBC Container Bin Resolutions(+ A Case Study)

December 8, 2020

by kallie Case Studies Featured News NEWS

There’s nothing magic about the date “January 1st.” It will be a Friday, so it has that going for it. But, collectively, we have decided that it’s a day for a new beginning. A day to start resolutions. A commitment to make 2021 better than 2020 (not a high bar to clear, but still).

The real magic day is December 31. For many businesses, that’s the last day to make an investment in your company before the I.R.S. taxes those dollars. And in the spirit of resolutions, Custom Powder is going to help you lose weight, get organized, and be happier in 2021. In addition to the tax advantages, place an order before 2020 runs out and receive a 2% discount on any payments made by year end.

bare foot stepping onto bathroom scale 768

Lose Weight

Provident Nutraceutical—a Division of Ortho Molecular Products realized one of their manufacturing plants could use some extra space and turned to us for ideas. Large, clunky industrial barrels were replaced with IBC Container Bins as a way to “trim down” the space that was being used up. Eric Peterson, Maintenance Supervisor for Provident, says this was done without losing capacity. The IBC Container Bins have “larger capacity, but with a smaller footprint,” says Peterson. “Previously, we were using barrels with double-lined bags…the reusability of the new bins makes things much more efficient with less waste.”

Get Organized

The bins also provided better organization for Provident. Brad Clary, Midwest Sales Executive for Custom Powder, was able to help Provident’s operation run smoother. “We had already developed the EZ-Down machinery, but this was going to be one of the largest drops we’ve designed,” says Clary. “It had to hit its destination, and still stay blended.” Eric Peterson also notes how this helped the operators on Provident’s fill line. “We had an auger system that would feed from the bottom, getting the room quite messy. With the EZ-Down System, it’s all contained and it’s made a huge difference on the cleanliness of the room.”

Be Happier

Provident was also aware that their previous process was presenting ergonomic difficulties. “There’s a certain size hopper on the machine and the operators would have to scoop it full. As the machine runs through the powder, they would have to scoop it to keep it full so the machine would keep running,” said Peterson. “So there was a time-wasting issue here, and with Custom Powder we got to figure out a better way to do this.”

The process, like everything we do, was customized for Provident. Custom Powder’s Brad Clary says, “we had already created solutions for Provident, so we had a bit of a head start. We knew what their processes were, and how they operate, so it was an advantage in helping them with this solution.”

Peterson and his team from Provident were able to come to Custom Powder for the F.A.T. and watch the new process in action before it was ever put in place at their operation. “That was huge,” says Peterson. “The previous exposure we had to it was at the PACK Expo, so to actually see our product go through the system and actually talk to the guys who built it was key.”

(Side note: We’ve gotten pretty darn good at virtual F.A.T.s this year, giving our customers the same experience from thousands of miles away)

When you put it all together, Provident ended up with a custom system that helped them lose weight (and gaining more floor space at their plant), get organized (by finding a cleaner, more efficient way to store their product, and they’re happier (because their operators can save time and use their skills more effectively).