Expert Perspective: Designing Effective Lab Containment Solutions

 

Jesse Coiro, director of business development at Plastic Concepts, Inc., has over 20 years of experience serving the biopharma, pharmaceutical, medical device, and educational markets. He has worked with hundreds of labs to implement engineered control solutions that protect personnel from hazards and advance sustainability goals. Coiro has also played a key role in helping pharmaceutical and healthcare organizations comply with USP <797> and <800> standards, ensuring high levels of safety and quality.

Michael Thompson, founder, owner, and president of Plastic Concepts, Inc., has over 35 years of experience in plastics fabrication, design, and industrial ventilation, particularly in highly corrosive environments. Thompson also specializes in controlled environment and containment design for liquids, powders, and live species studies. 

Q: How is the rise of automation changing containment and safety needs in the lab?

JC: “With automation, containment can be very challenging for the end user. As robotics are introduced, there are always variables to consider as part of the design. Sometimes we’re protecting users from bioaerosols or chemical emissions; other times, we need to provide user and product protection. We also have to consider if connecting to the house exhaust is an option or if we need a fully filtered system. 

Labs often don’t realize until late in the process that their autosamplers or liquid handlers require an enclosure. Even if some filtration is built into these systems, it only considers one safety factor and can’t account for all variables. This is where Plastic Concepts comes in. We take on those complex requirements and design truly customized enclosures. Our engineering team works directly from the client’s specifications to design, deliver, and install a solution that fits their equipment and safety requirements.”

MT: “For us, the key difference is that we’re building an enclosure around the automation, rather than trying to fit the equipment into a pre-existing one. That customization allows for a much better fit, greater flexibility, and smoother interaction between the machines and operators, and of course, an increased level of safety.”

Q: Can you walk us through your design process for enclosures?

MT: “We start by sitting down with the client to gather all the specifications for their process and equipment, including dimensions, access points, and where products are transported into the process. Once we have that information, we begin developing concept ideas and drawings. From there, we’ll make any necessary revisions to make sure everything meets the client’s needs before finalizing pricing and providing a quote.”

JC: “There are so many variables to consider during the design process. It’s not just about the equipment going inside the enclosure, but also how that enclosure will get into the facility. That’s a big piece that can sometimes get overlooked, and if it’s not planned for, it could create some challenging obstacles to work around. Every single detail has to be reviewed, and there are many meetings between our team and the customer before delivery.”

Q: What technologies do you build into containment solutions to support lab workflows?

JC: “There are a number of different technologies we use when designing enclosures. For containment, there are two main approaches: exhausting air through filtration or connecting the system to the facility’s exhaust. The details are critical—what handlings are performed, what chemicals are used, and whether bioaerosols are a concern. These factors determine the technologies we integrate, such as high-efficiency particulate or high-capacity carbon filtration, or both, as well as the sensing technology. In some cases, we need to detect spikes in VOCs, acids, formaldehyde, or particles. We may also need to monitor air flow or integrate controls that communicate with a programmable logic controller, for example, to shut down a robotic arm if an enclosure door is open.”

Q: When selecting materials for enclosures, what factors guide your decision-making?

MT: “Chemical compatibility is an important part of the design process. Clients provide us with a full list of the chemistries used in their process, along with concentrations, temperatures, and other relevant details. We use that information to ensure that every material within the environment is chemical-resistant.”

JC: “When we’re working with pharmaceutical clients, there are often additional material requirements. For example, the enclosure may need to be made from USP Class VI-certified material, which means it won’t leach or contaminate the product. We also comply with fire safety standards, such as FM4910 and NFPA 45, by selecting materials with appropriate fire ratings. 

There’s a lot of variability, and these factors, along with chemical compatibility, guide our material selection.”

Q: How does polypropylene compare to traditional materials when it comes to safety and sustainability?  

JC: “When we think about sustainability, it really comes down to the longevity of the product once it’s installed. Polypropylene is very durable and non-corrosive, so it could last a lifetime in almost any environment. If you can get 20, 30, or even 40 years of use out of a product, that’s inherently more sustainable than materials like metal or wood, which corrode and rot.”

MT: “Another reason polypropylene is used is that it’s a virgin material, which offers process protection and prevents contamination. Other materials can do this as well, such as Teflon, but they’re more expensive. Polypropylene strikes a good balance as a mid-cost material that satisfies sterile requirements.”

Q: What should lab managers know about the regulatory standards that apply to containment solutions?

JC: “For both ductless and ducted containment devices, we comply with the traditional standards of ASHRAE 110, ANSI Z9.5, CSA Z316, as well as NFPA 45. These standards are really about the system’s structure, containment, and, if applicable, the filtrations level of efficiency and allowable exhaust threshold limit value release.

In addition to these standards, there’s also the AFNOR NF X 15-211 standard, which emphasizes the filtration efficiency. This is based on an assessment of the customer’s specific application. The evaluation is performed by trained laboratory technicians who verify that the filters are appropriate for the chemicals being handled.”

MT: “For ducted applications specifically, we comply with the ACGIH Industrial Ventilation recommendations, which outline design parameters for the hood, ductwork, and ventilation system. There are other relevant standards as well, including those Jesse mentioned, and the exact ones we follow depend on the specific process or client requirements.”

Q: How does Plastic Concepts help labs navigate the world of containment and automation?

JC: “We take a very consultative approach. We don’t want to tell customers about ourselves; we want to understand what they do so we can support their workflow. That’s really what differentiates Plastic Concepts. We make a point of understanding each client’s challenges and pain points so we can develop solutions that meet their needs.”

MT: “We work closely with our clients throughout the entire process, which may take anywhere from a few weeks to a few months. We look at every part of their workflow, including pre- and post-operations. Asking these questions early helps us create better-designed equipment that supports their workflows and automation equipment.

We stand behind every design, and our customer service, alongside our design and fabrication capabilities, is our greatest strength. Our customers are what make our company, and they will never be ignored. There are times when on-site changes are needed, or when a product requires cleaning or rework after years of use. Whatever it takes, we make sure our customers can use their equipment with confidence for years to come.”

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