Abstract: On July 21, 2008, Employee #1 loaded capsules with a mixture of aluminum, potassium perchlorate, and sulfur. She was using a brush made from camel hair to sweep the excess mixture from the catch bin into a specially designed cup, so the excess mixture could be used again. There was a sudden ignition of the mixture that had fallen into one of the hollow legs of the assembly equipment. A specific ignition source could not be identified, the equipment was properly grounded, and Employee #1 was wearing the appropriate personal protective equipment. Employee #1 was severely burned from her waist upwards. She was hospitalized and died.