To provide a process for production of pyrotechnic or explosive device containing encased hazardous solid material.

The material is dispersed in an inert liquid, the dispersion is formed into droplets which are solidified in a cooling medium. The solidified droplets are loaded into a casing and freeze-dries in the casing to produce dry particles of a hazardous material, which may optionally be pressed within the casing, advantageously under vacuum. Only the operation (if any) subsequent to the freezing-drying need special precautions to be taken to prevent damage to personnel or equipment. The invention is advantageous for the preparation of detonators, igniters and other devices containing hazardous materials for example lead azide, lead styphnate, pentaerythritol tetranitrate and boron/ potassium nitrate mixture.