The bulk bag unloader system is designed for use in highly contaminant-sensitive process areas handling bulk materials known to generate combustible dusts. A 9.525mm, polycarbonate encasement surrounds the bulk bag unloader to prevent migrant dusts that piggyback on the exterior of bulk bags from becoming airborne and entering the work zone during bag conditioning and bag collapse. The combustible input material is introduced, dust-free, directly to an integrated surge hopper through the closed-cycle dust recovery system that secures and encloses the bag spout within a sealed containment cylinder. The surge hopper is constructed with explosion protection and control features, including: an explosion venting system, calculated on a Kst value of 170 and Pmax of 9.5, to direct and release overpressure to prepared areas. The hopper construction includes reinforced walls and a reinforced cover, and is rated for 4.5 PSI internal pressure.