The importance of ATEX risk analysis and the Lawer approach

ATEX risk analysis is a fundamental step in the design of industrial systems intended for handling potentially explosive dusts. In such environments, safety is not only a regulatory requirement but a core design principle that guides every engineering, construction, and application choice.

Dosing and storage operations involving combustible dusts inherently create potentially explosive atmospheres, classified into ATEX Zones 20, 21, and 22 depending on the frequency and duration of their presence. The primary objective is to prevent the simultaneous occurrence of the three elements of the explosion triangle: fuel (dust), oxidizer (oxygen), and ignition source. Since dust and oxygen are unavoidable in most industrial processes, the design approach focuses on eliminating or controlling potential ignition sources.

Lawer’s experience enables a structured and effective ATEX risk analysis process for each new project or customization. This process is activated whenever a new component, material, or system configuration is introduced and is based on strict compliance with relevant technical standards, taking into account the process, material characteristics, and destination country. The analysis involves specialized internal safety and engineering teams and, when required, accredited third-party bodies for validation. This ensures both regulatory compliance and high levels of system reliability and safety.

A key aspect of ATEX risk management is the identification and mitigation of ignition sources. In automatic dosing systems, these may originate from mechanical phenomena such as hot surfaces or friction sparks, as well as from electrical components. Particular attention is given to electrostatic discharges, which are among the few ignition sources that cannot be completely eliminated. In these cases, mitigation strategies include grounding and electrical continuity, combined with careful evaluation of the minimum ignition energy of the handled dusts. This ensures operation below critical thresholds, preventing potential ignition events.

From a design perspective, ATEX compliance is achieved through specific engineering choices. The use of conductive or antistatic materials, control of relative mechanical speeds, limitation of installed power, and implementation of sealing and isolation systems are key measures to reduce ignition risks. Additional solutions include ensuring electrical continuity, selecting compatible materials to prevent sparking, and implementing control systems that maintain safe operating conditions. All components, whether electrical or mechanical, must be properly certified and marked for use in classified zones.

The selection of electrical and electronic components follows the same principle: each element is chosen according to the ATEX classification of the installation environment. Components are sourced as certified products compliant with European ATEX directives or, for non-EU markets, equivalent standards such as Hazardous Locations (HAZ-LOC). This ensures full system compliance and safe operation in hazardous environments.

The customer also plays a crucial role in the ATEX risk analysis process by providing essential information about the handled dusts — particularly minimum ignition energy and explosion parameters — as well as the installation layout. When such data is incomplete, Lawer defines clear operational limits during the contractual phase to ensure safe working conditions. This approach also supports the correct sizing of auxiliary systems, such as dust extraction units, which are typically the only areas where explosion limitation may be required.

Compliance is ultimately formalized through the documentation provided with the system. Each installation includes operation and maintenance manuals, declarations of conformity, and documentation related to certified components. The technical file and risk assessment documentation are generally retained internally but can be made available to authorities or upon request. This documentation plays a critical role during inspections and validation processes, ensuring transparency and regulatory compliance.

Lawer’s approach to ATEX goes beyond compliance, adopting a proactive and optimization-driven mindset. Continuous updates on evolving standards and extensive field experience allow the identification of design solutions that maximize safety while optimizing costs and performance. This balance between compliance, innovation, and competitiveness enables Lawer to deliver systems that are not only safe but also efficient and sustainable over time.