Safety and compliance note
This guide supports commercial scoping only. It is not a substitute for a competent DSEAR assessment, hazardous-area classification, conformity assessment, installation design or legal advice.
1. Why ATEX projects need earlier planning
A hazardous-area filling project depends on both the product and the environment around the line. Flammable liquids, vapour, mists and related products can introduce requirements for the filler, product supply, ventilation, static control, operator devices, non-electrical equipment and downstream machinery.
In Great Britain, workplace risk control is addressed through DSEAR, while equipment intended for potentially explosive atmospheres is subject to the Equipment and Protective Systems Intended for Use in Potentially Explosive Atmospheres Regulations 2016. The machinery must be specified against the site classification and intended use.
2. Build the application brief first
Start with the product SDS and real production conditions. Product name alone does not define the hazard or the filling method.
- Full formulation, concentration, flash point and operating temperature.
- Viscosity, density, foam, particles, conductivity and shear sensitivity.
- Container material, dimensions, neck opening, closure and label.
- Minimum and maximum fill, required tolerance and measurement method.
- Sustained output, batch pattern and changeover frequency.
- Cleaning method, waste handling and product recovery.
3. Provide the hazardous-area classification
The project should state the applicable zone, gas or dust group, temperature class and equipment protection requirements where relevant. It should also identify the physical boundaries of the classified area and whether vapour can reach capping, labelling, conveyors or utilities.
Do not assume that one “ATEX motor” makes a complete filling machine suitable. Electrical and non-electrical ignition sources, hot surfaces, static, friction, impact, bearings, controls and maintenance all need consideration.
4. Select the filling principle
The dosing method must suit the product before hazardous-area modifications are finalised.
- Piston filling: positive displacement for many viscous liquids and pastes.
- Pump filling: gear, diaphragm, peristaltic or other routes for compatible products.
- Flow-meter filling: mass or magnetic-flow routes where product conductivity and properties suit.
- Weigh filling: mass control for larger packs such as jerrycans and drums.
- Fill-to-level: considered where visual fill height matters more than measured volume.
Trials with the real product and containers are especially useful where foam, vapour, stringing, particles or temperature affect cut-off.
5. Plan static control, ventilation and product supply
Grounding and bonding arrangements depend on the containers, transfer system and equipment. Plastic packs can require different controls from conductive metal containers. Product supply tanks, pumps, hoses and pipework are part of the process and should be included in the review.
Ventilation or local exhaust may be a facility responsibility, a machine interface or a combined scope. The boundaries must be explicit before manufacture.
6. Review the whole packaging line
A fast filler can still create an unreliable line if bottle presentation, capping, labelling or discharge cannot keep pace. For hazardous products, the line hand-offs also affect vapour release, static, operator access and emergency-stop architecture.
- Bottle unscrambling, rinsing and infeed.
- Filling, drip control and rejected-container handling.
- Cap feeding, torque, crimping or lid pressing.
- Labelling, coding and inspection.
- Conveying, accumulation, packing and pallet preparation.
7. Define documentation and acceptance
The quotation should make the conformity scope, supplied documentation and site responsibilities clear. Agree the equipment schedule, drawings, manuals, certificates where applicable, declarations, FAT protocol, installation checks, SAT, operator training and maintenance requirements.
8. Plan maintenance and lifecycle support
Hazardous-area equipment needs inspection and maintenance consistent with the protection concept and manufacturer instructions. Agree critical spares, competent maintenance requirements, change-part control and how future modifications will be reviewed.