Retrofit and integration question

Can an existing filling line be upgraded for ATEX use?

An upgrade may be possible, but it requires a whole-system review of intended use, ignition sources, components, controls, documentation, location and retained equipment.

Read the answer Discuss a project

Existing automatic filling machine used to explain the scope of an ATEX retrofit review

Direct answer

An existing filling line may be upgradeable for ATEX use, but the project cannot be reduced to replacing a few electrical parts with Ex-marked alternatives. The assembled machinery, mechanical and electrical ignition sources, product path, controls, static, extraction, guards, documentation, intended location, retained modules and workplace assessment all need review. In some cases, a new station or relocation is more practical than conversion.

Begin with the current line evidence and the new intended use. Missing drawings, modified controls or undocumented components can be as important as the visible hardware.

Retrofit evidence

Establish what exists before deciding what can be retained.

Evidence	Questions for the review	Possible outcome
Original declarations, manuals and drawings	What was the intended use, configuration and modification status?	Retain as evidence, update, or rebuild the technical baseline.
Hazardous-area drawing and DSEAR assessment	Where will each existing item be located and what conditions apply?	Retain location, relocate equipment or redesign the boundary.
Electrical, pneumatic and control systems	Which components, functions and energy sources can create or control risk?	Replace, re-engineer, segregate or demonstrate suitability.
Product path and mechanical equipment	Are pumps, bearings, belts, friction points, hoses, valves and nozzles suitable for the intended use?	Modify the process path, add monitoring or replace the module.

Buyer questions

Three questions that expose the real conversion scope.

Can standard parts simply be replaced with Ex-rated parts?

No. Replacing visible electrical parts does not by itself establish the suitability of the complete filling line. The review must include non-electrical ignition sources, static, product release, mechanical changes, wiring, control functions, installation, documentation and the interfaces between retained and new equipment.

Component markings support the technical file, but the assembled intended use and conformity route still need competent engineering assessment.

What existing line information is needed for an ATEX retrofit review?

Provide the machine identification, manuals, declarations, drawings, component lists, control software and backups, modification history, maintenance records, product path, utilities, layout and current risk assessments. Also define the new products, containers, output, cleaning and area classification.

Where evidence is missing, the scope should state how the installed condition will be surveyed and verified. An assumption that an old component is unchanged is not a substitute for inspection.

When is a new filling station more practical than conversion?

A new station may be more practical when the existing design lacks reliable documentation, requires extensive component and control replacement, has unsuitable mechanical arrangements, cannot support the new product path or would leave difficult interface and verification risks. Conversion can also create prolonged downtime or a mixed technical file that is hard to maintain.

Compare both routes against the same intended use, site works, testing, documentation, production disruption and lifecycle inspection needs rather than only the initial machine price.

Retained cappers, labellers and conveyors

Map each item against the zone boundary and process state. Review motors, sensors, drives, friction and static sources, controls, container accumulation, emergency stops and how the module behaves when the filler stops. Equipment outside the zone can still affect the safe sequence.

Upgrade acceptance plan

Approved intended-use and interface specification.
Controlled drawings and component evidence.
Inspection of the installed condition.
Cause-and-effect and protective-function tests.
FAT where reproducible and SAT for site-dependent conditions.
Updated instructions, maintenance and change control.

Use current official equipment and workplace guidance.

Review HSE ATEX equipment guidance, HSE explosive-atmosphere lifecycle guidance and the current GB equipment-regulations guidance.

Tell us what you need to fill — we’ll recommend the most suitable machine.

Send your product SDS, container details, fill range, target output and any ATEX information. You’ll receive a practical shortlist matched to your application.

☎ 01494 623015 ✉ sales@lancinguk.com

Direct support for new machines, line upgrades and complete filling projects.