ATEX and Ex Protection: Handling Technology for Areas at Risk of Explosion
- Zeilhofer HHT
- Jun 26
- 3 min read
In paint shops, the chemical industry, powder handling or battery manufacturing, explosive atmospheres can occur. Anyone lifting and moving loads there needs an ATEX manipulator that does not form an ignition source. This article explains what ATEX means, which zones exist and why the drive determines suitability or unsuitability.
What does ATEX mean?
ATEX stands for the EU directives on explosion protection, derived from the French term ATmosphères EXplosibles. They regulate which equipment may be used in areas where flammable gases, vapors, mists or dusts can form an explosive atmosphere. For operators the rule is: in designated Ex areas, only tested and marked equipment may be used.
This also applies to lifting aids and manipulators. A system that runs without problems in a normal production area is not automatically approved for use in an Ex area. The requirements must be incorporated into the design from the outset.
Ex zones: where is which protection needed?
Areas at risk of explosion are divided into zones, depending on how frequently and how long a hazardous atmosphere occurs:
Zones 0, 1, 2: for gases, vapors and mists, from permanently present (0) to rare and short-term (2).
Zones 20, 21, 22: for combustible dusts, analogously from permanent (20) to rare (22).
The lower the number, the more frequently an explosive atmosphere is to be expected and the stricter the requirements for the equipment used. Which zone applies is determined by the operator in the explosion protection document. From this it follows which equipment category a lifting aid must meet.
ATEX manipulator: why the drive determines suitability
The decisive factor in the Ex area is avoiding ignition sources such as sparks, hot surfaces or electrostatic discharge. Here the drive plays the main role. A pneumatically operated ATEX manipulator works without electrical drive energy at the load and is therefore fundamentally well suited for use in areas at risk of explosion, provided all components are designed and grounded accordingly.
Which strengths pneumatic and electric drives each have is explained in the guide Pneumatic or electric drive. Fundamentals on the systems are provided by the guide to lifting aids. What always matters is the overall view: grippers, sensors and grounding must also fit the Ex protection concept.
Typical industries with Ex requirements
Explosion protection is relevant in, among others, painting and coating technology, the chemical and pharmaceutical industry, the handling of powdered substances, and increasingly in battery and cell manufacturing. How handling technology works in sensitive environments is shown in the articles on cleanroom and pharma and on battery module handling.
In battery manufacturing in particular, the topic is gaining importance, because both solvent vapors and reactive materials can occur there. Sway-free, process-reliable handling is doubly important here.
What operators should pay attention to
It is crucial to include the Ex requirements in the design early: zone, material properties and required equipment category belong in the first needs analysis. This way the lifting aid is designed appropriately from the start, instead of being retrofitted at great expense later. Zeilhofer Handhabungstechnik engineers every solution individually, is certified to ISO 9001 and works in accordance with TISAX Level 2 with prototype protection.
Frequently asked questions
Are pneumatic manipulators suitable for Ex areas?
Pneumatic manipulators work without electrical drive energy at the load and are therefore fundamentally well suited for areas at risk of explosion, provided all components are designed and grounded accordingly.
What is an Ex zone?
An Ex zone classifies an area according to how frequently an explosive atmosphere occurs. From this it is derived which equipment may be used there.
Who defines the Ex zone?
The operator defines the zones as part of their explosion protection document. The design of the handling technology is based on this.
In which industries is ATEX relevant?
Above all in painting and coating technology, in chemicals and pharmaceuticals, in powder handling, and increasingly in battery and cell manufacturing.
Planning handling in an Ex area?
Do you need an ATEX manipulator for an area at risk of explosion? Our engineers incorporate the Ex requirements from the outset and design your solution individually, Made in Germany, from a single source.
For more depth on individual topics, see our guides on handling technology.
