Food manufacturers in the UK and Ireland face a wide range of safety considerations, from hygiene and product quality to machine guarding and operator welfare. Steve Merritt, Managing Director of European Process Plant Ltd (EPP), shares one area that requires particular attention in bakery environments, the management of combustible dusts.
Flour, sugar, starches and other fine powders are handled daily throughout the baking process. While these materials are essential ingredients, they can also create potentially explosive atmospheres under certain conditions. This is where the EU framework covering equipment and workplace safety, ATEX regulations and DSEAR compliance play a critical role[1].
For bakery operators, understanding ATEX requires a thorough understanding of how dust is generated, where hazardous areas exist and how risks can be controlled throughout the production process.
Why ATEX Matters in Bakery Production
ATEX is the framework used to manage explosive atmospheres in industrial environments. In the UK, these requirements are implemented through the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR)[2], which place a legal responsibility on employers to identify and control risks associated with potentially explosive atmospheres.
A dust explosion occurs when five conditions are present simultaneously: combustible dust, oxygen, dust dispersion in air, confinement and an ignition source. In bakeries, combustible dust is generated during ingredient handling, conveying, mixing, sifting and storage operations. Fine particles can become suspended in the air and accumulate on equipment surfaces, ductwork and building structures. If disturbed and exposed to a suitable ignition source, these dust clouds can ignite rapidly, creating the potential for a dust explosion.
Understanding ATEX Zones
A key part of DSEAR compliance is the classification of hazardous areas according to the likelihood of an explosive atmosphere occurring. For combustible dusts, three classifications apply:
| Zone 20
|
An explosive dust atmosphere is present continuously, frequently or for long periods.Typical examples include flour silos, enclosed conveying systems and certain internal equipment surfaces. |
| Zone 21
|
An explosive dust atmosphere is likely to occur during normal operation.Examples include flour discharge points, ingredient weighing stations, mixers and bulk ingredient transfer areas. |
| Zone 22
|
An explosive dust atmosphere is not expected during normal operation but may occur occasionally and for short durations.This often includes production areas surrounding processing equipment, packaging halls and adjacent walkways. |
Importantly, ATEX zones are determined by dust behaviour rather than physical room boundaries. Changes to equipment layout, production methods or ingredient handling practices can affect classification and should trigger a review of zoning assessments.
Selecting Equipment for ATEX Zones
Once zones have been established, equipment should be selected according to the level of risk present. This means ensuring it is certified for the relevant dust classification, operates below the ignition temperature of the materials being handled, and is designed to prevent dust ingress into critical components such as motors, bearings and electrical enclosures.
Managing Ignition Risks
Potential ignition sources such as static electricity, electrical faults, mechanical friction and hot surfaces must be identified and controlled throughout the production environment.
This may include earthing and bonding equipment, using anti-static materials where required, implementing safe maintenance procedures and ensuring work involving heat or electrical systems is carried out with appropriate controls in place.
Dust Control and Housekeeping
Reducing airborne dust is one of the most effective ways to minimise explosion risk. Measures such as dust extraction, enclosed ingredient handling, sealed transfer systems and industrial vacuum cleaning can help prevent explosive atmospheres from developing.
Good housekeeping is equally important, especially where dust deposits can accumulate on elevated structures, pipework and equipment surfaces, creating the potential for secondary explosions if disturbed. Regular cleaning and ongoing monitoring should form part of any ATEX management strategy.
Need Support with ATEX-Compliant Bakery Equipment?
Whether you’re reviewing a new process line, upgrading existing equipment or assessing ATEX requirements within a bakery environment, EPP can help identify solutions that align with both operational requirements and safety obligations.
To discuss and explore ATEX-compliant equipment for bakery processes, contact the EPP team at sales@eppltd.co.uk or visit https://www.eppltd.co.uk/
[1] https://www.hse.gov.uk/food/safety-hazards/dustexplosion.htm
