Explosion protection in intralogistics
Safely through the hazardous area
No matter whether you work in chemistry, pharmaceuticals, food, logistics or recycling, explosive mixtures of gases, vapors and dust are created in numerous industries. Industrial trucks that are used in these hazardous zones must guarantee comprehensive explosion protection. At the same time, they need to be just as efficient and ergonomic as in any other area of intralogistics.
Explosion protection from Linde Material Handling is geared towards precisely these requirements. Suitable explosion-proof versions are available for numerous counterbalanced trucks, reach trucks, pallet stackers and pallet trucks. They comply with EU regulations (EN 1755) and the ATEX Directive (2014/34/EU). Linde Material Handling can provide the right truck solution tailored to the relevant processes. This means that the material flow can be processed with a high handling capacity and level of ergonomics even in explosion-protected conditions.
The Right Protection for any Potential Hazard
The extent to which there is a risk of explosion in a production area or warehouse depends on two factors: firstly, it is necessary to consider the amount of hazardous material that combines with oxygen to form a flammable compound. Secondly, there needs to be an ignition source, which in certain circumstances triggers an explosion due to sparks or hot surfaces. Due to their electrical and mechanical components, industrial trucks can become an ignition source, which is why special equipment is a mandatory requirement in environments where there is a risk of explosion.
Certified Safety
Linde MH offers certified explosion-protected trucks for all environments where an explosive atmosphere may occur occasionally (Zone 1/21) or only for short periods (Zone 2/22). The specific requirements are stipulated in the ATEX Product Directive (derived from the French term “Atmosphères Explosibles”) depending on the zone type, the explosion group of gases and dusts and according to the temperature class. As an experienced explosion protection partner, Linde MH carries out all the necessary certifications and conducts extensive quality checks on the trucks. Alongside the individual assemblies, Linde MH also certifies the entire truck for Zone 1 and Zone 21.
Explosion Protection from A to Z
Linde MH offers explosion-protected versions for a large selection of its series trucks for various ATEX zones, specifically tailored to the requirements of different industries.
Explosion-Protected Solutions from Linde MH for Relevant Industries
Chemistry, Pharmaceuticals and Cosmetics
In addition to warehouse and transport movements, in the production departments of the chemical and pharmaceutical industry, liquids and solid materials are decanted, mixed and refined. Linde MH provides the right trucks to meet the specific requirements of these process steps. For example, the drum cradle helps to decant a liquid such as isopropanol safely and precisely. Using a remote control, the operator can control the tipping process with an optimum view of the drum, for example from a bridge. The quantity is measured by an integrated scale.
Food and Drinks
Explosive gas or dust mixtures can be generated in food and drinks production. For example, highly flammable vapors may form due to evaporation during distillation and storage in wooden barrels. When transporting barrels, there is the additional complicating factor of the driver having a restricted view. Fortunately, Linde MH offers comprehensive safety features for ATEX-compliant environments, ranging from the Reverse Assist Camera and red warning lines to Linde BlueSpot and the Linde Safety Guard assistance system, which automatically reduces speed in response to approaching trucks.
Logistics
Hazardous substances are stored and transported throughout the entire production process: from the storage of raw materials, the transport for further processing right though to transport and storage of the finished products. These logistical processes take place in the production plants, but substances are increasingly also being stored in external warehouses by logistics service providers. In this area, a high turnaround is just as important as safety. In addition to electric forklift trucks, Linde MH offers reach trucks and very narrow aisle trucks for fast and efficient storage and retrieval in ATEX zones 2/22.
Recycling and the Military
Hazardous substances are decanted, drums are emptied and containers are transported during disposal and recycling. Linde MH’s E25 – E35 electric forklift trucks ensure safe and ergonomic handling in these applications. ATEX-certified attachments such as drum clamps help with the disposal process. Military uses of industrial trucks frequently involve the transport of explosive materials or the disposal of ammunition. Linde MH’s explosion-protected trucks provide a safe foundation for this sector.
Complete Explosion Protection from a Single Source
Linde MH believes that users should be able to get all products and services from a single source. This applies in particular for the knowledge-intensive area of explosion protection. Linde MH offers comprehensive explosion protection packages that meet all legal requirements. Even after delivery, Linde MH is on hand to assist with an extensive service network. Service technicians trained according to international explosion protection regulations ensure that the truck is ready for operation at all times. As with the provision of spare series parts, service partners worldwide also provide spare parts for explosion-proof trucks from a supply which is available 24/7.
Series Level Explosion Protection
Linde MH’s explosion-protected trucks combine the proven advantages of series-produced trucks with precisely tailored explosion protection measures. Electrical components such as the motor, control, sensors, switches or displays are protected using various ignition protection measures.
The mechanics are also fully protected. Spark formation is consistently avoided on prongs, brakes and hydraulics. Plastic components, such as foot mats and tires, are protected against electrostatic charges. In addition, temperature monitoring ensures that the temperatures remain below the maximum limit even when the truck is fully loaded.
Innovative Technologies with Explosion Protection
Implementing new features and assistance systems on explosion-protected trucks is far from straightforward; instead, they need to be adapted to comply with the relevant standards and regulations. Thanks to the close collaboration between the Linde MH standard and explosion protection development teams, innovative assistance systems, safety features, and special equipment are made available for use in ATEX zones in the shortest possible time. This means that fleet operators are able to offer their drivers the same level of operating comfort and safety for standard and explosion-proof trucks. This uniform level of equipment helps to comprehensively avoid accidents.
Examples of Safety Solutions in the ATEX Area
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Linde Reverse and Front Assist Camera
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Linde Safety Guard
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Linde BlueSpot
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Red Warning Lines
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myLinde Fleet Management
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Pre-Operational Check on the Truck Display
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Ex-Monitoring App
Linde Reverse and Front Assist Camera
The Linde Reverse Assist Camera uses artificial intelligence to reliably detect pedestrians and is fully integrated into the truck’s display. It gives the driver multi-stage visual and audible hazard warnings when reversing and can reduce the truck’s speed automatically if required. The system is available with all the standard benefits of the new generation of counterbalanced forklift trucks for ATEX zones 1/21 and 2/22, including a Front Assist Camera. It can also be combined with the Linde Safety Guard.
In addition to the Reverse Assist Camera, other camera systems are available for use in explosion-risk zones. For reach trucks, cameras on the mast, the overhead guard, or the forks assist the operator in limited visibility and enable precise load handling, for example.
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Linde Safety Guard
The assistance system detects hazards and automatically adjusts the speed of the trucks involved. A reduced speed can also be stipulated for a particular ATEX zone or an entire Zone 2/22 hall. The Safety Guard also allows for access restrictions for ATEX zones. Drivers of non-ATEX trucks are made aware of the ATEX area by a creep speed function and visual signals.
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Linde BlueSpot
The Linde BlueSpot is mounted on the truck roof in a pressure-resistant housing that is approved for all ATEX zones. The blue light spot projected onto the floor warns pedestrians and other forklift drivers when trucks are approaching.
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Red Warning Lines
Red warning lines projected onto the floor give pedestrians a clear visual signal to keep a sufficient distance from the forklift truck. The lights are available for ATEX zones 1/21 and 2/22.
myLinde Fleet Management
The myLinde fleet management system enables reliable access control and in-depth utilization analysis, including in potentially explosive atmospheres. All hardware components required for myLinde are available as explosion-protected versions with pressure-resistant enclosures. These include the data transmission unit, the RFID scanner, the numeric access control keypad, and the shock sensor.
Find out morePre-Operational Check on the Truck Display
The pre-operation check for electric counterbalanced forklifts allows you to inspect the truck’s condition directly on the explosion-protected display before starting a shift or workday. A separate terminal is no longer required. With up to 50 safety criteria, the scope of the inspection can be customized to meet specific operational requirements. The driver can only start the truck once the check has been successfully completed. If critical issues like truck damage are detected, fleet managers are automatically notified so they can immediately arrange for repairs and maintenance.
Ex-Monitoring App
High truck availability is particularly important in explosion-protection areas, as these trucks cannot be replaced with standard models. The Ex-Monitoring app helps prevent downtime as much as possible by providing comprehensive real-time condition and wear monitoring. Drivers receive targeted alerts in the event of malfunctions, and the system provides predictive maintenance alerts to help prevent downtime.
Staying Safe in the ATEX Zone: The Linde Safety Guard in Use
Hazardous areas in one of our explosion-protected zones have been effectively mitigated using the new explosion-protected version of the Linde Safety Guard. Pedestrians are warned in advance by flashing lights when forklifts are operating in these hazardous areas. The forklift’s speed is reduced fully automatically and with pinpoint precision. Once the truck leaves the hazardous area, its speed automatically increases again. We are all very satisfied with the Linde Safety Guard
Ralf Froitzheim, Asset Management, BASF Personal Care and Nutrition GmbH, Düsseldorf
Simple and Precise Drum Handling
Drum handling is one of the most common applications for explosion-proof pallet stackers. Linde Material Handling offers both a manual and a remote-control solution for the safe handling of drums. Both versions are available for ATEX zones 1/21 and 2/22.
Advantages at a glance
FAQ—Frequently Asked Questions about Explosion-Protected Trucks
Are there any explosion-protected camera systems available for industrial trucks?
Yes, Linde Material Handling offers specially designed explosion-protected camera systems for use in potentially explosive atmospheres that are fully compatible with our explosion-protected forklifts. They play a key role in ensuring safety, for example when reversing in Zone 1/21, maneuvering in narrow aisles, or operating in hazardous materials storage areas. The cameras significantly improve the driver’s view and thus reduce the risk of accidents, particularly in areas with limited visibility. There are solutions available for both forward and reverse travel, as well as cameras that provide a better view when storing materials. The entire product range is also available for use in Zone 2/22.
Are there explosion-protected electric forklift trucks available?
Yes, Linde Material Handling offers a wide range of specially designed electric forklift trucks for use in potentially explosive atmospheres. These trucks are designed for ATEX zones 1/21 and 2/22 and combine the advantages of zero-emission power units with comprehensive explosion protection. Explosion-protected electric forklift trucks are most commonly used in the chemical, food, and beverage industries. They are also suitable for applications in the recycling and military sectors.
Are there ATEX-certified reach trucks available?
Yes, Linde Material Handling offers ATEX-certified reach trucks for logistics areas with a risk of explosion. The product range includes models for all relevant zones, from typical warehouse operations in Zone 2/22 to short-distance transport from production to the warehouse in Zone 1/21. This enables goods to be stored and retrieved quickly and efficiently, even under demanding safety conditions. The reach trucks are equipped with safety measures in accordance with the ATEX directive, combining high safety standards with impressive performance.
Are there pallet trucks available in an ATEX-compliant version?
Linde Material Handling’s product range includes a variety of explosion-protected pallet trucks for use in potentially explosive atmospheres. They range from manual to electric models, including pallet trucks (both walk-behind and platform models), pallet stackers, and special pallet stackers designed for picking up and tipping drums. This means that there is a suitable truck for every requirement, whether in the chemical and pharmaceutical sectors or in the paint and coatings industry. All models meet the highest safety standards and ensure reliable operation in ATEX environments.
No matter whether you already have experience of your hazardous zones and the requirements, or whether you are still on the look-out for suitable solutions and the right advice. We’re happy to help you on the path to greater safety.
