Explosion protection in intralogistics
Safely through the danger zone
Whether in the chemical, pharmaceutical, food, logistics, or recycling industries, explosive mixtures of gases, vapors, and dusts are generated in numerous sectors. Industrial trucks used in such hazardous areas must provide comprehensive explosion protection. At the same time, they must be just as efficient and ergonomic as in any other intralogistics environment.
Linde Material Handling’s explosion-proof solutions are specifically designed to meet these requirements. Suitable explosion-proof versions are available for a wide range of counterbalanced forklifts, reach trucks, pallet trucks, and pallet stackers. They comply with EU regulations (EN 1755) and the ATEX Directive (2014/34/EU). Linde Material Handling offers the right vehicle solution tailored to each specific process. This ensures that material flow can be handled with high throughput and ergonomic efficiency, even in explosion-protected environments.
The right protection for every potential hazard
The explosion hazard level in a production area or warehouse depends on two factors: First, the quantity of hazardous material that can combine with oxygen to form a flammable mixture must be taken into account. On the other hand, an ignition source is required, which can trigger an explosion under certain conditions through sparks or hot surfaces. Industrial trucks can become an ignition source due to their electrical and mechanical components, which is why special equipment is absolutely essential in potentially explosive environments.
Certified Safety
Linde MH offers certified explosion-proof vehicles for all environments where an explosive atmosphere may occur occasionally (Zone 1/21) or for short periods (Zone 2/22). The specific requirements are defined in the ATEX Product Directive (derived from the French “Atmosphères Explosibles”) based on the zone type, the explosion group of gases and dusts, and the temperature class. As an experienced explosion-proof partner, Linde MH handles all necessary certifications and conducts extensive quality controls on the vehicles. In addition, for Zone 1 and Zone 21, Linde MH certifies not only the individual components but also the entire vehicle.
Explosion Protection from A to Z
Tailored to the specific requirements of various industries, Linde MH offers a wide selection of its standard models as explosion-proof vehicles for various ATEX zones.
Explosion-proof solutions from Linde MH for relevant industries
Chemicals, Pharmaceuticals, and Cosmetics
In addition to warehousing and transport operations, liquids and solids are transferred, mixed, and processed in the production areas of the chemical and pharmaceutical industries. Linde MH provides the right vehicles to meet the specific requirements of these process steps. For example, the drum tipper helps to safely and precisely fill a liquid such as isopropanol. Using a remote control, the operator can control the tipping process while maintaining an optimal view of the drum, for instance from a bridge. An integrated scale measures the quantity.
Food and Beverages
Explosive gas or dust mixtures can form in food and beverage production. For example, highly flammable vapors can form through evaporation during distillation and storage in wooden barrels. When transporting barrels, the driver’s limited visibility adds to the challenge. 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 automatic speed reduction when vehicles approach, all via the Linde Safety Guard assistance system.
Logistics
Hazardous materials are stored and transported throughout the entire manufacturing process: from the storage of raw materials and their transport for further processing to the transport and storage of finished products. These logistics operations take place at production facilities, though storage is increasingly being handled in external warehouses by logistics service providers. In addition to safety, high handling capacity is also a key consideration here. In addition to electric forklifts, Linde MH offers reach trucks and narrow-aisle forklifts for fast and efficient storage and retrieval in ATEX Zones 2/22.
Recycling and the Military
During disposal and reprocessing, hazardous materials are also transferred, drums are emptied, and containers are transported. Linde MH’s E25 – E35 electric forklifts ensure safe and ergonomic handling in these operations. ATEX-certified attachments, such as drum clamps, support the disposal process. Military applications of industrial trucks often involve the transport of explosives or ammunition disposal. Linde MH’s explosion-protected vehicles provide a safe foundation for this sector.
Comprehensive explosion protection from a single source
A core principle of Linde MH is that users receive all products and services from a single source. This is particularly true in the knowledge-intensive field of explosion protection. Linde MH offers comprehensive explosion protection packages that ensure compliance with all legal requirements. Even after delivery, Linde MH remains available through a broad service network. Service technicians trained in accordance with international explosion protection regulations ensure that the vehicle is ready for operation at all times. Similar to the supply of standard replacement parts, service partners also have access to replacement parts for explosion-protected vehicles via a 24/7 global supply chain.
Explosion protection at the production level
Linde MH's explosion-protected vehicles combine the proven advantages of standard models with precisely tailored explosion protection measures. Electrical components such as the motor, control system, sensors, switches, and displays are protected by various types of ignition protection.
The mechanical components are also fully protected. Sparking is consistently prevented in the forks, brakes, and hydraulic system. Plastic components, such as floor mats and tires, are protected against electrostatic charging. In addition, temperature monitoring ensures that temperatures remain below the maximum limit even under full load.
Innovative technologies with explosion protection
New functions and assistance systems cannot simply be carried over to explosion-protected vehicles; instead, they must be structurally adapted to comply with the relevant standards and regulations. Thanks to close collaboration between Linde MH’s standard and explosion-protected vehicle development teams, innovative assistance systems, safety features, and optional equipment are made available for use in ATEX zones in the shortest possible time. This allows fleet operators to offer their drivers the same level of operating comfort and safety in both standard and explosion-protected vehicles. This consistent level of equipment helps to comprehensively prevent accidents.
Examples of safety solutions for ATEX applications
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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 Vehicle Display
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Ex Monitoring App
Linde Reverse and Front Assist Camera
The Linde Reverse Assist Camera uses artificial intelligence to provide reliable pedestrian detection and is fully integrated into the vehicle display. It alerts the driver to hazards while reversing through a multi-stage visual and audible warning system and can optionally reduce the driving speed automatically. The system is available with all standard features for new-generation counterbalanced forklifts in ATEX Zones 1/21 and 2/22—including as a Front Assist Camera for the front of the vehicle. 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 hazardous areas. For reach trucks, for example, cameras mounted on the mast, the overhead guard, or the forks assist the operator in situations where visibility is limited and enable precise loading and unloading.
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Linde Safety Guard
The assistance system detects hazards and automatically adjusts the speed of the vehicles involved. A reduced speed can also be set for a specific ATEX area or an entire Zone 2/22 facility. In addition, Safety Guard enables access restrictions for ATEX zones. Drivers of non-ATEX vehicles are alerted to the ATEX area via a crawl speed setting and visual signals.
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Linde BlueSpot
The Linde BlueSpot is mounted on the vehicle roof in a pressure-resistant housing that is approved for all ATEX zones. The blue light projected onto the ground warns pedestrians and other forklift operators of approaching vehicles.
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Red Warning Lines
Red warning lines projected onto the floor provide pedestrians with a clear visual signal to maintain a safe distance from the forklift. 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 comprehensive usage analysis even in potentially explosive atmospheres. All hardware components required for myLinde are available in explosion-proof versions with pressure-resistant enclosures. These include the data transmission unit, the RFID scanner, the numeric keypad for access control, and the shock sensor.
Learn morePre-Operational Check on the Vehicle Display
The pre-operation check for electric counterbalanced forklifts allows operators to inspect the vehicle’s condition before the start of a shift or workday directly on the explosion-proof display. 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 vehicle once the check has been successfully completed. In the event of critical findings, such as vehicle damage, fleet managers are automatically notified so they can immediately arrange for repairs and service.
Ex Monitoring App
High vehicle availability is particularly important in hazardous areas, as these vehicles cannot be replaced with standard equipment. The Ex Monitoring App helps prevent breakdowns 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 avoid downtime.
Staying safe in the ATEX zone: The Linde Safety Guard in action
Hazardous areas in one of our explosion-protected zones have been effectively mitigated using the new explosion-proof 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 forklift 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-protected high-lift trucks. Linde Material Handling offers both manual and remote-controlled solutions for the safe handling of drums. Both versions are available for ATEX Zones 1/21 and 2/22.
Your benefits at a glance
FAQ - Frequently Asked Questions About Explosion-Proof Vehicles
Are there explosion-proof camera systems for industrial trucks?
Yes, for use in potentially explosive atmospheres, Linde Material Handling offers special explosion-proof camera systems that are fully compatible with explosion-proof forklifts. They play a key role in ensuring safety, for example when reversing in Zone 1/21, maneuvering in narrow aisles, or handling materials in hazardous-material storage areas.Especially in conditions of limited visibility, the cameras significantly improve visibility and thus reduce the risk of accidents. Solutions are available for both forward and reverse driving, as well as cameras that provide better visibility during storage operations. The entire range is also available for use in Zone 2/22.
Are there explosion-proof electric forklifts?
Yes, Linde Material Handling offers a wide range of specially designed electric forklifts for use in potentially explosive atmospheres. These vehicles are designed for ATEX Zones 1/21 and 2/22 and combine the advantages of zero-emission drives with comprehensive explosion protection. Explosion-protected electric forklifts 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 any pallet trucks available in an ATEX-compliant version?
Linde Material Handling’s product range includes a variety of explosion-proof 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 ensures that there is a suitable vehicle 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.
Whether you already have experience with your hazard zones and the associated requirements, or whether you’re still looking for the right solutions and expert advice, we’re here to help you on your journey toward greater safety.
