How Entecon Engineered a Fully ATEX-Compliant Powder Transfer System for an Ultra-Low MIE Powder

The Project

This case study demonstrates how a specialised Fertiliser powder manufacturer successfully eliminated severe electrostatic dust explosion hazards by replacing a non-compliant legacy system with fully certified ATEX machinery.

By upgrading to an integrated Entecon Industries FIBC Discharge Station (FDS) and Aero Mechanical Conveyor (AMC) , the facility successfully mitigated risk for a powder highly sensitive to ignition, securing both workplace safety and complete regulatory compliance.

The Design Brief

The Challenge: Managing Low Minimum Ignition Energy (MIE)

The manufacturing facility processes a fine bulk powder with an exceptionally low Minimum Ignition Energy (MIE) of just 6 to 10 mJ . Powder clouds with an MIE under 10 mJ are classified as highly sensitive to ignition. At this threshold, a minor, invisible electrostatic spark—imperceptible to human touch—is enough to trigger a catastrophic dust explosion.

As production requirements evolved, the facility's existing powder handling and bulk bag unloading system was repurposed to handle a product for which it had never been originally designed, creating several critical operational and safety risks.

Complex Risk Zoning: The internal environment of the conveyor experiences continuous, turbulent dust clouds during regular operation, demanding an ATEX Zone 21 (Internal) classification. The external plant environment surrounding the bulk bag station faces occasional dust emissions during bag connections, defining it as ATEX Zone 22 (External) .
The Static Accumulation Hazard: The legacy system relied on ungrounded mechanical components and high-friction internal parts. In an aero-mechanical system—where a wire rope and discs travel at high speeds—frictional contact creates rapid static charging. Without active dissipation, voltage potentials easily exceed the 6 mJ ignition threshold of the product.
Regulatory & Compliance Gaps: Operating non-certified machinery in designated ATEX zones violated corporate safety mandates and stringent local health and safety legislations, risking facility closure, severe regulatory fines, and loss of insurance coverage.

The Solution: A Fully Certified ATEX Powder Handling System

To completely eliminate potential ignition sources, Entecon first carried out a detailed assessment of the powder's ignition characteristics, facility zoning requirements, throughput targets and existing process constraints. Based on this evaluation, Entecon engineered a complete ATEX-compliant powder handling solution.

The project included hazard analysis, ATEX equipment selection, grounding strategy design, equipment integration, commissioning support, and compliance documentation.

1. Entecon FIBC Discharge Station (FDS) — Zone 22 External

The new Entecon FDS handles bulk bag discharging within a dust-tight, sealed docking interface to maintain a clean Zone 22 environment.

Active Grounding Interlocks: To combat the immense static risk associated with bulk bags, the station integrates grounding. This safety feature ensures the operator has safely bonded the Type C conductive bulk bag to the earth before the product can be discharged.
Controlled Product Flow: Integrated pneumatic bag massagers and vibrating plates ensure a smooth, controlled product feed into the conveyor inlet, preventing friction-inducing product blockages.

2. Entecon Aero Mechanical Conveyor (AMC) — Zone 21 Internal

The Entecon AMC moves material at high velocities by displacing air inside a sealed tube assembly. To meet strict ATEX Category 2D (Zone 21) internal requirements, several anti-static safety enhancements were integrated:

Equipotential Bonding: All metal tubular housings, flanges, and structural frames feature robust, certified earth-bonding straps. This guarantees an uninterrupted path-to-ground, keeping static buildup well below the critical 6 mJ mark.
Friction Monitoring: The drive system uses an Atex motor, while secondary sensors monitor rope sprocket speeds to immediately shut down the system in the event of mechanical slip plus a temperature sensor has been added for extra peace of mind.

The benefits to the customer

100% ATEX Compliance: The manufacturing line achieves full alignment with ATEX Zone 21 (Internal) / Zone 22 (External) mandates, successfully clearing external health and safety audits.
Dust-Free, High-Throughput Operation: The fully sealed, tubular construction of the Entecon AMC prevents hazardous dust from escaping into the workforce atmosphere, protecting workers while maintaining a high-capacity transfer rate.
Elimination of unmanaged static discharge risks.
Safe handling of powder with an MIE of just 6-10 mJ.
Successful return to production.
Reliable long-term operation.

Designed & Built by Entecon

Why Entecon Was Selected

Following an unsuccessful investment of more than £1 million in an alternative system supplied by a European manufacturer, the customer required a proven partner with extensive ATEX expertise and a track record in difficult powder handling applications. Having previously operated Entecon equipment successfully for many years, the customer selected Entecon to engineer a reliable long-term solution. Following commissioning, the customer's feedback was simple: “ I wish we had come to you in the first place. ”

"This project demonstrates Entecon Industries' ability to design, manufacture and integrate complete powder handling solutions for challenging ATEX environments. By combining specialist discharge technology, ATEX-certified conveying systems, and advanced static control measures, Entecon enabled the customer to safely handle an extremely ignition-sensitive powder while achieving reliable, high-capacity production."

Entecon Industries Ltd are a leading UK specialists in bulk material and powder handling. Every machine is engineered to order, ensuring optimal performance, safety, and long-term reliability.

For more information about our AMC or FDS machine or any of our other products or services, please contact us. +44 (0) 1276 414540 .