ATEX Vacuums for Food Manufacturing: Compliance and Safety in Food Production
Why food manufacturing facilities need ATEX-rated vacuum equipment. In this guide learn about combustible dust risks from flour, sugar, and food ingredients, and how to maintain compliance.
Explosive Atmospheres in Food Production
Food manufacturing handles some of the most common combustible dusts: flour, sugar, starch, milk powder, cocoa, spices, and grain. These everyday ingredients become explosion hazards when dispersed in air at the right concentration.
The history of food industry explosions is sobering. Flour mill explosions have occurred for centuries. Sugar refinery explosions have killed workers and destroyed facilities. Even in modern, well-regulated operations, the fundamental hazard remains—fine food particles plus oxygen plus an ignition source equals potential disaster.
This guide explains the specific dust hazards in food manufacturing, how DSEAR applies to food production facilities, and why ATEX-rated cleaning equipment is essential for safe operations. [LINK: Complete Guide to Combustible Dusts]
Combustible Dust Hazards in Food Production
Food manufacturing involves a remarkable range of combustible materials:
Grain and Flour
Wheat flour, corn starch, rice flour, and other grain products are highly combustible. Flour has a Kst value typically between 50-100 bar·m/s (St 1 class) and can ignite at relatively low energies. Grain handling facilities—silos, elevators, and mills—have the highest historical incident rates in the food industry.
Sugar and Sweeteners
Sugar dust is explosive and burns intensely. The 2008 Imperial Sugar refinery explosion in the United States killed 14 workers and injured 38 others—caused by sugar dust accumulation igniting. Icing sugar, powdered glucose, and other fine sweeteners present similar risks.
Dairy Powders
Milk powder, whey powder, and infant formula are combustible. Spray drying operations, where liquid dairy is converted to powder, create significant dust generation points. The organic content and fine particle size make these materials explosive.
Cocoa and Chocolate
Cocoa powder has relatively high explosibility. Chocolate manufacturing, particularly during ingredient handling and mixing, generates combustible dust. The combination of cocoa with other powdered ingredients creates mixed dust hazards.
Spices and Flavourings
Ground spices, dried herbs, and flavouring powders are combustible. Some spices have very low minimum ignition energies. Spice grinding and blending operations require particular attention.
Other Food Ingredients
Egg powder, gelatine, yeast, dried fruit powders, protein powders, and food additives all present combustible dust hazards. Even coffee and tea dusts are explosive in the right conditions.
Zone Classifications in Food Facilities
Food manufacturing facilities typically have areas classified across multiple zones: [LINK: ATEX Zone Classifications Explained]
Zone 20 areas are usually found inside processing equipment: mixers, blenders, silos, hoppers, and dust collection systems. These enclosed spaces can have explosive dust clouds present frequently during normal operation.
Zone 21 areas commonly include: bag dump stations where ingredients are manually emptied, filling and packaging stations, areas immediately surrounding Zone 20 equipment, and locations where dust is regularly released during normal operations.
Zone 22 areas typically cover: general production floors where dust may accumulate, warehouse and storage areas for powdered ingredients, areas surrounding Zone 21 locations, and anywhere dust layers might be disturbed.
The extent of each zone depends on factors including ventilation, housekeeping standards, and the specific materials handled. A proper DSEAR assessment will determine the classifications for your facility. [LINK: DSEAR Compliance Guide]
Cleaning Challenges in Food Manufacturing
Food production presents unique cleaning challenges that make ATEX vacuum equipment particularly valuable:
Food safety requirements: Food production areas must be kept clean for hygiene as well as explosion safety. Regular, thorough cleaning is essential—but it must be done with equipment that won't create ignition risks.
Dust accumulation: Ingredient handling naturally generates dust. Fine particles settle on equipment, ledges, ducts, and elevated surfaces. This accumulation must be removed regularly to prevent both explosion risks and product contamination.
Equipment complexity: Food processing equipment often has intricate surfaces, crevices, and hard-to-reach areas where dust accumulates. Vacuum cleaning provides the most effective method for thorough cleaning without dispersing dust into the air.
Multiple materials: Many food operations handle various ingredients with different explosion characteristics. Cleaning equipment must be suitable for all materials present.
Continuous operations: Food production often runs extended hours. Cleaning during production requires equipment that can operate safely in active processing areas.
Why ATEX Vacuums Are Essential
Standard vacuum cleaners are dangerous in food manufacturing environments with combustible dust:
Standard motors can spark during normal operation
Static electricity builds up in non-conductive hoses and containers
Motor surfaces can reach temperatures that ignite dust clouds or layers
The act of vacuuming can create explosive dust concentrations inside the equipment
ATEX-rated industrial vacuums address all these risks through protected motors, static-dissipative construction, temperature-controlled surfaces, and certified design for dust-laden atmospheres. [LINK: ATEX vs Standard Industrial Vacuums]
Using standard cleaning equipment in classified zones is a direct breach of DSEAR and creates unacceptable explosion risk.
Selecting ATEX Vacuums for Food Manufacturing
When selecting ATEX vacuum equipment for food production, consider: [LINK: ATEX Vacuum Buying Guide]
Zone rating: Match equipment to your zone classifications. Zone 21 areas require Category 2D equipment; Zone 22 areas require minimum Category 3D equipment.
Dust group: Food dusts are typically Group IIIB (non-conductive) or Group IIIC (conductive, for some additives). Ensure equipment is rated for your materials.
Temperature class: Check the minimum ignition temperature of your dusts. Equipment surface temperature ratings must not exceed these limits.
Capacity and duty cycle: Food production often generates significant dust volumes. Select equipment with appropriate collection capacity and motor rating for continuous or extended use.
Hygiene features: Stainless steel construction, easy-clean surfaces, and appropriate filtration support food safety requirements alongside explosion protection.
ATEX Vacuums for Your Food Facility
CFM North East supplies Nilfisk ATEX industrial vacuums suitable for food manufacturing environments. Our range includes Zone 21 and Zone 22 rated equipment in configurations suited to food production—from portable units for spot cleaning to continuous-duty machines for high-volume applications.
With over 25 years of industrial cleaning equipment experience, we understand the dual demands of explosion safety and food hygiene. We can help you specify equipment that meets both requirements.
