Unique Manufacturing: Extrusion within an ATEX Setting
Equipment intended for operation in potentially explosive atmospheres presents a unique and highly demanding set of challenges within modern process engineering. In industries where combustible gases, vapors, powders, or dusts may be present during production, ensuring both process performance and operational safety is absolutely critical. To address these requirements, we provide advanced gravimetric feeding systems and extrusion solutions specifically engineered and certified for operation in hazardous environments in accordance with ATEX directives.
By fully adhering to ATEX guidelines and safety standards, our process engineering equipment is designed for safe and reliable use in potentially explosive atmospheres while maintaining the high levels of precision, efficiency, and process control required in demanding industrial applications. Our systems are developed to minimize operational risk while ensuring stable processing conditions for sensitive or complex formulations.
In one particular application, a client approached us with a highly specialized requirement involving the homogeneous incorporation of particulate fillers into a polymer matrix using a twin-screw extrusion process. The application involved exceptionally high process viscosities, specified at a minimum of 10^6 mPa·s, creating substantial technical challenges in terms of material handling, mixing performance, torque stability, and thermal management. In addition to the demanding rheological properties of the material, the production process also presented the possibility of generating an explosive gas atmosphere during operation. As a result, compliance with the stringent ATEX classification II 2G Ex h IIB T4 Gb was mandatory for the complete system.
To satisfy these complex processing and safety requirements, a customized ZE 12 HMI co-rotating twin-screw extruder was specifically engineered and manufactured. The system was equipped with a 12 mm screw diameter optimized for precise small-scale and pilot-scale processing while maintaining excellent mixing efficiency and process stability. The extruder barrel incorporated advanced liquid temperature-control functionality together with integrated sensors for continuous monitoring of barrel temperature, product temperature, and process pressure. This allowed accurate thermal management and enhanced process safety throughout operation.
The extrusion system was further complemented by the ZD 9 FB flat-bottom gravimetric feeder, enabling highly accurate and consistent feeding of powdered materials with bulk densities ranging from 0.25 to 1.6 kg/dm³. The gravimetric feeding technology ensured precise dosing performance and homogeneous incorporation of fillers into the polymer matrix, even under challenging processing conditions.
To maximize operational safety, the entire extrusion and feeding system was controlled remotely through an Ethernet connection to a PC located in a separate control room outside the production area. This configuration reduced operator exposure to hazardous zones while allowing full process monitoring and control capabilities.
If your application requires a specialized or custom-engineered process solution, our in-house development and manufacturing capabilities at our Seon AG facility enable us to deliver highly flexible, application-specific systems while maintaining the highest standards of quality, precision, and compliance. From concept development to final implementation, we work closely with customers to create tailored solutions that meet even the most demanding technical and regulatory requirements. We welcome the opportunity to discuss your unique process challenges and look forward to your inquiries.