Efficient Safety Systems To Keep Food Production Safe And Food Supply Secure

Industrial processes involving dry foodstuffs or animal feed can quickly create an explosive atmosphere by stirring up dust. Dust explosions present a huge risk not only to human life, but also in terms of destroyed equipment and unplanned production downtimes. Efficient safety systems effectively nip dust explosions in the bud or minimise their effects.

The effects of the war in Ukraine and the associated energy crisis continue to be felt across all industries in Europe. Companies that make and process foodstuffs and animal feed face major challenges. Maintaining food security has become a major issue in society. One of the keys to a secure and reliable supply of food is ensuring a continuous production process. 

But the processing or storing of powdered foodstuffs presents a major risk of unplanned production stops. Dust explosions are a pernicious threat with devastating potential due to the massive rise in pressure they create.

Virtually all dry bulk products used in agriculture, such as flours made from grain, pulses and seeds, can form an explosive mixture in the right dust concentration. Other potentially explosive substances include starches, binders, sugars and sweeteners. Even non-powdered materials like feed pellets often create fine, flammable dusts through constant friction.

Critical mixtures of dust and air frequently arise around machines like conveyor systems, mills, dust filters or cyclones, especially if they are operated pneumatically. Excess powder can escape from a bucket elevator and concentrate in the air. The movement means that the dust particles remain airborne much longer than usual.

Alongside flames and glowing embers, dust explosions can also be triggered by hot surfaces, static electricity or sparks generated mechanically or electrically. These are too many risk factors that cannot be completely eliminated. Certified explosion protection in design is therefore essential for process managers looking to safeguard production.

Suppression the key to explosion protection

Active, fast-acting suppression systems nip dust explosions in the bud. They stop the initial spark of any explosion in a fraction of a second, well before the explosive pressure can unleash its full destructive potential. Thus keeping the explosions as small as possible, they allow production to restart quickly.

Those systems use sensors that immediately detect any critical rise in pressure, such as in the head or base of a bucket elevator and then suppress the explosion by spraying an effective, food-safe extinguishing agent directly at the source.

Preventing the spread of an explosion

The same technical operating principle is used to isolate explosions. Applying an extinguishing agent creates a barrier that prevents the flames from spreading to connected systems. Active mechanical systems are also effective: Active isolation valves or pinch valves reliably stop the spread of an explosion.

Pressure relief prevents damage

Conventional pressure relief systems like rupture discs offer reliable basic explosion protection in areas where the escape of flames and burning particles is acceptable. They burst immediately upon reaching the predefined activation pressure. By reacting quickly and instantly creating a large relief opening, they protect systems against the effects of pressure and prevent damage.

So-called flame-free pressure relief systems are a suitable alternative for indoor areas and environments that do not have a sufficiently large safety zone. A multi-layer filter made of stainless steel retains flames and particles while allowing the pressure wave to escape.

Another preventative explosion protection system detects sparks, hot particles, embers or flames in the production flow before extinguishing them automatically and reliably to stop them from igniting an explosion.

Explosion protection in design is vital

Potential sources of ignition for explosions can rarely be entirely prevented. Design-based explosion protection combines excellent safety with long-term economic efficiency, providing a suitable level of protection for personnel and facilities. Operators can therefore also rest assured that they are compliant with the relevant occupational safety regulations.

FAQs: Food Industry Explosion Protection

What causes dust explosions in food production?
Explosive atmospheres form when fine dust from dry products mixes with air and is ignited

Why is explosion protection important?
It prevents production stops equipment damage and risk to life from pressure and fire

Which foodstuffs are hazardous?
Flours starches sugars sweeteners and even feed pellets can form explosive dust clouds

Where do critical dust-air mixtures occur?
Around equipment like mills conveyors dust filters and bucket elevators

What triggers a dust explosion?
Flames static electricity hot surfaces and mechanical or electrical sparks

How do suppression systems work?
They detect pressure rise and release extinguishing agents in milliseconds to stop explosions early

What is explosion isolation?
It stops flames from spreading between connected systems using chemical or mechanical barriers

What is the role of pressure relief systems?
They release pressure safely to prevent structural damage when explosions occur

Are there safe options for indoor environments?
Yes flame-free relief systems retain flames and particles while venting pressure

Why include explosion protection in system design?
It ensures compliance reduces risk and supports reliable and efficient long-term production