ATEX Weighing: When is it required and what should you consider?

In many production processes, weighing is a crucial step. Whether it involves filling drums, handling powders, dosing raw materials, or checking incoming goods, accurate weighing directly determines the quality of the final product. However, as soon as this takes place in an environment where flammable vapours, powders, or dust particles are present, the situation changes immediately. A single spark or an excessively high surface temperature can be enough to cause an explosion. This is why ATEX weighing exists: equipment specifically designed to operate safely under such conditions.

Nevertheless, many organisations are still unsure when ATEX is mandatory and which requirements apply to a safe weighing system. In this blog, we explain it clearly and practically, helping you determine which solution best fits your process.

When is ATEX weighing mandatory?

The answer is simpler than many organisations think: ATEX weighing equipment is required as soon as your weighing system is located in an environment that has officially been classified as an ATEX zone. This happens more quickly than many companies expect. As soon as flammable vapours, powders, or dust particles can be released, the location must be assessed for explosion risks. Based on this assessment, the area is classified into a specific zone.

Explosion-hazardous environments are divided into two main groups: gas (G) and dust (D). Within these groups, different zones exist depending on how frequently and for how long an explosive atmosphere may occur. This classification determines which equipment can be used safely and which protection category is required.

The main zones are:

Gas (G):

• Zone 0 – environments where explosive gas mixtures are present continuously or for long periods.

• Zone 1 – situations where, during normal operation, explosive gases are likely to occur.

• Zone 2 – areas where explosive gases occur only infrequently and for short periods.

Dust (D):

• Zone 20 – locations with a continuous or long-term presence of explosive dust clouds.

• Zone 21 – areas where dust may be released during normal operations and can lead to ignition.

• Zone 22 – zones where dust accumulation or dust clouds occur only occasionally.

Each zone corresponds to a specific equipment category. Category 1 is suitable for the most critical situations (Zones 0 and 20), Category 2 for environments where danger occurs regularly (Zones 1 and 21), and Category 3 for areas with a limited risk (Zones 2 and 22). These categories define which safety measures equipment must include, such as intrinsic safety or a flameproof enclosure, and what the maximum permitted surface temperature is.

Why ATEX weighing is necessary in practice

An environment does not need to appear extremely dangerous to be classified as explosion-hazardous. In many processes, flammable vapours, powders, or dust particles are generated without being immediately visible. Examples include solvents evaporating during drum filling, grain dust released when emptying silos, fine powder dosed into a mixer, or vapours formed when transferring chemicals. These are everyday operations that, in combination with an electric weighing scale, can pose a risk.

A standard weighing system can generate heat, cause sparking, or experience internal electrical faults. In an explosive atmosphere, this may be sufficient to trigger ignition. ATEX weighing equipment is therefore designed to remain safe under all conditions. This means components are tested for maximum surface temperature, electronics operate intrinsically safely, and connections are mechanically and electrically protected.

What should you consider when selecting an ATEX weighing system?

An ATEX weighing system is never just about the scale itself. It is always a combination of components that must function safely together within a hazardous area. Tegra supplies, among other things, ATEX-certified indicators, stainless steel bench scales, and platform scales. Depending on your process, zone, and environment, these components must meet specific requirements.

That is why it is important to clearly determine in advance how and where the system will be used. The points below will help you make a safe and appropriate choice.

Zone classification as a starting point
The zone in which the system is installed directly determines which safety measures are required. A correct zone classification is therefore always the basis for selecting the appropriate equipment.

The correct temperature class
ATEX equipment has a maximum permitted surface temperature that must not be exceeded. In environments with flammable vapours or dust, excessive heat can already cause ignition. The temperature class must therefore match the conditions in your zone.

Fully ATEX system or hybrid solution
Not all equipment necessarily needs to be installed within the hazardous area. For example, an ATEX scale can be placed in Zone 1 or 21, while the indicator is located in a safe area. This simplifies the system and can help reduce risks.

Application and operating conditions
Every application has different requirements. A compact bench scale for lightweight components requires different specifications than a large platform scale for industrial processes. Hygiene, cleanability, exposure to moisture, and mechanical loads also play an important role.

Mechanical and electrical safety
Within an ATEX zone, equipment must be designed so that it does not become an ignition source. This includes controlled heat dissipation, safe electronics, and robust enclosures. This applies to both the indicator and the scale itself, ensuring the entire system operates safely within the designated zone.

ATEX solutions from Tegra Systems

On our ATEX page you will find an overview of all the solutions offered by Tegra Systems:
https://tegrasystems.nl/en/products/weighing/atex/

We supply ATEX-certified indicators, stainless steel bench scales, and platform scales in various configurations. These weighing solutions are suitable for use in explosion-hazardous environments and comply with the applicable ATEX zone categories.

In addition, we support you in selecting the right solution for your process and environment. We are also happy to assist with integration into existing production lines, inspection, service, and periodic calibration within ATEX zones.

Conclusion

ATEX weighing is about safety and business continuity. With the right equipment, you reduce risks, minimise downtime, and ensure your process complies with legislation and regulations. By aligning your weighing solution with your zone classification and application, you create a safe, reliable, and efficient working environment.

Would you like to know which ATEX solution best suits your situation? We are happy to help.