Introduction
In industrial settings where release agents are applied, especially by spraying, it is essential to assess both production efficiency and the risks associated with potentially explosive atmospheres (ATEX).
ATEX regulations provide the European framework for the manufacture, installation and use of equipment in explosive atmospheres.
Depending on their formulation, many release agents—particularly solvent based products—can generate flammable vapours during application. The risk increases considerably when these vapours encounter an ignition source, such as uncertified electrical equipment, electrostatic discharge or hot surfaces.
If a flammable liquid has a flash point above the maximum temperature at which it is handled, an explosive atmosphere cannot form (EN 60079-10, Section 4.4.1). In other words, a flammable liquid cannot ignite while its temperature remains below its flash point.
There is, however, a key consideration: if a flammable substance is released as a mist—as happens when a release agent is applied with a spray gun—an explosive atmosphere may form even below its flash point.
The main factors to consider are:
- ATEX zone classification: Determine whether application creates a Zone 0, 1 or 2 area, even temporarily or in a confined location.
- Type of release agent: Where the process allows, prioritise water-based products to reduce the risk.
- Application equipment: Spray guns, pumps and electrical systems must be certified for the applicable equipment category.
- Static electricity control: Grounding, conductive hoses and electrostatic charge control are critical.
- Adequate ventilation: A well-designed extraction system can prevent dangerous concentrations from building up and substantially reduce the risk.
Increasing a product’s flash point may mean that it is no longer classified as flammable (above 62 °C), but it does not make it non-combustible. An ATEX atmosphere may therefore still form when a combustible substance, an oxidiser and an ignition source are present together.
Consequently, the only way to avoid working in ATEX atmospheres is to use a water-based release agent.
ATEX safety should be treated as an integral part of release agent application in industry, rather than merely a documentation requirement. A proper risk assessment protects people and facilities while helping to prevent unplanned shutdowns and legal liability.
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