Coatings Manufacturer Implements ATEX-rated Tugs

A Polish protective woodcare coatings manufacturer selects MasterMover electric tugs converted by Pyroban to ensure complete safety when moving vessels within its potentially explosive operation.

The production of varnishes and wood stains involves working with highly flammable solvents that contain VOCs (volatile organic compounds), creating an environment where even minor sparks or heat from equipment could lead to catastrophic explosions. 

“The flammable vapour from varnishes and woodstains containing highly flammable solvents can be ignited by the heat or sparks found within standard material handling equipment,” says Rob Vesty, Sales Manager, UK and Ireland, for safety company Pyroban.

This risk underscores the need for equipment specifically designed to operate in ATEX zones (Atmospheres Explosibles), as governed by the EU’s stringent ATEX 2014/34/EU directive. The directive mandates robust safety measures for equipment operating in potentially explosive atmospheres, which includes chemical plants, oil refineries, and, in this case, woodcare manufacturing facilities. 

Why electric tugs?

Two electric MasterMover tugs are being used at the facility in Poland to push, pull, and steer loads on castor wheels in areas where solvents are stored and transported in volume. This solution not only enhances safety by reducing manual handling but also boosts efficiency, allowing workers to focus on precision and quality rather than physically manoeuvring difficult loads.

The MasterMover MT400 electric tugs concentrate the load weight directly over the drive wheel making it easy for the operator to manoeuvre. Traction is achieved by a hydraulic weight transfer system giving the operator up to 4,000kg capacity for loads on castors.

Each MT400 electric tug concentrates load weight directly over its drive wheel, enabling operators to easily move loads weighing up to 4,000kg. The hydraulic weight transfer system ensures smooth handling of even the heaviest materials, ideal for moving solvent-laden vessels. 

The Pyroban conversion

Rob explained that "these electric tugs presented many possible ignition sources that needed to be addressed."

Recognising the potential ignition risks, Pyroban adapted the electric tugs to comply with ATEX regulations, ensuring they were safe to use in hazardous zones. The conversion process incorporates system6000E™, a comprehensive safety solution designed specifically for equipment in volatile environments. 

Key features of the ATEX-compliant conversion include: 

• Restricted breathing enclosures: These enclosures prevent flammable vapours from entering electrical components, reducing the risk of ignition. 
• Temperature Control: The system ensures surface temperatures remain below T4 classification (135°C), which is critical given the auto-ignition temperature of many solvents used in woodcare coatings. Should temperatures exceed this threshold, the system triggers an automatic shutdown to prevent overheating. 
• Gas Detection: Equipped with pellistor-based sensors, system6000E continuously monitors for hazardous gas concentrations. Upon detection, the tug halts operation, bringing it to a controlled stop and safeguarding workers and materials. Daily auto-calibration and self-testing reassure operators of the system’s functionality. 

A decade-long partnership

The partnership between MasterMover and Pyroban reflects a decade of successful collaboration, delivering safe, tailored solutions designed by experts for industries operating in explosive atmospheres. 

“We’ve completed an increasing number of projects with Pyroban over the last ten years,” says Hugh Freer, Sales Director of MasterMover.

Service support is provided through the local MasterMover dealer in Poland and technicians are trained to maintain the Pyroban system.

By integrating MasterMover tugs converted by Pyroban, the Polish woodcare coatings manufacturer has set a benchmark for safe, efficient material handling in hazardous environments. This partnership demonstrates the importance of addressing operational risks proactively, leveraging innovative solutions that meet the strictest safety standards.