Safety for processes involving critical dusts, sparks & aerosols
Many industrial applications generate dust, sparks, aerosols, or vapors that are flammable, combustible, or explosive. Standard extraction systems are insufficient for such processes – they require systems designed from the outset for fire and explosion protection.
ULMATEC develops fully ATEX-compliant extraction systems, tailored to specific materials, processes, and spatial conditions. From aluminum and magnesium to wood dust, powders, and composites, and even thermal processing, our systems capture and filter critical emissions safely and reliably.
Why ATEX extraction systems are indispensable
As soon as flammable or explosive substances are extracted, the extraction system itself becomes part of the explosion protection concept. Incorrect filter technology, uncontrolled sparks, or missing protective modules can trigger fires or explosions in filter chambers and pipelines.
ULMATEC implements a three-stage protection principle:
Primary explosion protection
The aim is to prevent the formation of an explosive atmosphere. This is achieved, for example, through stable airflows, reduction of critical dust concentrations, controlled material handling, or the use of wet separation or inerting.
Secondary explosion protection
Ignition sources are eliminated here. This includes conductive and grounded system components, ATEX-certified fans, temperature monitoring, potential-free sensors, as well as spark control and automatic spark extinguishing.
Tertiary explosion protection
If an explosion occurs despite all precautions, the damage must be limited. ULMATEC uses pressure-shock resistant housings, rupture discs, backflow preventers, and explosion vents to ensure controlled release of pressure and flame.
ATEX directives and regulations – what requirements apply?
In Europe, two key ATEX directives govern explosion protection, setting binding requirements for manufacturers and operators. Both apply to the planning, design, selection, and operation of explosion-proof extraction systems.
ATEX 2014/34/EU – Equipment category & product requirements
This directive regulates the requirements for equipment, components, and protective systems used in potentially explosive atmospheres. It defines, among other things, equipment groups, equipment categories (1/2/3), zones, markings, testing, and conformity assessment.
For ULMATEC, this means: Every explosion-proof extraction system is designed, tested and delivered with the correct ATEX marking according to the indoor zone (e.g. Zone 20/21).
ATEX 1999/92/EC – Operator obligations & zone classification
This guideline is aimed at companies and describes the measures necessary for safe operation. These include zone classification (0/1/2 and 20/21/22), documentation requirements, the explosion protection document, hazard assessments, and organizational protective measures.
For customers, this means: The system must not only be built in compliance with ATEX standards, but also be integrated into a coordinated operating concept.
Supplementary standards and regulations
In addition to the ATEX directives, other technical standards apply that are relevant for industrial extraction systems – such as EN and ISO standards for design, DGUV regulations for dust and fire hazards, and guidelines for machine and ventilation safety.
ULMATEC combines these requirements into a comprehensive concept to ensure that every system is designed correctly from a technical, legal, and safety perspective.
These guidelines can be found on the official EU website:
https://eur-lex.europa.eu/legal-content/DE/TXT/?uri=CELEX:31999L0092
https://eur-lex.europa.eu/legal-content/DE/TXT/HTML/?uri=CELEX:32014L0034
ATEX zones – where explosive atmospheres can occur
Explosion protection begins with correct zone classification. The following zones are relevant for industrial extraction systems:
Gases / Vapors
- Zone 0 – permanent explosive atmosphere
- Zone 1 – occasionally explosive atmosphere
- Zone 2 – rarely / briefly explosive
dusts
- Zone 20 – permanent explosive dust atmosphere
- Zone 21 – occasional dust clouds
- Zone 22 – Rarely occurring dust clouds
Two areas must be considered independently when dealing with extraction systems:
Indoor area
The atmosphere in the filter room, in the pipeline, or at the separator. It is often located in zone 20 or 21, e.g., in the case of combustible metal dusts or organic dusts.
Outdoor area / Installation environment
Depending on the location, the exterior may be classified as a safe area or a Zone 2/22 zone. ULMATEC consistently separates these considerations and designs the system according to its internal and external requirements.
Device groups and categories
For industrial extraction hardware, ATEX equipment group II is relevant (surface applications).
The device category determines in which zone a component may be used:
- Category 1 → Zone 0 / 20
- Category 2 → Zone 1 / 21
- Category 3 → Zone 2 / 22
ULMATEC classifies fans, filter housings, sensors, controls and accessories so that they can be operated safely in the respective indoor zone.
Materials that require explosion-proof extraction systems
- Aluminum and magnesium dusts
- Organic dusts (wood, flour, textile fibers, food)
- Powders, pigments and additives
- Metal dust with spark formation
- Aerosols and oil mist with ignition potential
- Hybrid mixtures of dust and gas
Typical applications
- Grinding, brushing and polishing of light metals
- CNC processes with flying chips and sparks
- Powder handling, filling, dosing
- Wood, plastics and composite material processing
- Thermal processes, coatings, laser and plasma processes
- Mixing and conveying processes of bulk materials
- Processing of reactive or glowing materials
Overview of ULMATEC ATEX extraction systems
Our explosion-proof systems are designed for maximum safety – technically, structurally, and in terms of control technology. Different designs and protective modules are used depending on the process.
ATEX dry separator
For combustible dusts, powders and material mixtures.
With automatic cleaning, spark and coarse separation, inerting (optional) and temperature and process monitoring.
ATEX wet scrubber
For glowing and reactive dusts such as magnesium or aluminum that produce sparks.
Binds particles in the water bath – filter ignition is structurally impossible.
Explosion-proof compact systems
Space-saving, modular and ideal for individual workstations or machine connections.
Explosion-proof central extraction systems
For high air volumes, multiple detection points and complete production lines.
With pressure relief, explosion protection flaps, backflow preventers and optional heat recovery.
Protection concepts – how ULMATEC makes ATEX systems safe
Each system is equipped according to the specific process, including:
cyclone pre-separators
Removes coarse particles, shavings and sparks before they reach the filter.
Spark detection & spark extinguishing
Sensors detect sparks in the pipeline; automatic extinguishing systems neutralize them immediately.
Extinguishing modules
Water, extinguishing agent containers or inert gases – suitable for the material and process.
Explosion protection valves & backflow preventers
Prevents the spread of pressure and flames into connected pipes and systems.
Explosion pressure relief
Burst discs or flameless pressure relief devices dissipate explosion energy in a controlled manner.
Pressure shock resistant filter housings
Designed for defined explosion pressures, adapted to the respective zone.
Temperature and process monitoring
Continuous monitoring of critical parameters in the filter and pipe area.
Why ULMATEC
ULMATEC develops and manufactures fire- and explosion-proof extraction systems entirely in-house – including ATEX-relevant components, protection modules and control technology.
This means for you:
- Everything from one source
Consulting, engineering, manufacturing, assembly & service – worldwide. - Over 10 million configurable variants
Thanks to our modular system, we can design each system precisely to suit the process, material and hazard scenario. - Solutions for all industries
From metals and plastics to food, chemicals & composites. - Standards-compliant & future-proof
ATEX-compliant, DGUV-compliant, in accordance with the latest guidelines.
Technical solutions for every hazard class
ULMATEC provides solutions for:
- Combustible dusts
- Explosive gas/dust mixtures
- Reactive metal dusts
- Glowing particles
- Spark-intensive processes
- Aerosols and oil mist with ignition potential
Planning and implementation
1. Hazard analysis & zoning
Testing of material, process, airflows and ATEX requirements.
2. Plant concept & dimensioning
Design of filter technology, detection, piping, protection modules and control.
3. Design, Manufacturing & Assembly
In-house production for the highest quality and operational reliability.
4. Commissioning & Documentation
ATEX testing, full documentation and training.
5. Service, Maintenance & Expandability
Long-term support, spare parts and expandability.
FAQ – Frequently Asked Questions about ATEX Extraction Systems
Material properties, particle size, dust concentration, and potential ignition sources are crucial. ATEX certification is mandatory as soon as an explosive atmosphere can develop. ULMATEC conducts a hazard analysis for this purpose.
Yes. ATEX systems have conductive components, grounded systems, pressure-shock resistant enclosures, special fans, spark control, and protective modules. Sensors and controls are also designed to prevent ignition sources.
For reactive metal dusts, wet scrubbers, spark extinguishing systems, backdraft protection devices, and impact-resistant filter housings are frequently combined. Dry scrubbers are only suitable under certain conditions.
The indoor zone of the system is determined by the material being extracted. For example, a filter with an indoor zone of 20 can be installed in an outdoor area without a zoned zone. Components must be certified for indoor use.
In many cases, yes – for example, through spark suppression, backflow prevention devices, inerting, or pressure-resistant filter modules. ULMATEC checks whether retrofitting is technically feasible and complies with standards.