Understanding and Preventing Explosions in Pharmaceutical Industry

Dust explosion is when a fine powders become airborne and reach a critical concentration, they can ignite with devastating force—especially in enclosed spaces like dryers or mills.

Solvent or vapor explosions are alcohol-based solvents used in granulation or cleaning can evaporate and form flammable vapors. Without proper ventilation, these vapors can ignite from a spark or hot surface.

Static electricity, friction from moving parts, electrical faults, and even improperly maintained equipment can act as ignition triggers. These risks are especially high in areas where combustible materials are present.

Where do these hazards occur?

• Dryers and mills: prone to dust accumulation and heat generation
• Mixers and granulators: often involve solvents and mechanical friction
• Storage areas and warehouses: where vapors may build up without active ventilation
• Packaging zones: where static discharge can occur due to material handling

Based on the above, it is clear that the use of protective equipment certified according to the main international standards for hazardous areas can make the real difference.

But from research labs to full-scale production facilities, every plant has its own unique operational challenges. That’s why standard solutions simply may not cut it.

BARTEC solution for pharmaceutical industry and the prevention of pharma explosions by Robert Kancar, Business Development Manager, BARTEC ESS

BARTEC is the best-in-class supplier for engineered and customized explosion-proof solutions, designed to meet the highest international safety standards.

Our strength lies in delivering tailored systems that align perfectly with your plant’s layout, processes, and risk profile—because when it comes to safety, precision makes all the difference.

Backed by a complete and integrated supply chain, we support every step of the process—from design and engineering to manufacturing and delivery—ensuring that each solution is built to specification, on time, and ready to perform in the pharmaceutical environment.

Find below BARTEC solutions for pharmaceutical environments.

In pharmaceutical manufacturing, any downtime or loss of precision can have serious consequences, many of its processes require applications for around-the-clock operation. Our POLARIS Smart HMI PC panels are engineered for 24/7 operation, ensuring reliable plant control and data acquisition in cleanroom settings. Equipped with the Intel® Atom x6425RE quad-core CPU at up to 3 GHz, 16 GB RAM, it is engineered for seamless, high-performance visualizations that fully satisfies this need.

Thanks to a toolkit with interchangeable elements the modular system offers customizable configurations, from compact 7" displays to 24" widescreens, adapting seamlessly to operator needs and providing first-class devices and solutions for all tasks relating to process visualization.

With stainless steel enclosures in a hygienic brushed finish, the Smart HMI Series integrates effortlessly into GMP-compliant cleanrooms.

BARTEC offers cutting-edge Bus technology for hazardous locations. Infrastructure and simple, modular extensions to existing (remote I/O) systems are becoming increasingly important, even in explosive areas. With the compact design of MODEX (Bus interface and I/O in one module), signals can be easily integrated into the existing control system or used as a data collector for edge-to-cloud applications. Our MODEX solution provides simple and robust applications with fast signal processing for the most challenging enviroments.The MODEX Bus modules guarantee to conduct standard Bus systems from safe areas to hazardous. The wide variety of our MODEX modules enable flexible solutions suitable for a large number of applications.

Ex p pressurization is the ideal solution for a large number of applications, like cleanrooms, mixing & blending stations, sterilization units. This technology allows standard devices to be flexibly and efficiently converted for use in Ex areas (Zones 1, 2, 21, and 22). BARTEC’s portfolio in the field of pressurized equipment helps to create complex electrical solutions for potentially explosive atmospheres. The BARTEC designed Ex p control and switchgear panel can boast on its high vertical integration, i.e. the use of proprietary Ex components and assemblies. When dealing with pressurized enclosures, in particular, the advantage is to have all the in-house components installed in the enclosure, such as ComEx elements and POLARIS operating and display units. In this regard, BARTEC can provide the following solutions:

• Automation solutions
• Control and monitoring systems
• Visualizations
• Process water analyzers

When it is necessary to provide products with type plates, batch markings or logistics labels, our Ex-p printer solutions are the right answer to optimize the process flow in hazardous areas. Due to operational requirements and constraints, many of the possible Ex protection concepts are not suitable. Compliant to ATEX / IECEx Zone 1/21 or Zone 2/22, our BARTEC printer is protected by the Ex-pressurization protection type, which provides the most flexible and cost-effective solution.

When it comes to designing systems for hazardous areas, complexity and compliance can quickly become overwhelming. That’s where BARTEC Ex p control units make a real difference—streamlining design, accelerating approval processes, and improving both delivery accuracy and long-term reliability. Different units are available in for zone 1/21 or zone 2/22 and globally certified in Ex p technology pxb, pyb and pzc.

In pharmaceutical manufacturing, where hazardous atmospheres and strict safety standards prevail, ATEX and IECEx-certified LED lighting fixtures offer a reliable and compliant solution. Their compact size makes them ideal for cleanrooms and confined process areas, while directional light emission ensures focused illumination where precision is critical. LEDs also emit minimal heat, reducing the risk of igniting flammable vapors or dust—a key advantage in explosion-prone zones. With enhanced efficiency, durability, and low maintenance requirements, these luminaires support continuous operations and lower energy costs. Additionally, their superior color rendering improves visibility for operators.

BARTEC provides a complete range of control & switchgear systems for pharma industry managing power distribution, protecting equipment from overloads, and ensuring uninterrupted operation—crucial for 24/7 pharmaceutical production. Our solutions also ensure accurate monitoring and regulation of critical parameters like temperature, pressure, and flow essential for maintaining product quality and consistency. Our enclosures and components meet hygienic design standards, made from stainless steel with smooth finishes to prevent contamination and support easy cleaning while granting compliance with GMP (Good Manufacturing Practice.)

Stainless steel surface infact are very easy to clean and represent the ideal solution for clean rooms applications. In addition the electropolishing process applied on our enclosures can increase the cleaness of the surface with a shiny, smooth, ultra-clean finishing. Our ComEx global series is our command and signalling device system. It allows us to realise and market standardised solutions as well as customerspecific solutions. This flexible and modular portfolio includes enclosures, modules, actuators and accessories.

ComEx components can be installed in our Ex e GRP (glass reinforced polyester) aluminium and stainless steel solutions. It can be used as: emergency stop function, control of machines, motors and control systems, components for OEM machine builders and control stations. A full set of accessories, cable glands and entries, conduit fittings complete the package for a one-stop shop solution.

In pharmaceutical manufacturing, reliable connectivity is essential for maintaining control and compliance throughout critical processes — from ingredient handling to formulation and final drug production.

The ability to securely access and transmit process data in real time enables precise monitoring of key parameters, ensuring quality, consistency, and traceability. In hygienic and cleanroom environments, where equipment must meet stringent standards and operational downtime is costly, a robust hazardous area wireless network provides the foundation for seamless data flow. It connects IoT sensors, supports mobile worker communication, enables RTLS applications, and delivers the insights needed to optimize efficiency and safety.

With decades of experience, BARTEC delivers proven wireless solutions for hazardous and regulated environments. The recent acquisition of Extronics has strengthened our solutions, and now BARTEC has the most comprehensive and flexible range of Wireless solutions for hazardous areas.

BARTEC’s range of specialized wireless enclosure solutions offer purpose-built products for housing radio devices with either integrated or externally mounted antennas. These enclosures provide the essential Ex certification required for safely mounting wireless communication devices in hazardous areas and come in range of materials, including stainless steel for clean rooms and areas that require regular cleaning.

• EXgate™ – Next-generation Zone 1 enclosure for access points, gateways, and radios, with easy mounting and RF-transparent dome.
• iWAP107 & iWAPXN3 – Universal wireless enclosures for Zone 1 and Zone 2, designed to host standard wireless devices from any vendor.
• Xbeam™ Ex Antennas (0.5–6 GHz) – Ex antennas for Wi-Fi, LTE/5G, Zigbee, WirelessHART, and more.
•  iANT Antennas – Our iANT Antenna Range, fully assessed by Extronics' engineers as 'simple apparatus' under intrinsic safety standards, provides a wide choice of standard antenna options for use with our iWAP range of hazardous area wireless enclosures. 
• iSOLATE501 – RF galvanic isolator enabling safe use of standard antennas in hazardous environments.

From raw material receipt to final packaging, smartphones, cameras, tablets, barcode scanners, and mobile computers play a vital role across every stage of pharmaceutical manufacturing. These devices enable precise identification and verification of incoming ingredients, support accurate weighing and dispensing, and maintain full traceability as materials move through processing and storage. In cleanroom and hygienic environments, digital tools replace paper-based systems to ensure compliance and minimize contamination risk. Smartphones and cameras allow visual documentation of processes, samples, and materials, while tablets provide large-screen access to batch records, operational systems, and real-time data. Across sampling, quality control, inventory management, and equipment tracking, mobile data capture integrates seamlessly with MES and electronic batch record systems, ensuring connected, compliant workflows from ingredients handling to final product packaging.

Working in pharmaceutical manufacturing means operating in environments where precision, safety, and compliance are absolutely critical. BARTEC’s intrinsically safe mobile devices empower teams to work smarter and faster—without compromising product integrity or operational safety. From cleanrooms and production suites to formulation areas and packaging lines, our technology keeps personnel connected, data flowing, and processes compliant with stringent industry standards.

By combining technologies such as Wi-Fi, GPS, and Bluetooth Low Energy (BLE), hybrid RTLS solutions provide accurate and comprehensive location data with minimal infrastructure. In pharmaceutical manufacturing and ingredient processing environments, RTLS adds an essential layer of safety, compliance, and operational efficiency, enabling real-time tracking of personnel, materials, and equipment. Maintain full visibility over critical ingredients, monitor movements within cleanroom or controlled areas, and ensure secure, compliant handling throughout every stage of processing.

• iTAG XB: A range of low-cost Ex-rated asset and personnel tags, available in Quuppa or iBeacon/Eddystone BLE options, or as a Wirepas RTLS solution, ideal for tracking critical ingredient containers, production tools, and personnel within cleanroom and processing areas to ensure materials are always in the right location and operators are accounted for in real time.
• iTAG X-Range: Intrinsically safe, rugged hybrid location technology tags for worker safety and location tracking, leveraging Wi-Fi, BLE, GPS, and other location technologies, with options for Wi-Fi, LoRaWAN, and Cellular connectivity. These tags enable monitoring of staff working in controlled or hazardous areas, such as weighing and dispensing zones, while also tracking the movement of high-value or sensitive ingredients across the facility.
• iTAG XM App: Turns any Ex-certified Android smartphone into a location tracking device for indoors and outdoors, allowing real-time tracking of supervisors, QC staff, or mobile operators during ingredient handling and processing, ensuring personnel safety and providing managers with visibility into workflow progress and resource allocation.
• Extronics Location Engine (ELE): Software delivering flexible, precise “dot-on-a-map” visualization with easy API integration into existing platforms, giving pharmaceutical manufacturers the ability to visualize ingredient batches, production equipment, and personnel across the facility to support process optimization, compliance audits, and rapid response to safety or operational incidents

BARTEC trace heating systems allow precise temperature control for the entire value chain of pharmaceuticals.

Our range of self-regulating heating cables such as the MSB are well suited for the delicate temperature requirements of the pharmaceutical industry. With rising temperatures the power output of the MSB decreases. The outer jacket consists of a fluorinated polymer, which is highly resistant to most chemicals. The cables can be cut to length allowing easy installation for existing production.

BARTEC also offers a wide selection of temperature controllers, sensors and limiters. Our electrical PID controllers e.g. the DPC III allow for a quick, stable and precise regulation of temperature.