The food processing industry faces a unique challenge: maintaining the highest hygiene standards while also protecting against electrical and explosion-related hazards in areas where flammable dust, gases, or vapors may be present.
In these environments, standard industrial tools won’t cut it. You need equipment that is not only intrinsically safe—meaning it cannot ignite a hazardous atmosphere—but also food-safe, capable of withstanding frequent washdowns and compliant with hygienic standards.
In this article, we’ll break down what intrinsically safe devices mean in the context of food safety, why certification matters, and how to choose the right tools for production lines, cleanrooms, and food-grade zones.
Explore our full range of ATEX & IECEx certified food-grade devices for use in production lines, cleanrooms, and food-grade environments.
What Are Intrinsically Safe Devices in Food Safety?
Definition and Industry Context
Intrinsically safe (IS) devices are designed to prevent ignition in hazardous areas by limiting the electrical or thermal energy they produce. In food processing, these devices are used in facilities where combustible dust (e.g., flour, sugar, cornstarch), gas buildup (CO₂, ammonia), or sanitation chemicals present explosion risks.
Food-grade intrinsically safe devices combine hazard zone protection with cleanability, non-toxic materials, and rugged, sealed designs that meet hygiene protocols.
Key Differences from Standard IS Equipment
Materials: Must resist corrosion from caustic cleaners and comply with FDA or NSF guidelines
Design: Sealed or smooth-body housings without crevices to prevent contamination
Cleaning compatibility: Can withstand high-pressure washdowns and CIP (clean-in-place) systems
Certifications: Require both explosion safety ratings (ATEX, IECEx, UL913) and food-safe designations (NSF, 3-A, EHEDG)
Why Are Intrinsically Safe Devices Critical in Food Environments?
Food manufacturing often involves:
Explosive dusts like grain, milk powder, or sugar
Chemical sanitation agents that increase flammability
Confined spaces (silos, mixers, ducts) prone to gas accumulation
Even a small spark from a non-certified sensor, radio, or flashlight can ignite an explosion in these high-risk zones. Intrinsically safe devices provide peace of mind by meeting both safety and hygiene demands.
Which Certifications Matter for Food-Safe IS Devices?
ATEX and IECEx
These are the primary global standards for equipment used in explosive atmospheres:
ATEX (Europe): Classifies equipment by Zone (0, 1, 2) and Dust Group (IIA, IIB, IIC)
IECEx (Global): Similar classifications with a focus on testing consistency
NSF, 3-A, and EHEDG
These ensure materials and designs are appropriate for food contact or placement in food zones:
NSF International: Covers washdown compatibility and material safety
3-A Sanitary Standards: Common in dairy and beverage sectors
EHEDG: European guideline for hygienic design in food environments
IP Ratings and Ingress Protection
Devices should carry ratings like IP67, IP68, or IP69K to ensure protection against water ingress and aggressive cleaning.
What Types of Intrinsically Safe Devices Are Used in Food Processing?
Let’s break down five essential product categories used in food-grade hazardous environments:
What Are the Best Gas Detectors for Food Facilities?
Answer: Gas detectors help monitor buildup of flammable vapors like ammonia, CO₂, or VOCs from fermenting, refrigeration, or cleaning operations.
Featured Products:
Ion Science TIGER XTL VOC Detector – Intrinsically Safe
ATEX-certified handheld VOC detector, ideal for confined areas and sanitation monitoring.SENKO SGT Portable Gas Detector
Detects toxic gases, offers long battery life, and comes in sealed, compact form.
What Lighting Is Safe for Use in Washdown Zones?
Answer: Food-safe IS lighting must be sealed, waterproof, and explosion-proof for use in spray-down areas.
Featured Products:
NICOR XPQ1B150U50GRP Titan LED FloodLight
Rugged housing, IP66+, rated for explosive dust and vapor zones.Cary Technology KLE1017 Explosion Proof LED Light
Corrosion-resistant with a food-grade sealed body.
Can Cameras Be Used in Food-Safe Hazard Zones?
Answer: Yes, provided they’re explosion-proof, sealed, and made of non-corrosive materials like stainless steel.
Featured Products:
CorDEX ToughPIX EXTREME TP3EX Digital Camera
High-resolution documentation for inspections in powder/dust-prone areas.Kaixuan KX-EX2000PSB2 Explosion Proof Dome Camera
Stainless body ideal for plant-floor and line monitoring.
What Are the Best Communication Devices for Food Manufacturing?
Answer: IS headsets and smartphones ensure safe communication on loud or humid production floors.
Featured Products:
Sensear SM1P02 IS Two Way Radio Headset
Noise-canceling headset for use in ATEX Zones 1 and 2.Ecom Smart Ex-02 DZ1 Smartphone
Intrinsically safe Android device ideal for food traceability and digital checklists.
Are There Sensors Designed for Hygienic IS Applications?
Answer: Yes. Temperature, pressure, and pH sensors built for food processing must be both ATEX-rated and food-contact certified. While not in the current product list, many partners offer these under EHEDG or 3-A specs.
How to Choose the Right Certified Device?
Evaluate the Hazard Zone
Use ATEX Zone 0 or IECEx Ex ia gear for spaces with constant gas/dust exposure
Zone 1/2 devices work for intermittently hazardous areas
Confirm Food Safety Design
Look for FDA-approved materials, IP67+ ratings, and smooth or stainless steel housing
Avoid devices with exposed screws or porous surfaces
Match to Cleaning Protocols
Devices must withstand high-pressure steam, alkaline detergents, or CIP washdowns
Check for NSF listings or manufacturer documentation for cleaning compatibility
Intrinsically Safe Device Comparison Table
| Product | Certifications | Food-Safe Features | Best Use Case |
|---|---|---|---|
| Ion Science TIGER XTL VOC Detector | ATEX Zone 1, IECEx | Compact, IP-rated body | Sanitation and VOC monitoring |
| SENKO SGT Gas Detector | Likely ATEX Zone 0 | Small, sealed, easy to clean | Ambient gas checks |
| NICOR Titan Flood Light | ATEX/IECEx (IP66+) | Powder-coated, sealed | Plant lighting in wet zones |
| CorDEX ToughPIX Camera | ATEX, Class I Div 1 | Shockproof, sealed | Documentation and inspection |
| Sensear SM1P02 Headset | ATEX Zone 1 | Enclosed, moisture-resistant | Production floor comms |
| Ecom Smart Ex-02 Smartphone | ATEX Zone 1 | Cleanable touchscreen, rugged | HACCP or traceability systems |
What Are the Best Practices for Implementation?
Install in verified ATEX/IECEx zones only
Calibrate gas detectors monthly
Inspect lighting and camera seals regularly
Avoid using damaged or unverified gear in wet environments
Train workers on device use, zones, and limitations
Document all inspections and maintenance in your food safety plan
Looking for ATEX or IECEx devices built for food zones?
Talk to an expert today or request a quote for tailored safety solutions.
Frequently Asked Questions (FAQs)
What makes a device intrinsically safe and food-safe?
It must prevent ignition in explosive atmospheres (via ATEX/IECEx certification) and use hygienic design/materials that resist contamination and cleaning damage.
Can explosion-proof lights be cleaned with high-pressure sprays?
Yes—if they are rated IP67, IP68, or IP69K, and explicitly marked as suitable for food-grade sanitation.
Are intrinsically safe food devices more expensive?
Yes, but they reduce liability, prevent downtime, and are often required for regulatory compliance in food-grade explosive zones.
How often should IS devices be maintained?
Gas detectors: Monthly calibration
Lighting and sensors: Quarterly inspection
Communication and smart devices: Annual functional tests
What documentation do I need for audits?
Keep:
Product datasheets with certification proof
Maintenance logs
Hazard zone maps
Cleaning validation (NSF/3-A letters if applicable)
Conclusion
In modern food manufacturing, safety goes beyond hygiene. If your operations involve dust, vapors, or flammable sanitizers, you need intrinsically safe devices in food safety zones to avoid catastrophic incidents and remain compliant.
The right equipment combines ATEX or IECEx protection with NSF-grade designs, ensuring safe operations even in washdown areas and confined processing zones.
