HTPHow to PackageProduction answers by Lancing UK
Planning and improvement

How do I improve ATEX and hazardous areas?

Practical guidance for ATEX and hazardous areas: reduce product loss, damaged packs, film waste and avoidable rejects.

Answer format: direct explanation, ordered checks and relevant solution routes. . Application-specific engineering review is still required.

Direct answer

For ATEX and hazardous areas, measure where material or product is lost and calculate waste per good pack. Improvement starts with a clear definition, measured baseline and an agreed result that can be tested after the change. Start by separate product, packaging and rework waste and record a defined before-and-after metric supported by production records. Make one controlled change at a time so the original cause is not hidden by several new settings.

Production environment relevant to planning and improvement
Higher-risk application: Use competent engineering, product-safety and compliance support. Product data, site classification, ventilation, containment, hygiene and validation requirements may change the correct solution.

What usually causes this?

  • overfilling, over-application or excessive trim used as a safety margin
  • A change in data definition and collection or operator and maintenance method.
  • start-up and changeover settings not standardised
  • The equipment or handling method not being set for classification and equipment requirements where explosive atmospheres may occur.
  • damaged or misfed packaging creating repeated rejects

Checks to make in order

  1. Separate product, packaging and rework waste
  2. Record a defined before-and-after metric supported by production records using a representative sample.
  3. Weigh or count loss during start-up, running and changeover
  4. Check product and format variation, machine condition and process capability and acceptance, risk and commercial criteria.
  5. Record the reason for every reject in a sample period
  6. Check whether waste changes with speed or pack size
  7. Calculate the financial value of giveaway and damaged packs

How to decide the next step

Atex and hazardous areas involves classification and equipment requirements where explosive atmospheres may occur. Prioritise the largest measured loss, then verify that the change does not reduce seal, dose or closure quality.

If adjustment and maintenance cannot hold the required result across the complete product and pack range, compare the machinery route against a written acceptance test. The important comparison is sustained good output—not only maximum cycle speed.

What to include in your production brief

Supplying the information below makes it much easier to distinguish a setup problem from a machinery or packaging limitation:

  • Current baseline data
  • Affected products and formats
  • Cost or risk of the problem
  • Required future state
  • Site and compliance constraints
  • Acceptance test and owner
  • Samples that represent atex and hazardous areas
  • A short video of the current process and fault

Relevant solution websites

These specialist sites match the production process discussed above. Final suitability should be confirmed with samples, output, site and acceptance information.

ATEX Filling MachinesChemical FillersLancing UK Machinery

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Common search questions

Questions customers also ask

Open a question for a concise answer, then use the detailed guide above for the full production checks.

What should I check first for ATEX and hazardous areas?

Separate product, packaging and rework waste

What commonly causes this problem with ATEX and hazardous areas?

Common causes include overfilling, over-application or excessive trim used as a safety margin; A change in data definition and collection or operator and maintenance method.; start-up and changeover settings not standardised.

How can I prove that an adjustment has worked for ATEX and hazardous areas?

Record a representative baseline, change one variable at a time and repeat the same measurement over enough packs to show that the result is stable rather than a one-off improvement.

When should I consider a different machine or production method for ATEX and hazardous areas?

Consider a different route when correct setup and maintenance cannot hold the required quality and sustained output across the complete product and pack range.

What information should I send before asking for a solution for ATEX and hazardous areas?

Include Current baseline data; Affected products and formats; Cost or risk of the problem; Required future state.

Which solution website is most relevant to this question?

The clearest starting point on this page is ATEX Filling Machines. Final suitability still needs to be confirmed using the actual product, packaging, output and site information.