News

EXAIR Launches Redesigned Website for Enhanced Digital Experience

            EXAIR has unveiled a redesigned website that delivers a more streamlined experience for engineers, maintenance professionals, and manufacturers searching for compressed air solutions. Featuring a modern look that reflects EXAIR's updated brand identity, the new website makes it easier than ever to explore products, learn about applications, and find the right solution for virtually any industrial challenge. Built with performance and usability in mind, the site offers faster page loads, improved navigation, and a cleaner interface.

            The redesigned website introduces several customer-focused enhancements that simplify the buying process from research to checkout. A streamlined shopping experience reduces the number of steps required to purchase products, allowing customers to move from product selection to checkout more quickly than ever before. Visitors can also browse new industry-specific pages featuring relevant product recommendations, application examples, and educational resources, making it easier for users to discover solutions designed specifically for their manufacturing environment. The site also offers ample opportunities to connect with EXAIR through catalog requests, newsletter signups, or speaking directly with Application Engineers to get answers for case-by-case manufacturing dilemmas.

            EXAIR.com reinforces EXAIR's commitment to providing customers with the tools and resources needed to solve industrial challenges efficiently. In addition, visitors have access to the application database, videos, CAD models, blogs, an extensive Knowledge Base, and direct support from EXAIR's Application Engineers. Combined with enhanced site performance and an improved user experience, the redesigned website makes finding, selecting, and purchasing EXAIR solutions easier than ever. https://exair.co/190-newsite

From Operational Data to Explosion Risk Intelligence

Industrial organisations generate a massive amount of information about how risk is identified, managed and controlled, from DSEAR and ATEX assessments and hazardous area classifications to inspection findings, maintenance activity, equipment records, management of change and operational procedures. Most of this information is considered independently and often represents conditions at a particular point in time.
 
EXPAS was founded to address this gap by transforming engineering evidence and operational data into a transparent view of explosion risk and how that risk may be changing.
Central to the EXPAS approach is operational control. Rather than focusing solely on whether assessments, safeguards and systems exist, it considers the factors that determine whether those controls can continue to be relied upon in practice.
 
A critical safeguard may have been correctly specified and installed, but its effectiveness over time can be influenced by maintenance activity, equipment condition, inspection findings, outstanding actions and the operational behaviours and management systems that support it. Individually, these are separate pieces of information. Considered collectively, they can provide valuable signals about the underlying condition of the risk and where weaknesses may be developing. EXPAS structure this evidence across four connected dimensions: Ignition Exposure, Control Fragility, Escalation Potential and Risk Trajectory.
 
Ignition Exposure considers the conditions and operational factors influencing exposure to credible ignition sources, while Control Fragility examines the resilience of the engineering and operational controls relied upon to prevent or mitigate an event. This moves the focus beyond simply confirming that a control exists, towards understanding how effectively it is being maintained, managed and supported operationally.
 
Escalation Potential considers how an initial event could develop if prevention or mitigation measures were unsuccessful, providing greater visibility of the pathways through which an incident could escalate into a more significant explosion, fire, business interruption or loss.
Bringing these signals together over time creates Risk Trajectory, providing a view of whether the underlying risk position is stable, improving or deteriorating as operational conditions and evidence change.
 
Transparency is fundamental to the approach. Rather than producing a black box score, the intelligence remains traceable to the engineering evidence and operational information supporting it, allowing users to understand what is influencing the risk position and where attention may be required.
EXPAS is not intended to replace established DSEAR, ATEX, engineering assessment or inspection processes.
 
Instead, it builds upon them by connecting information that has traditionally existed across separate documents, systems and operational activities.
 
For industrial operators, this can provide earlier visibility of emerging weaknesses and stronger evidence of how explosion risk is being controlled. For insurers and risk engineers, it can provide a more consistent and transparent understanding of the operational factors influencing the underlying risk.
Knowing that a control exists is only part of the picture.
 
Understanding whether it can still be relied upon, what could happen if it fails and which direction the risk is moving provides a much deeper view of risk.
 
That is the shift from static assessment to Explosion Risk Intelligence.
 
Author 
Mike Brimble
 

Windows or Android? Choose the right mobile HMI for the job

Every mobile operator needs the right tool for the task. In Ex-environments, the choice is not about safety certification alone, it is about how the device fits into the tasks that lay ahead in the field. The Mobile Operator Panel from i.safe MOBILE combines an intrinsically safe tablet with the IS-CS1A.1 Connectivity System, creating a robust docking and communication platform. On this shared foundation, two tablet options are available: the Android-based IS940.1 and the Windows-based IS945.1, both built for demanding industrial use.

The Android tablet is the ideal choice for mobile workers who need a fast, intuitive companion for guided workflows, routine checks, and structured data capture. It supports the kind of tasks that must be completed quickly and efficiently, with a user experience that feels familiar and easy to adopt. For mobile applications where responsiveness and simplicity matter most, Android is the natural fit.

The Windows tablet is designed for users who need more than a companion device. It becomes part of the production and control environment, giving direct access to native supervision, and commissioning software. With Windows 11 IoT Enterprise LTSC for Arm64, the IS945.1 runs desktop-class applications directly on the tablet, making it a powerful extension of existing control systems.

One platform, two use cases

This dual-platform approach gives industrial users maximum flexibility. Android supports mobile workflows that are fast, repetitive, and task oriented. Windows supports deeper integration with production and control systems, where familiar software and full application compatibility are essential. Both tablets use the same docking and connectivity backbone, allowing one unified concept to serve different roles across the operation.

Built for the right role

The strength of the concept lies in matching the device to the use case. Android brings speed, simplicity, and mobility to the hands of the worker. Windows delivers the software compatibility and system integration needed for production-related tasks. Together, they provide a flexible mobile HMI strategy that adapts to the way industrial teams really work.

www.isafe-mobile.com

 

 

Battery Testing under IEC 60079-11: Five things Manufacturers should consider

As battery-powered technologies continue to transform industries, they are also becoming increasingly common in equipment designed for use in hazardous areas. From portable gas detectors and wireless sensors to communication devices and monitoring systems, batteries are enabling greater mobility and functionality than ever before.

However, batteries also present one of the most significant challenges when designing intrinsically safe equipment. Unlike many other electrical components, they store substantial amounts of energy and, under certain conditions, have the potential to become an ignition source. IEC 60079-11 helps manufacturers address these risks by defining requirements for equipment protected by intrinsic safety.

When developing battery-powered equipment, there are five key considerations manufacturers should keep in mind.

1. Battery selection matters

Not all battery chemistries behave in the same way. Characteristics such as energy density, internal resistance and thermal behaviour can all influence how a battery performs under both normal operation and fault conditions. Selecting an appropriate battery technology early in the design process can help minimise development challenges later.

2. Consider the complete system, not just the battery

Battery safety cannot be assessed in isolation. Protective circuitry, charging arrangements, electrical interfaces and the surrounding equipment all influence the overall intrinsic safety of the product. Understanding how these elements interact is essential when demonstrating compliance.

3. Prepare for foreseeable fault conditions

Intrinsic safety is based on ensuring equipment remains safe even when faults occur. Manufacturers should consider scenarios such as short circuits, component failures and abnormal operating conditions early in development, rather than waiting until formal compliance testing begins.

4. Design for compliance from the outset

Battery-related design changes introduced late in a project can have significant consequences for cost and programme timelines. Incorporating intrinsic safety considerations during concept development can reduce redesign, improve efficiency and help avoid delays during product approval.

When using lithium battery technology, IEC 60079-11 is not the only standard to consider. While IEC 60079-11 governs intrinsic safety, including under fault conditions, it relies on the underlying cell being fundamentally stable. Depending on the target market, baseline cell-level safety certifications to UL 1642 (for North America) and IEC 62133-2 (globally) are typically required to validate core chemical and mechanical stability. Furthermore, regardless of the explosive atmosphere certification, UN 38.3 testing is legally mandatory for all lithium battery types to permit commercial transport and air freight.

5. Work with experienced technical specialists

Battery technologies continue to evolve rapidly, bringing new opportunities alongside new engineering challenges. Working with specialists who understand both battery behaviour and intrinsic safety requirements can help manufacturers interpret technical requirements, identify potential issues early and build confidence throughout the development process.

As demand for battery-powered equipment in hazardous locations continues to grow, intrinsic safety remains a critical design consideration rather than a final compliance exercise. By considering battery selection, system design and foreseeable fault conditions from the beginning of a project, manufacturers can reduce technical risk, streamline development and support a smoother route to certification.

Ultimately, successful battery testing is not simply about demonstrating compliance with a standard. It is about ensuring products can operate safely and reliably in some of the world's most demanding environments.

Adrian Smart, Senior Consultant Engineer, Hazardous Locations at Intertek

Learn more about Intertek’s battery testing and certification services at https://www.intertek.com/batteries/

Atexxo Introduces ATEX / IECEx Certified Samsung Galaxy Tab Active5 (Pro) Series

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Digitalisation is rapidly transforming hazardous industries. From maintenance and inspection to asset management and remote collaboration, field workers increasingly depend on mobile technology. Atexxo Manufacturing now brings Samsung’s latest rugged tablet technology into explosive atmospheres with ATEX-certified versions of the Samsung Galaxy Tab Active5 and Galaxy Tab Active5 Pro.

The compact Samsung Galaxy Tab Active5 ATEX is designed for use in gas Zone 1 and dust Zone 21 environments. Atexxo converts the original Samsung tablet using a modified aluminium enclosure and protected electrical circuitry, while retaining the functionality required by modern field workers. The device is certified as II 2G Ex db IIC T6 Gb and II 2D Ex tb IIIC T85°C Db under ATEX, with corresponding IECEx certification.

Its 8-inch, 120Hz display offers excellent visibility, while 5G, Wi-Fi 6, Bluetooth, Samsung Knox and physical SIM or eSIM connectivity support connected-worker applications. The tablet is available in Wi-Fi and Wi-Fi-plus-5G configurations, with 128GB or 256GB storage options.

For applications requiring a larger workspace, Atexxo offers the Samsung Galaxy Tab Active5 Pro ATEX for gas Zone 2 and dust Zone 22. Its 10.1-inch display provides additional space for technical drawings, digital work instructions, inspection forms and industrial software. The Atexxo version carries the markings II 3G Ex ec ic IIC T4 Gc and II 3D Ex tc IIIB T85°C Dc.

The Tab Active5 Pro combines 5G connectivity with a powerful processor, Samsung Knox security, glove-compatible operation and reinforced tether points. The original Samsung platform also offers a 120Hz display, up to 600-nit brightness and expandable storage, making it suitable for demanding industrial workflows.

Together, the two tablets provide organisations with a choice between a highly portable Zone 1/21 solution and a larger Zone 2/22 productivity platform. Applications include petrochemical facilities, offshore installations, hazardous-goods storage, maintenance, digital inspections, connected-worker systems and safe industrial photography.

With these new products, Atexxo enables companies to introduce modern Samsung mobile technology into hazardous locations without compromising explosion safety.

For more information, visit www.atexxo.com

EXAIR’s New Cabinet Cooler® System Calculator Simplifies the Process of Selecting the Ideal Model

EXAIR Cabinet Cooler® systems provide a rugged, industrial duty solution for cooling and purging electronic cabinets. They are CE compliant and available with cooling capacities up to 5,600 BTU/Hr. and UL listed NEMA 12, NEMA 4, and NEMA 4X enclosure ratings. There are also UL Classified Hazardous Location models for use with purge systems. With the breadth of available options, choosing the best Cabinet Cooler for a specific environment can be a tedious task and depends on a few key factors. EXAIR’s new Cabinet Cooler system Calculator, found online at www.EXAIR.com in the Knowledge Base, makes it fast and easy to find the ideal model of Cabinet Cooler system for any specific application.

            By providing certain information like size of the enclosure, NEMA rating needed, and environmental conditions, our new calculator will sort through our large selection of ready-to-ship Cabinet Cooler® Systems and provide instant feedback on the best model number for any applicable electrical enclosure.  Taking the guess work out of the equation, EXAIR’s Calculator ensures the customer that they can be confident in selecting the correct product for their unique specifications.

            EXAIR’s complete line of Cabinet Cooler systems include 120V AC, 240V AC and 24V DC thermostat voltage, continuous operation, type 316 stainless steel and high temperature models – all of which are selectable with the new calculator. Find this new tool on the website EXAIR.com, in the Knowledge Base Calculator Library along with many other resources, such as the CAD Library and Application Database, which also help customers choose a perfect solution. https://exair.co/190-cccalc

AI Hits Zero Misses in Industrial Safety Trials

First industrial deployments of AI safety agent achieve a perfect recommendation capture rate across real production environments, as Ultimo expands AI offering across maintenance, safety, and operations

Ultimo today released results from the first commercial deployments of its health, safety & environment (HSE) digital worker, an AI agent built for industrial safety teams. Across a controlled trial group of manufacturing businesses, the agent did not miss a single recommended safety action - a result that matters in a sector where the International Labour Organization estimates1 nearly three million workers die from work-related accidents and diseases every year, and a further 395 million sustain non-fatal injuries.

The HSE digital worker continuously monitors work orders and shift logs. It surfaces recommended safety actions before they become incidents, handles compliance reporting automatically, and flags conditions that warrant attention from safety teams - without replacing the professionals who act on them. Every recommendation is audit-logged. The human makes the final call. The agent can be purchased and operated independently of the Ultimo EAM platform, giving industrial organizations a direct route to benefit from AI-assisted safety management across every site in their organization.

Agristo, a major European potato processor, was among the first to deploy the digital worker in production. "Ultimo's AI suggests our HSE actions. Reliable, smart, and to date not a single measure has missed the mark," said Piet Gabriël, Group Maintenance Engineer at Agristo.

The pattern held across the trial group. AI-generated safety recommendations were acted on, compliance workflows that previously required manual review were automated, and safety teams redirected time toward analysis and prevention rather than administration.

"Industrial safety teams are being asked to track more hazards, across more assets, with the same headcount,” added Steven Elsham, CEO of Ultimo. "The regulatory environment is tightening, and the consequences of a missed action are severe. In hazardous industrial environments, that pressure falls on skilled people who should be focused on the complex, high-stakes decisions that only they can make - not on routine monitoring and compliance administration. What we have built handles that load automatically, so the humans who work in these environments can direct their expertise where it counts. These early results validate the approach, and we are moving quickly to put it in the hands of more customers."

The HSE digital worker is part of a broader suite from Ultimo covering maintenance planning, technician guidance, and natural-language reporting. Each agent can be deployed independently or alongside the Ultimo EAM platform. These agents don't stand still - the HSE digital worker learns continuously from every work order, shift log, and safety action it handles, growing sharper and more capable over time. It is the first of an expanding line-up of Ultimo digital workers, with more scheduled to join across maintenance, operations, and safety through 2026 and beyond. Details will be announced at www.ultimo.com.

Ultimo is a 2025 Gartner Customers' Choice award winner (4.7/5, 90 percent recommend) and a Verdantix Green Quadrant Leader for EAM software for two consecutive years. The company supports more than 150,000 technicians managing over 22 million assets across 2,500-plus customers in manufacturing, logistics, energy & utilities, and healthcare worldwide.

Enerpac Launches LU-Series Lightweight Electric Torque Pump

Industrial tools and heavy lift systems specialist, Enerpac, announces the new LU-Series Electric Torque Pump specifically engineered for intermittent bolting applications. Lightweight and highly portable, the LU-Series is a compact alternative to the oversized, continuous-duty pumps traditionally used by maintenance and repair teams, without compromising on performance.
At just 15 kg empty, the Enerpac LU-Series is designed for safe handling and true portability. Its balanced lifting points and multiple carry points ensure that manoeuvring equipment across ladders, platforms, and tight spaces is simple and ergonomic. Critical components are fully protected, ensuring reliable operation in harsh field conditions where smaller, less robust pumps may fail.
"The Enerpac LU-Series provides a compact, right-sized solution that simplifies the workflow for field technicians and maintenance teams," said Angie Wallace, Global Product Manager, Enerpac. “Feedback from MRO technicians has included - lightweight and easy to transport thanks to the exposed frame design and multiple secure grip points - responsive and easier to operate remote control even with gloves on - a perfect combination of simplicity, size and weight.”  
Solving the Oversized Pump Burden in Intermittent Bolting
Intermittent bolting involves periodic or on-demand bolting in response to ongoing maintenance monitoring such as routine torque checks and servicing a limited number of bolts across multiple sites. Traditionally, technicians have had to transport heavy, continuous-duty industrial pumps for these quick, routine checks. The Enerpac LU-Series eliminates this logistical burden by delivering consistent, repeatable torque performance and the exact power required for standard maintenance, packaged in a significantly smaller, lighter footprint.
Designed for Real-World Bolting Maintenance
The introduction of the Enerpac LU-Series fills a critical gap in Enerpac’s wider wind energy and industrial portfolio. While Enerpac’s larger high-flow pumps remain the industry standard for heavy-duty, continuous installation operations, the LU-Series provides a dedicated, highly mobile solution for distributed, application-specific maintenance work.
The Enerpac LU-Series is fully optimised for the rapidly evolving wind energy sector, where technicians face intense pressure regarding mobility, tight maintenance windows, and challenging environments. Developed closely with operators, OEMs, and contractors, the pump’s design directly addresses how crews interact with equipment in real-world conditions.
As maintenance and operation tasks grow larger and installations become more complex, Enerpac continues to support industry growth through practical, application-driven innovation that enhances safety, improves operator efficiency, and maximises uptime.
For more information on the Enerpac LU-Series lightweight electric torque pumps, visit www.enerpac.com
 

ATEX for Manufacturers: How to Estimate Cost, Time and Certification Difficulty Before You Enter the EU Market

ATEX projects rarely become expensive because of one test alone. More often, they become expensive because manufacturers start too late, choose the wrong conformity route, or underestimate what the marking already implies.

If you want to place explosion-protected equipment on the EU market, the first question is not price. It is scope. You need to confirm that the product really falls under ATEX 2014/34/EU as equipment, a protective system, or a component intended for use in potentially explosive atmospheres. Many projects become inefficient from the start because companies begin budgeting before confirming that ATEX applies in the product sense at all.

The marking already tells you a lot

Once scope is clear, the next major indicator is the marking. In practice, the marking already tells you a great deal about future cost and difficulty.

A Category 3 product is usually the lightest route. It still requires proper technical documentation, risk assessment, and compliant marking, but notified body involvement is normally more limited. A Category 2 non-electrical product is a step up: the route may remain manageable, but the technical file may still need to be lodged with a notified body. A Category 2 electrical product, or equipment involving internal combustion engines, usually becomes more demanding because EU-type examination and production quality elements are more likely to apply. Category 1 products are typically the heaviest route in both time and money.

Why simple products become expensive

The category is only part of the story. Some markings make a project harder even when the product looks simple. IIC is harder than IIA or IIB. T6 is often more restrictive than T4 or T3. Dust protection can create additional design and temperature-control challenges. So can extended ambient ranges, batteries, encapsulation, cable entries, plastics, display windows, and multiple variants within one certification scope.

What you actually pay for

Manufacturers also need to understand when ATEX cost moves beyond testing. In some routes, the real budget includes more than laboratory work and certificate issue. It can include EU-type examination, technical file handling, factory audit, quality assurance assessment, surveillance visits, corrective actions, and reassessment after design changes. That is especially important for serial production.

What usually delays the project

ATEX timelines usually slip for practical reasons: the design is still changing, the sample does not match the final product, the BOM is not frozen, drawings are not production-ready, ignition hazard assessment is incomplete, or critical components do not have stable traceability.

What to review before you budget

The most reliable way to estimate ATEX cost before spending money is to review four things together: intended marking, conformity route, production readiness, and change-control risk. That is usually where the real budget and timeline are decided.

Danem Test supports manufacturers with testing, inspection, certification and regulatory compliance for international market access, including ATEX / IECEx, CE marking, CBAM, industrial testing and third-party inspection.

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Get ready for new carbon emissions tax rules

From 1 January 2027, businesses importing goods into the UK from the aluminium, cement, fertiliser, hydrogen, and iron and steel sectors will need to keep records to comply with the new UK Carbon Border Adjustment Mechanism (CBAM).

CBAM aims to tackle carbon leakage, helping to achieve net zero by 2050.  

HM Revenue and Customs’ Head of CBAM Policy Peter Connell outlines what it means for businesses and what they can do to start preparing for it.

What is CBAM?

CBAM is a new tax designed to address the risk of carbon leakage by ensuring certain highly traded, carbon intensive goods imported into the UK face a comparable carbon price to equivalent goods produced in the UK.

What’s happening from January 2027?

From 1 January 2027, businesses importing into the UK specific goods from the aluminium, cement, fertiliser, hydrogen, and iron and steel sectors will need to begin keeping records.

Businesses can check whether they need to register and what records to keep on GOV.UK.

Keeping records of CBAM imports

From 1 January 2027, businesses importing CBAM goods are required to keep records relating to CBAM goods they have imported. Records must be kept for 6 years.

Businesses that do not keep adequate records relating to CBAM may be liable for penalties, so it’s important to find out what you need to do beforehand and to get it right.

More information about the record-keeping requirements is available on GOV.UK.

I use a carrier when importing, aren’t they responsible?

No. If someone imports CBAM goods or completes the import declaration on your behalf, such as a customs broker, freight forwarder, haulier or tax agent, you may still be classed as the importer and therefore responsible for meeting CBAM obligations.

Find out more about who is classed as the importer on GOV.UK.

I’ve started keeping records for CBAM. What happens next?

Businesses importing CBAM goods into the UK must keep records of those goods from 1 January 2027, regardless of whether they will need to register for CBAM.

Registration for CBAM will open on 1 January 2028. If the value of the goods imported is more than £50,000 for the previous 12 months, or you are expecting to import within the next 30 days, you will need to register with HMRC.

How much do I pay and when?

HMRC will publish further guidance on CBAM rates, default emissions values and monitoring, reporting and verifying emissions in the coming months.

If you are registered for CBAM, you must submit a return – even if there is no tax to pay – and pay any liability for the 1 January to 31 December 2027 accounting period by 31 May 2028.

Find out more about preparing for CBAM on GOV.UK.