Digital level measurement, automated inventory reports, and seamless monitoring of mobile liquid containers promise the chemical industry greater transparency, reduced safety stock levels, and more efficient supply chains. However, as soon as IoT sensors are to be used on IBCs, tanks, or other containers in potentially explosive atmospheres, a technically sound sensor alone is not enough.
This raises a crucial question for procurement:
Is the proposed IoT solution actually suitable for the intended application and properly ATEX-certified?
An incorrect choice can have far-reaching consequences: from delays in commissioning to additional testing and retrofitting costs, all the way to safety risks and compliance violations. At the same time, the topic is complex because procurement, occupational safety, production, maintenance, IT, and logistics all place different demands on the solution.
This article explains the key terms, typical use cases, and five points that chemical industry buyers should consider when procuring ATEX-compliant IoT sensors.
The term ATEX is derived from the French “ATmosphères EXplosibles.” It refers to European regulations for equipment and work areas where explosive atmospheres may occur.
There are essentially two directives to distinguish between:
For purchasing companies, this means that an ATEX-certified sensor does not relieve the operator of its own obligations. The device’s certification and the operational suitability test must be consistent with one another.
An explosive atmosphere can form when flammable gases, vapors, mists, or dusts mix with air in a specific ratio. If an effective ignition source is present, combustion can spread rapidly.
Even small electronic devices can contain potential ignition sources, for example through:
For this reason, even a compact, battery-powered IoT sensor intended for use in hazardous areas must be appropriately designed, tested, and labeled.
Typical applications in the chemical industry include:
Level monitoring of IBCs and tanks
Sensors continuously or at defined intervals measure the fill level of raw materials, auxiliary materials, or finished products.
Automated replenishment planning
Real-time inventory data can trigger ordering processes or alert suppliers early on to an impending stockout.
Monitoring of mobile containers
For mobile IBCs and reusable packaging, location, fill level, and movement data can be linked together.
Prevention of unplanned plant downtime
Consumption data helps ensure that critical materials are made available in a timely manner and prevents supply disruptions.
Inventory and Container Management
Companies gain transparency into which containers are located at which sites and how much product they contain.
However, the economic benefits are realized only if the sensor technology is suitable for actual use, both technically and from a regulatory standpoint.
One of the most common sources of error in the procurement process is selecting a sensor first and only then checking whether it is permitted for use in the intended environment.
The correct order is the reverse: First, the application area is evaluated; then, the appropriate device category is selected.
For gases, vapors, and mists, potentially explosive areas are typically classified into the following zones:
For combustible dusts, Zones 20, 21, and 22 apply accordingly.
Purchasing professionals often receive a requirement such as “The sensor must be ATEX-compliant.” This statement is too vague. A device suitable for Zone 2 must not automatically be used in Zone 1 or Zone 0.
Therefore, before issuing a request for proposals, at least the following information should be available:
The zone classification should be specified in the operational risk assessment or the explosion protection document. It must not be assumed solely by the sensor supplier or determined on a blanket basis.
Purchasing: requires a clear, comparable specification for the request for proposals.
HSE and Occupational Safety: must ensure that the zone classification and device suitability match.
Production and site managers: are familiar with the actual process conditions and possible deviations from normal operation.
Maintenance: must know where and under what conditions the sensor is installed, tested, or replaced.
ATEX is not a simple yes-or-no characteristic. What matters is not merely whether a supplier uses the term “ATEX,” but for which equipment group, category, atmosphere, and protection class the product is approved.
A typical Ex marking may include information on the following points, among others:
An example such as “II 2G” simply describes a Group II device for non-mining applications that is intended for gas-explosion-hazardous areas of a specific protection category. However, the complete marking contains additional information that may be relevant for operational approval.
Incomplete product data sheets often lead to lengthy coordination loops. Purchasing sees an ATEX logo, while HSE or electrical engineering later discover that important information is missing or does not match the application site.
Therefore, before placing an order, request at least the following documents:
Pay special attention to an “X” at the end of a certificate number. It typically indicates that special conditions for safe use must be observed. These may relate, for example, to installation, the temperature range, protection against electrostatic charge, or battery replacement.
Include the complete Ex marking as a required field in your supplier selection criteria. Instead of simply asking “ATEX available: yes/no,” the supplier should document the specific marking and the intended area of use.
Certification always refers to a specific model and a defined intended use. Changes to installation, power supply, housing, or accessories can affect safe use.
For IoT sensors on IBCs and tanks, the following questions—among others—should be answered:
An IoT project is often planned based on ideal operating conditions. In practice, however, the device must be installed, cleaned, maintained, and possibly repaired.
A solution that requires a container to be removed from the hazardous area or a special authorization to be obtained for every battery change can result in high operating costs. The same applies if sensors may only be installed by trained specialized personnel.
Purchasing should therefore evaluate not only the purchase price but the entire lifecycle:
Mobile IBCs pose an additional challenge. A container may be located in one zone at the filler’s facility, then transported, and end up in a differently classified area at the customer’s site.
For scalable container management, it must be clarified whether the sensor technology is suitable for all intended stations and usage scenarios. Otherwise, this will result in different hardware variants, manual special processes, or restrictions on the use of the container pool.
In IoT projects, the focus is often on data transmission, dashboards, interfaces, and artificial intelligence. For operation in potentially explosive atmospheres, however, the physical safety of the end device remains the primary consideration.
Whether a sensor uses cellular, NB-IoT, LTE-M, LoRaWAN, Bluetooth, or any other wireless technology does not, in and of itself, indicate its ATEX compliance.
The following characteristics also do not substitute for appropriate Ex certification:
The IP rating describes, for example, the protection a housing provides against the ingress of foreign objects and water. It does not automatically confirm explosion protection.
IT departments rightfully examine aspects such as information security, data sovereignty, interfaces, and network coverage. Procurement must reconcile these requirements with HSE and technical specifications.
A suitable IoT solution therefore requires several levels:
An ATEX-compliant sensor without reliable network coverage provides no operational value. Conversely, a high-performance IoT platform with unsuitable hardware may not be permitted for use in the relevant area at all.
Both perspectives must be taken into account in the requirements specification.
ATEX-certified hardware is more demanding than conventional electronics in terms of development, testing, and production. A simple comparison of sensor prices therefore falls short.
For procurement, the decisive factor is the measurable benefit that the overall solution delivers. Typical benefits include:
Pilot projects often yield interesting data but cannot be scaled economically. Reasons for this include, for example:
A viable business case should therefore not focus solely on the price per sensor. What matters is the total cost per monitored container or measurement point over the planned service life.
These include:
On the other hand, there are quantifiable savings and avoided risks.
Procurement must reconcile differing interests: HSE demands safety, IT requires secure interfaces, production needs reliable data, and management expects a quick return on investment.
A structured proof of concept should therefore not merely verify whether a sensor is technically capable of taking measurements. It should test the entire process:
Before making a procurement decision, at least the following questions should be clarified:
Certification and Scope of Application
Installation and Operation
IoT and Integration
Cost-Effectiveness and Scalability
ATEX-certified IoT sensors lay the foundation for digitally monitoring inventory, consumption, and mobile containers—even in demanding areas of the chemical industry.
However, for successful procurement, it is not enough to simply look for an ATEX logo on the data sheet. The certification must be appropriate for the zone, the substance, the temperature class, the installation, and the entire operational application scenario.
Successful projects therefore bring all relevant stakeholders together early on:
This transforms an isolated sensor project into a secure, scalable, and economically viable IoT solution.
Do you want to make the fill levels, consumption, and locations of your IBCs and tanks more transparent—even in demanding industrial environments?
Packwise helps companies digitally map mobile liquid containers using smart sensors and a central IoT platform. Together, we analyze your use case, operational conditions, and requirements for scalable integration.
Talk to our IoT experts and learn how your container and inventory processes can be made safe, transparent, and automated.
Note: This article is for general information purposes only and does not replace an individual risk assessment, ATEX suitability test, or explosion protection consulting.
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