News

Stargate Hydrogen, a European-born innovator in the field of green hydrogen production technologies, announced today the launch of two major new product families:
·        5 MW Electrolyser Stack named Starbase
·        10 MW Electrolyser System module Aurora

The new products are designed to accelerate industrial decarbonisation via green hydrogen by providing compact, high-performance systems that allow customers such as refineries, chemical plants, and steel manufacturers to produce green hydrogen directly on-site. Aurora, the 10 MW outdoor-ready system module, stands out with its record-low footprint of just 14.4 m² per MW, making it the most space-efficient alkaline electrolyser of its kind on the market.  More information about the products will be disclosed during the World Hydrogen TECH Expo in Hamburg on 20-22 October.

The system packs two 5 MW Starbase stacks that deliver strong efficiency with a stack consumption of less than 49 kWh/kg, allowing to bring down the cost of green hydrogen for industrial customers. Together, Starbase and Aurora provide scalable, industrial-grade solutions to the growing demand for efficient large-scale hydrogen production systems.

“With Starbase and Aurora, we are addressing the two main barriers for industrial hydrogen adoption: cost of hydrogen and space constraints at industrial sites. By delivering the most compact and high-efficiency 10 MW electrolyser system on the market, we are empowering industries to integrate green hydrogen production directly into their existing operations,” said Marko Virkebau, CEO of Stargate Hydrogen. “This is a critical step forward for hard-to-abate industries seeking to decarbonise at scale.”
Stargate Hydrogen noted strong market interest in its latest products, with several commercial negotiations already ongoing for the first deliveries. The launch underscores the company’s commitment to providing systems that reduce space and energy requirements, making hydrogen adoption practical for energy-intensive industries.
www.stargatehydrogen.com

EEMUA has released a new edition (Edition 2) of its publication EEMUA 222, ‘Guide to the application of IEC 61511 to safety instrumented systems in the process industries’.

Written by leading experts, including from EEMUA member companies and with input from the GB Health and Safety Executive, EEMUA 222 provides guidance and recommendations on the application of the IEC 61511 standard for the specification and implementation of safety instrumented systems designed to bring a process plant to a safe state should a hazardous incident occur.

EEMUA 222 is intended to explain how to use the IEC 61511 standard effectively and addresses the responsibility and deliverables of organisations involved in the specification, supply and maintenance of safety instrumented systems.

The second edition of EEMUA 222 has been extensively revised to reflect the greater maturity of the standards and the understanding of functional safety in general. There is new coverage on points of difficulty that are likely to be encountered and where standards currently lack detailed guidance.

EEMUA 222 is available to purchase directly from EEMUA. 

Working in explosive atmospheres is no joke – unless, of course, it’s in a cartoon!

At PVL, we know that the right ATEX-certified pressure switch can make all the difference when it comes to protecting people, plants, and processes.

Our latest light-hearted cartoon illustrates a serious point:
✅ Certification isn’t optional
✅ Materials matter
✅ Zone suitability is critical
✅ Safe switching saves lives

 Why This Matters

For businesses operating in hazardous environments, compliance with ATEX, UKCA, and UKEX regulations is critical. Since Brexit, the regulatory framework has evolved, creating both challenges and opportunities for manufacturers, suppliers, and end-users. This article outlines the 2025 situation—what’s confirmed, what’s changing, and what to watch out for.

UKEX and UKCA for Explosive Atmospheres

From January 2021, products intended for explosive atmospheres in Great Britain must comply with the UKEX scheme, under the umbrella of UKCA marking. Conformity assessments are carried out by UK Approved Bodies, under the amended Equipment and Protective Systems Intended for Use in Potentially Explosive Atmospheres Regulations 2016.

Recognition of CE and ATEX Certificates

The UK government now recognises CE-marked goods indefinitely in many categories, including Ex equipment. This provides flexibility for manufacturers already holding ATEX certificates, as their products can continue to be placed on the GB market without immediate retesting. However, conditions apply, particularly around certificate expiry dates and product modifications.

Transitional Labelling and Importer Requirements

Transitional easements mean UKCA/UKEX marks and importer details can be shown on packaging or accompanying documentation rather than directly on products. These easements have been extended, with some lasting until 2025 and others to 2027. Spare parts used to maintain existing systems can still be covered under earlier compliance approvals.

Substantial Change Ambiguity

A major area of uncertainty remains around what qualifies as a “substantial change” to a product. Minor updates may not require new certification, but significant modifications could trigger the need for fresh UKEX assessment. Clearer guidance is still awaited.

Approved Bodies and Conformity Assessment

UK Approved Bodies are now issuing UKEX certificates. In certain cases, conformity assessments completed by EU Notified Bodies before cut-off dates can still be used for UKEX purposes, helping manufacturers avoid duplicate testing. Careful tracking of certificate validity and evolving standards is essential.

Northern Ireland and EU Market Considerations

While UKEX/UKCA applies in Great Britain, Northern Ireland continues under EU rules, requiring CE marking (and sometimes UKNI marking). Businesses trading across GB, NI, and EU markets need to manage dual-marking and certification carefully.

Enforcement and Market Surveillance

Enforcement remains a developing area. Authorities are expected to step up checks on compliance, but feedback suggests consistency still varies by product category.

Conclusion

As of 2025, the key takeaway is that CE marking remains valid indefinitely in many cases, but UKEX certification is the long-term framework for explosive atmosphere equipment in Great Britain. Companies should:

• Monitor certificate expiry dates carefully.

• Use CE/ATEX certification where accepted, but prepare for UKEX transition.

• Stay alert to new announcements from UK government, OPSS, and Approved Bodies.

Stay Informed

At Hazardous Engineering Solutions and Engineering Maintenance Solutions, we track every regulatory update that impacts hazardous areas and maintenance professionals.

👉 For the latest ATEX / UKCA / UKEX insights, event previews, and compliance news, visit www.hazeng.com

uvex, a global leader in personal protective equipment renowned for comfort, innovation and uncompromising safety, has introduced the uvex 1 x-cite, a stylish new footwear range designed specifically for women who need to transition between corporate and operational environments with ease.

From site managers and engineers to architects, logistics coordinators, production supervisors and facilities teams, uvex 1 x-cite offers a sharp, modern look that complements uniforms and office clothing while delivering the protection required on the shop floor.

The uvex 1 x-cite collection proves there is no need to compromise on style when it comes to safety. Designed to transition effortlessly from office to site, it combines a smart, contemporary design with trusted protective features. The sleek, professional look pairs naturally with both uniforms and modern business attire, allowing wearers to maintain a polished image without sacrificing safety.

Every element has been shaped with women in mind. Built on a true female last, the shoes provide a refined fit and tailored silhouette, available in sizes 2–10 with multiple width options to ensure inclusivity. Discreet safety features include a lightweight, metal-free carbon-fibre toecap and flexible anti-penetration midsole, which together reduce weight, increase flexibility and help minimise fatigue during long shifts.

The design strikes the perfect balance between edgy, chunky styling and all-day WEARABILITY. Certified slip-resistant and ESD-compliant, uvex 1 x-cite delivers protection that meets the demands of modern workplaces while maintaining a fashionable, versatile aesthetic. 

The range has already earned recognition, winning the 2025 German Design Award and Red Dot Product Design Award for its elegant styling and comfort.

Available in a choice of low-cut shoes, Chelsea boots and high-cut boots, uvex 1 x-cite provides versatile options to suit different tastes and professional roles. 

“Women shouldn’t have to choose between safety, comfort and style,” says Clair Weston, Head of Marketing at uvex. “With uvex 1 x-cite, we developed footwear on a female last, reduced weight and created a contemporary silhouette that allows professionals to go from the office to the site without interruption.”

To explore the uvex 1 x-cite range further, or to book a footwear fit clinic for your workplace, contact uvex today.

As Thorne & Derrick International marks its 40th anniversary, the company celebrates industry transformation that mirrors the global energy shift—from fossil fuels to a sustainable future. Founded in 1985 as a regional supplier to the traditional energy industry, the company has evolved into key suppliers to the renewable revolution, delivering critical infrastructure for the Green Grid.

Its early years were rooted in the fossil fuel era, with key customers in the oil/gas, coal mining and heavy industries, when a pivotal moment came with an order for BAND-IT products from Swan Hunter shipyard for the Solitaire project, then the world’s largest offshore pipe-laying vessel. As the original UK Distributor for BAND-IT Cable Management Systems, Thorne & Derrick International established a reliable delivery model from shelf to site, laying the foundation for decades of collaboration in energy infrastructure.

For years, the company supplied the oil and gas industry but as climate goals and policies like the UK’s Net Zero 2050 target reshaped the energy landscape, Thorne & Derrick International proactively pivoted.

Today, the company is embedded in renewable energy and industry decarbonisation projects, supplying LV HV Cable Accessories, Tooling & Hazardous Area Electrical Equipment for offshore and onshore wind, solar farms, battery energy storage and process industry projects. Its expertise ensures safe, efficient power transmission in increasingly complex and demanding energy networks.

Growth has been both technological and geographic. What began as local supply company to North East of England projects now spans global markets as Framework Supply Partners to ECP’s and international energy providers across the UK and Europe including Spain, France, Germany, Switzerland, Sweden and Denmark, delivering mission-critical Cable Accessories where high-voltage cables are essential for long-distance, large-scale power transfer.

A powerful symbol of this shift is the former Swan Hunter site in Wallsend. Once a hub of ship and crude oil tanker building it is now reborn as the UK’s centre for renewable energy services and offshore wind manufacturing.

In September 2025, Thorne & Derrick International returns, this time to supply Cable Accessories & Tooling for the energisation and electrification of UK and international green energy projects. It’s a full-circle moment that reflects the company’s resilience and vision.

Innovation and partnerships have driven this evolution. Long-standing Distribution Agreements with manufacturers including BAND-IT, 3M, Nexans Euromold and Pfisterer has secured approved vendor status with major energy providers, reinforcing Thorne & Derrick’s role as a trusted supply-partner in the modern energy chain.

“From fossil fuels to Net Zero, we’ve adapted, innovated, and grown,” said Chris Dodds, Sales & Marketing Manager. “Our 40-year journey reflects our commitment to sustainability, partnership, and powering the future.”

Over four decades, the company has moved from local supplier to global partner—not just adapting to change, but advancing it. Thorne & Derrick’s story is one of purposeful transformation: powering progress, sustainably, from fossil fuels to a sustainable future.

www.PowerandCables.com

At this year’s Battery Show North America, taking place in Detroit, Michigan, October 7-9, 2025, Coperion will highlight its latest innovation - the Loss-in-Weight Roller Feeder, a precise gravimetric solution for dry electrode coating in battery manufacturing. This advanced feeder is designed to ensure uniform application, enhance process stability, and improve overall efficiency, marking a significant breakthrough in scalable, solvent-free electrode production. Attendees will have the opportunity to engage with Coperion experts and learn about the company’s latest plans how this technology can revolutionize their processes at Booth 5107. Additional focal points will be continuous extrusion capabilities that offer greater material efficiency and more cost-effective battery cell production.

Unique New Technology for Precise Active Coating Material Delivery

The new Coperion K-Tron Loss-in-Weight Roller Feeder is a state-of-the-art solution designed for continuous feeding of dry electrode coating powder blends directly into the calender gap in dry coating processes. The roller feeder is designed primarily for laboratory and pilot-scale production. The feeder is mounted on a robust platform scale utilizing high-accuracy SFT weighing technology. Its innovative dual roller design, housed within a compact enclosure, features a dynamic feeding gap that ensures gentle, consistent material handling while preventing bridging. This ensures uniform and repeatable mass distribution across adjustable widths up to 400 mm. The system’s stability and precision are essential for optimizing electrode production and achieving high-quality, scalable results. As part of an integrated manufacturing solution, the loss-in-weight roller feeder enhances process automation, material utilization, and overall productivity in cutting-edge battery production lines.

Unlocking Greater Efficiency through Continuous Dry Coating of Electrodes

Coperion’s ZSK extruder, in combination with high accuracy Coperion K-Tron screw feeders, provides an ideal solution for continuous extrusion of battery masses in dry coating applications. Its design allows for the simultaneous fibrillation binders and homogenization of raw materials. The shorter residence time in the extruder, along with precise temperature control of individual barrel sections, offers additional advantages in process flexibility — allowing thermal energy management tailored to the specific needs of battery electrode production.

The ZSK twin screw extruder offers a highly efficient solution for continuous manufacturing of dry coated electrodes, significantly optimizing the process. Automated operation ensures consistent product flow while reducing space requirements and personnel needs. Thanks to its excellent dispersive and distributive mixing capabilities, the ZSK extruder produces highly homogeneous materials, resulting in better product quality even when incorporating difficult-to-mix ingredients.

Coperion K-Tron twin screw feeders are ideal for battery electrode manufacturing processes due to their high accuracy and consistent material flow into the extruder. They ensure accurate feeding of dry electrode materials, such as active powders, conductive additives, and binders, which is critical for maintaining quality and consistency in electrode layers. Their advanced weighing technology provides real-time weight measurement, allowing for precise control of material feed rates and minimizing batch variability. These feeders are capable of handling challenging powder blends and sticky materials, which are common in electrode production. By maintaining a steady and accurate material supply, they optimize process efficiency and reduce material waste.

Coperion’s material handling solutions are tailored to meet the strict temperature requirements throughout the entire dry coating process. From conveying and feeding to handling the active material blends, Coperion supplies equipment that ensures precise temperature control and smooth processing, further enhancing efficiency and consistency in electrode manufacturing.

Battery Manufacturing Test Lab Capabilities

Coperion’s dedicated test centers, specifically designed for battery production research, provide comprehensive testing opportunities across various process steps, including pneumatic conveying, raw material handling and feeding, filtration, and continuous extrusion of battery masses. These facilities serve as ideal platforms for testing new products or process modifications. Supported by experienced Coperion experts, customers can optimize process design to maximize product quality, safety, and efficiency. The test centers accommodate all common raw materials used in active material and offer extensive simulation and scale-up expertise. A specialized research lab for hazardous substance testing is also available, ensuring a comprehensive approach to battery manufacturing innovation.

Nick Giefer, Batteries Business Unit Leader at Coperion says, “Our latest innovations, including the Loss-in-Weight Roller Feeder and advanced continuous extrusion capabilities, are designed to improve process stability, material efficiency, and scalability in battery manufacturing. These technologies help manufacturers produce high-quality, solvent-free electrodes more sustainably and cost-effectively, supporting the advancement of battery manufacturing."

www.hillenbrand.com

In avoiding costly breakdowns, Condition Based Maintenance (CBM) has been proven far superior to Planned Periodic Maintenance (PPM). Not only is PPM needlessly costly, due to the time wasted stripping down perfectly functioning machinery, it can sometimes make matters worse by introducing faults during the process of stripping down and rebuilding the machine. Even more of a problem is deciding the correct PPM time intervals. Too short an interval between services means more wasted time and cost (and more potential for introducing faults) but waiting too long means more unexpected breakdowns.

CBM makes use of tools such as vibration and temperature analysis to run an efficient and effective maintenance program able to predict faults BEFORE they occur. This is where the major cost benefit of CBM lies. Repairing faults AFTER a breakdown can be VERY costly, particularly where there has been collateral damage and/or injury to personnel. This is even more the case in hazardous locations where a complete shutdown of operations may also be required to effect repairs.

However, for use in hazardous locations, CBM instruments are required by law to be intrinsically safe and unable to ignite explosive atmospheres (ATEX). This means that vibration and temperature analysers must be CERTIFIED for use in the hazardous location. But the certification rules are different in different parts of the world AND in different “Zones” where explosive atmospheres are likely to exist. For example, a tanker vessel could visit many different oil and gas terminals in different countries, or a maintenance team might find themselves working unexpectedly at a wastewater treatment plant with the potential for methane build-up. So, how do you know you have the correct certification for your tools in all the different locations?

The simplest solution is to cover all eventualities by using instruments certified for Zone 0 (hazard exists continuously). Normally, that would make them much more expensive but fortunately Test Products International (TPI) has achieved a significant cost breakthrough with the very affordable TPI 9085Ex vibration analyser. With built-in on-meter diagnostics and the all-important ability to TREND readings over time, the “go anywhere” TPI 9085Ex has WORLDWIDE Zone 0 certification, meaning it can be used in ANY hazardous atmosphere and in ANY location.

 Based on international standards (ISO) the 9085Ex detects unbalance, misalignment and looseness in rotating equipment. It also measures “bearing noise” and displays it in bearing damage units (BDU) roughly equivalent to “percentage bearing wear”. In addition, the 9085Ex uniquely incorporates a directly contacting temperature sensor within its vibration probe. This gives a highly accurate, virtually instantaneous, surface temperature reading for the bearing, simultaneously as the vibration reading is taken. With a high BDU reading and high temperature, you know that what you are seeing really is a worn bearing.

The compact handheld TPI 9085Ex is extremely affordable and simple to use and an invaluable part of every maintenance tool kit. It can be used standalone for fault diagnosis or by using the FREE TPI Bridge App, “routes” and readings can be transferred to and from the 9085Ex anywhere in the world over the internet. “Routes” are simply lists of machines showing exactly what readings need to be taken and where to take them. The readings are then automatically time and date stamped by the 9085Ex and saved back into the route for automatic transfer to the included FREE TO USE computer-based trending software.

For more information please contact TPI Europe’s head office on +44 1293 530196 or take a look on the website at www.tpieurope.com or email This email address is being protected from spambots. You need JavaScript enabled to view it.

 Introduction

Explosion hazards can be hidden in everyday work tasks, yet they carry the potential for catastrophic harm to people, assets, and a company’s reputation. In the UK, the Dangerous Substances and Explosive Atmospheres Regulations (DSEAR) place a legal duty on employers to assess and control these risks. A key part of this process is establishing a basis of safety - a clear strategy for preventing or mitigating explosions in your operations.

Understanding the Legal Framework

DSEAR - the Dangerous Substances and Explosive Atmospheres Regulations - sets out the legal responsibilities for UK businesses handling flammable or explosive substances. Employers must identify hazardous materials, assess the likelihood of explosive atmospheres, evaluate possible ignition sources, and implement effective controls. Substances requiring assessment include raw materials, products, and by-products such as dusts, powders, gases, vapours, and flammable liquids.

Compliance goes beyond checking a legal box: it reduces the risk of devastating fires or explosions. To demonstrate this, businesses must document their findings in a suitable risk assessment. This record captures the properties of substances, outlines safe operating limits, and provides evidence that the business has taken systematic, proactive steps to protect its workforce and operations.

The Basis of Safety

A basis of safety is the defined method by which a business prevents or mitigates fires or explosions. Regulation 6 of DSEAR states that where employers cannot eliminate the risk, they should:

Control the Risks – reduce the quantity of dangerous substances, avoid/minimise/control the release, prevent the formation of a flammable atmosphere and control any ignition sources.

Mitigate the Effects of Fire or Explosion – reduce the number of employees exposed, explosion/fire propagation, explosion venting, suppression or containment systems.

The chosen basis must be justified with reliable data and supported by testing. Importantly, it should not be a “set and forget” measure, any basis of safety must be 

systematic, documented, and reviewed regularly to remain effective as processes, substances, or regulations evolve.

Role of Testing and Assessment

Testing is critical to understanding how substances behave and to defining a robust basis of safety. Accredited providers should offer a range of specialist tests, including:

• Dust explosibility testing (Kst, Pmax): measures explosion severity and maximum pressure rise.
• Minimum Ignition Energy (MIE): determines the smallest spark or discharge that can ignite the substance.
• Limiting Oxygen Concentration (LOC): identifies the oxygen level below which an explosion cannot occur.
• Electrostatic charge testing: assesses the likelihood of dangerous sparks from material handling or equipment.

These results feed directly into risk assessments, helping businesses establish safe operating parameters and select appropriate control measures. Independent, accredited testing not only builds confidence in safety systems but also provides credible evidence for regulators, insurers, and stakeholders that risks are being managed responsibly.

Conclusion

Explosion risks may not always be obvious, but their consequences are too serious to ignore. By complying with DSEAR, businesses not only meet legal obligations but also protect their people, assets, and reputation. Establishing a clear basis of safety, supported by accurate testing and independent expertise, ensures that controls are effective, justifiable, and resilient over time. Ultimately, managing explosion hazards is about more than ticking boxes, it is about creating a culture of safety that gives your business the confidence to operate securely and sustainably.

www.sigma-hse.com