Explosion-Proof Robots in Manufacturing: Applications, Safety, Brands, and Costs

In modern manufacturing environments where flammable gases, vapors, or dust are present, even a small spark can result in a catastrophic event. For instance, an automotive paint booth is a high-risk zone where flammable particles from solvent-based paints are suspended in the air. To operate safely in these volatile conditions, manufacturers increasingly rely on explosion-proof robots. These specialized robotic systems are engineered to prevent sparks or surface temperatures that might ignite hazardous atmospheres.

This article explores key applications of explosion-proof robots in manufacturing, the leading brands and certified models available, relevant safety standards (NEC, ATEX, CSA, OSHA), and provides an overview of typical cost and pricing factors. This information is especially relevant for business owners, safety officers, and automation decision-makers seeking to implement robotics in classified hazardous locations.

Real-World Applications of Explosion-Proof Robots

Explosion-proof robots are deployed across several industries to handle flammable substances safely. Common applications include:

Oil & Gas and Petrochemical

Facilities like refineries, offshore rigs, and chemical plants contain flammable gases and vapors. Robots like ANYbotics’ ANYmal X are designed for ATEX Zone 1 operation and perform autonomous tasks such as gas leak detection, gauge reading, and valve operation. Their sealed, pressurized bodies eliminate the risk of ignition, reducing the need to send humans into dangerous zones.

Automotive Paint Shops

Paint spraying generates flammable aerosols. Explosion-proof robotic arms like KUKA’s AGILUS EX and ABB’s IRB 5510 PixelPaint are certified for Class I Division 1 environments and use continuous purging to prevent ignition. These robots automate high-precision painting while ensuring safety in hazardous paint booth atmospheres.

Chemical and Pharmaceutical Manufacturing

Pharmaceutical plants, such as Pfizer’s Kalamazoo facility, use Staubli TX2-60 explosion-proof cobots in solvent-handling areas to automate ingredient transfer and mixing. These robots achieve precision and eliminate the risk of static discharge in Class I Div 1 areas. Chemical facilities benefit similarly when handling flammable solvents and powders.

Food and Grain Processing

Fine organic dusts (e.g., flour, sugar) can cause explosions in food processing facilities. Ardent Mills retrofitted its plant with explosion-proof robots for material handling, achieving a 63% reduction in dust explosion risk. These robots are sealed to IP66/IP67 standards and meet Class II Div 1 safety requirements for combustible dust environments.

Mining and Metals

In mines and metals processing, explosive methane or metallic dust is a hazard. Anglo American deployed explosion-rated cobots to monitor methane levels in coal mines, while Lockheed Martin uses explosion-proof ABB robots for assembling parts in aluminum dust environments.

Each application illustrates how hazardous-area certified robots enable safe automation in settings where traditional equipment is unsuitable.

Leading Brands and Explosion-Proof Robot Models

Manufacturers have developed a wide range of explosion-proof robotic arms and cobots. Notable options include:

FAIRINO FR Series

• Payloads: 3kg to 30kg

• Certifications: CE, CR, ISO9001, and explosion-proof

• IP Ratings: IP54 to IP66

• Programming: Python, C++, C#, Java

• Applications: Welding, palletizing, and hazardous material handling

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ABB Robotics (IRB 5400/5500 Series)

• Designed for automotive paint applications

• Certified for ATEX Zone 1 / Class I Div. 1

• Features positive internal pressure for flammable vapor environments

FANUC CRX-10iA/L Paint

• The world’s first explosion-proof collaborative robot

• Ideal for high-mix painting automation

• Certified for Class I Div. 1 hazardous areas

KUKA KR AGILUS EX

• Compact 6-axis robot (6–10 kg payload)

• Continuous air purging for Zone 2/22 operation

• Often used in automotive paint systems by Dürr

Yaskawa Motoman MPX / PX Series

• FM-approved for Class I Div. 1

• Includes handling robots like the MOTOMAN-MHP45L with 45kg payload

Kawasaki K Series Paint Robots

• Longstanding reputation for explosion-proof paint automation

• Certified for ATEX / Class I Div. 1 environments

• Hollow wrist designs and integrated paint controls

Other notable entries include:

• Han’s Robot Elfin-EX cobots with positive pressure enclosures

• ANYmal X and ExRobotics ExR-1 mobile units for Zone 1 inspections

Safety Standards and Certifications

Integrating explosion-proof robots requires strict adherence to standards:

NEC and OSHA (USA)

• NEC Class I, II, III covers gas, dust, and fibers

• Division 1: Hazard is likely present during operation

• OSHA requires compliance with 29 CFR 1910.307

• Equipment must be certified by NRTL labs (e.g., UL, CSA, FM)

ATEX (Europe) and IECEx

• Uses Zone 0/1/2 for gases and Zone 20/21/22 for dust

• Robots must meet Directive 2014/34/EU

• Markings like Ex II 2G denote suitable environments

CSA and CEC (Canada)

• Uses a Class/Zone system similar to the U.S.

• CSA-certified equipment ensures compliance with Canadian safety codes

Proper certification ensures robots are safe for specific hazardous zones and substances. For example, a robot operating around acetone vapors must carry Class I Div 1 Group D certification.

Cost Considerations for Explosion-Proof Robots

Base Pricing

• Standard industrial robots: $20,000 to $100,000+

• Explosion-proof models: 40%–60% higher

• Example: A $50,000 robot might cost $75,000–$85,000 in explosion-proof form

System Integration

• Includes purged control cabinets, certified grippers, and sensors

• Full system installations can exceed $200,000

• Retrofitting older facilities can cost $1 million+ in extreme cases

Maintenance and Operation

• Spare parts (e.g., explosion-proof motors) are 2–3× more expensive

• Routine inspections are required to maintain certifications

• Total cost of ownership includes safety compliance and inspection systems

Despite higher upfront costs, explosion-proof automation reduces long-term liabilities, insurance premiums, and risk exposure. Businesses also gain access to automated operations in environments that were previously inaccessible.

Final Thoughts

Explosion-proof robots are essential for safe, compliant automation in volatile industrial environments. Whether it’s a paint shop, chemical lab, grain processor, or petrochemical plant, these robots offer a reliable solution for boosting productivity while maintaining the highest safety standards.

Brands like FANUC, ABB, FAIRINO, KUKA, Yaskawa, and Kawasaki have set the benchmark for Class I Division 1 and ATEX-certified robots. As safety regulations evolve and the need for automation grows, investing in explosion-proof robotic systems will become a standard best practice in hazardous manufacturing.