Less bang, less bucks
June 1st 2009

There's usually more than one way to skin a cat, and that applies to flame-proofing MHE, according to Pyroban business development manager, Malcolm Davis. He says the firm's knowledge of EX and ATEX regulations, and how to balance appropriate solutions with individual applications, can save end-users a lot of money. Brendan Coyne reports

Pyroban's pioneering work in explosion proof equipment has seen it become a trusted partner of some of the world's largest companies and materials handling equipment manufacturers alike. At a component level, the firm devises a solution for any part that could conceivably cause an explosion in a hazardous environment, sources new parts, builds new enclosures and deploys its patented explosion-proof technology into the rebuild. Sound complicated? According to Malcolm Davis, business development manager for the Pyroban group, it is:

"Apart from the most common, every truck that comes through the works is different – and therefore a development in itself. But our success is built on creating solutions based around the customers choice of equipment." For example, he says the new turbo diesel engines found on recent Linde and Jungheinrich trucks, meant sourcing a turbo charger from Japan that's surfaces won't cause a simultaneous explosion when they come into contact with gas or vapour. "Then we have to match the turbo charger to the engine and then the engine management system, ensure it is emissions-compliant and meets all the other regulations," Davis explains. "It's a lot more than meets the eye. Technology, such as new CANbus systems, is advancing all the time. So we spend a lot on R&D (new product development represents five per cent of turnover) to ensure we can give customers their choice of flame-proof trucks."

Given the complexities, how long does a conversion take – and how much does it cost? Davis says that depends on whether Pyroban is converting it for the first time or repeating a process, and whether the requirement is ATEX Zone 1 or Zone 2. "If we hadn't done the truck before, the process is typically 16 weeks, but can be up to 20 on a complex conversion for the first time. We have to work out how we will do it without compromising the Machinery and EMC Directives before we do anything. So we study the truck, work with the original manufacturers to work out where the limitations are, and study the technical information we need as part of the process. Once that has been achieved for a particular model, you've halved the time."

Cost is dependent on what the truck is being used for – for example a truck that works both in and outside may need a cab, lights, windscreen wipers, all of which require flameproofing.

"A Zone 1 counterbalance conversion can be £25,000 - £30,000. But it's not related to the cost of the original equipment: A pallet truck costing £4,000 might cost £12,500 to convert."

A Zone 2 conversion, though, is considerably less – around half according to Davis – and Pyroban's knowledge of matching equipment to applications is increasingly where the firm makes its money, giving the customer more (or should that be less?) bang for their buck.

"In most cases there is more than one way of doing things. We give free, impartial advice to manufacturers, dealers and end users. We don't tell people what to do or how to operate their equipment but asking us for our opinion has seen tremendous results." By way of recent example, Davis cites GlaxoSmithKline, six miles along the coast in Worthing.

"GlaxoSmithKline was looking at having a couple of Linde trucks made explosion proof to Zone 1, but when it came to sign off, the cost was prohibitive given the current climate. So the Linde account manager asked me to have a meeting at the site and see if there was any other route forward: there was; we could use Zone 2 equipment where, maybe 10 years ago they would use Zone 1. GlaxoSmithKline's people came here, we demonstrated how it could be done, and they decided it could be classified as Zone 2," Davies explains. "The order was placed two weeks ago – so GlaxoSmithKline has its trucks, Linde has its order, we have our order – and all at a fraction of what it would have cost."

Maintenance savings for Zone 2 trucks compared to Zone 1 are also significant: "many thousands of pounds over the lifetime of the truck" according to Davis. Pyroban trains lift truck suppliers' engineers at the Shoreham plant – and provides an annual audit as a safety net. "You have to ensure what was delivered on day one as explosion proof remains explosion proof throughout its lifetime. End users want the people who supply the truck to maintain it: we ensure they understand how to do that; and the service engineers who come to us for training tend to be the better ones. If a truck breaks down in a standard application, there's a loss of productivity. But if a flameproof truck is not correctly maintained, it can cause devastating loss of life."

However, Davis says Pyroban's field service engineers support the manufacturer's or dealer's own engineers when a problem needs addressing.

For applications where some level of explosion protection is required, Pyroban has recently developed the Gas Checker product – which essentially will not allow a piece of equipment to operate if there is gas or vapour in the environment. It is relatively low cost and takes only a day to fit, giving firms "an umbrella of safety around their operations," according to Davis.

"For example, a chemical manufacturer might be operating 10 trucks that need to be converted to Zone 2. To do that all at once would disrupt or halt the operation for months. It is more viable to convert one or two trucks at a time. In the meantime, the remaining trucks could be fitted with the Gas Checker to satisfy health and safety requirements, Davis explains. "It helps reduce the exposure of end users – and is being picked up by companies including Proctor & Gamble, Shell, BP, Calor Gas and many more. It can be taken on or off a piece of equipment, is relatively low cost and can be used time and time again on different pieces of kit."

It is this solutions-driven approach – matching technology to applications – that has seen Pyroban grow steadily to a £36m firm. Some of the lift truck industry's more knowledgeable people have been through its doors at some time or another, and the company is well regarded by manufacturers, dealers and end users alike. Which is a sound example of how to turn disaster into success – if the explosion at ICI in 1969 had never happened, operators around the world would not be as safe as they are today.

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