How do you ensure effective process safety not in one, but across multiple plants? The most efficient approach is standardisation – both in documentation and in the selection of protection measures. This is exactly how one Polish grain processing group approached the challenge in cooperation with GRUPA WOLFF.
Companies from various industries often turn to us for support in industrial safety. This applies not only to technical solutions that actively protect specific installations or areas within a plant, but also to developing the procedures and documentation required by law.
We often see that in large organisations each plant “works in its own way”. Documentation is created in different formats, based on different assumptions and with varying risk-assessment criteria. The result? Comparing outcomes becomes difficult, which makes it harder to set investment priorities across the group. Inconsistent protection concepts also make implementation longer and more expensive. Dispersed efforts extend the investment process, increase costs and blur accountability for compliance.
The solution is standardisation, i.e. organising documents and procedures, which makes it easier to maintain compliance with ATEX directives across the entire organisation. This was the case for one of the Polish grain companies. Systematically expanding its knowledge of explosion safety, the team came to the conclusion that a systematic approach to implementing safety measures across the entire group was needed, rather than just at the level of individual plants. And it all started with… an ATEX audit.
The Need to Standardise Explosion Protection Across Multiple Plants in Poland
The client recognised that, in addition to technical solutions, comprehensive documentation was required – above all, Explosion Protection Documents for each facility.
However, management wanted to introduce standardisation, as up to this point each plant had operated independently and handled explosion protection on its own. This approach was about to change.
The company’s leadership sought a partner to guide them through this standardisation process. Key selection criteria included comprehensive explosion safety services and the ability to deliver solutions tailored to the specific needs of each production stage. Equally important was the partner’s extensive experience in assessing explosion risks and selecting the appropriate protective measures to reduce them.
From Initial Meeting to ATEX Audit
Originally, the grain company approached us with a request to carry out an ATEX audit for three plants, followed by the development of the required Explosion Protection Documents. During the meeting, however, our experts realised that the client was, in fact, looking for a solution that would enable a comprehensive approach to explosion safety across all sites.
The ATEX audit was therefore the ideal starting point. As a proven method for assessing the current state of explosion safety, it provided a clear diagnosis and formed the basis for planning further actions to improve safety and introduce the necessary standardisation across the organisation.
What Is an ATEX Audit?
An ATEX audit provides comprehensive support in identifying explosion hazards within industrial plants and strengthens awareness of explosion protection. It also helps to tailor protective measures to the specific needs of the facility.
Why an ATEX Audit?
During the audit, we conduct interviews, carry out a site inspection, and then prepare a report for the client. The next step is a meeting to discuss the findings and present possible actions to enhance safety. We propose protection measures in a comprehensive and structured way.
We start by assessing how to minimise the formation of explosive atmospheres during production processes. Next, we identify potential ignition sources that must be eliminated. Only as the third step do we select safeguards to reduce the consequences of a potential explosion.
Why It’s Worth It: Operational and Financial Benefits
Each audit report includes an analysis, photographic documentation, a list of recommendations and proposed next steps. We set clear priorities – indicating which actions should be taken first to improve explosion safety as quickly as possible. This also helps plan the budget required for implementing protection measures.
We recommend solutions that provide the best safety results at an optimal cost. We also advise on organisational measures that can enhance safety before any investment in technical systems is made. In this way, the audit not only shows the client what needs to be done, but also in what order, to achieve the greatest effect.
From Audit to Explosion Protection Document (EPD)
After completing the audit, the client implemented our recommendations and secured the critical areas identified in the report, which allowed us to move efficiently to preparing the EPD. This stage was significantly easier and faster thanks to the ATEX audit findings and the actions already taken by the client — we knew the plant was properly protected.
After completing the audit, the client implemented our recommendations and secured the critical areas identified in the report, which allowed us to move efficiently to preparing the EPD. This stage was significantly easier and faster thanks to the ATEX audit findings and the actions already taken by the client — we knew the plant was properly protected.
Based on our observations, up to 80% of industrial plants are not ready to sign the declaration in the EPD, as they have not implemented the required measures or the selected safeguards do not reduce the risk to an acceptable level.
Standardising Documentation and Recommendations Across Further Sites
After completing the first three plants, the client saw the value of standardisation. A repeatable audit and assessment process, tailored recommendations, and a unified EPD structure led the client to request additional ATEX audits for other locations even before the initial documentation was finalised. They also decided to begin implementing some of the recommended solutions immediately.
We are particularly pleased that we were able to effectively share our expertise. How do we know this? First, throughout the cooperation, the client continuously consulted their actions with us. Second, we were invited to deliver internal training sessions for employees on explosion safety and protection against static electricity.
Benefits of Standardisation
Standardisation is not a cost, but an investment in improving safety, as it enables comprehensive and consistent protection across the plant.
Introducing standardisation in both documentation and protective measures brings more than just order. The benefits support organisations on multiple levels.
Order in Documentation
A single standard defines one template for all sites. This makes document control and prioritisation easier, and facility managers know what the procedures look like, what risks to address and how to maintain the required level of safety.
Consistent documentation also enhances the company’s credibility with insurence companies, as it allows them to quickly review and understand the safety standards that are key to the organisation.
Easier Creation of New Documentation
Standardisation defines clear elements that must be included in every document. This ensures transparency and prevents the creation of unclear or impractical documentation.
When technological processes change or machinery is replaced, the explosion risk must be reassessed. With a standard in place, updating existing documents or preparing new ones becomes much easier.
It also supports cooperation with external service providers, as they immediately know what documentation standard the client expects.
Increasing Safety Across the Plant
Standardisation also helps to build good habits and increase risk awareness among employees. This, in turn, reduces human error – and it is human error, combined with low hazard awareness, that most often leads to serious incidents.
Easier Resource Management Across the Group
Introducing uniform solutions and standards in all plants enables more effective resource management. For example, applying the same maintenance procedures for technological processes allows for more accurate planning of servicing, repairs and cleaning activities at each site.
Standardisation also ensures that production, storage and logistics processes take into account the required equipment inspection procedures, which is crucial in explosive atmospheres.
Better insurance terms
Insurance companies pay close attention to documentation, equipment and procedures – everything that demonstrates a commitment to safety, including internal standards.
Standardisation shows that safety is a well-planned and consistently executed process, not an ad-hoc effort. It proves credibility and reduces the likelihood of gaps in protection. Using one risk-assessment standard and uniform protective measures across all plants also enables insurers to easily compare safety levels.
Implementing well-designed standards for documentation and protection systems sends a clear signal to insurers: the company understands the risks and actively manages safety.
By reducing the probability of an explosion or fire, the company increases its chances of securing more favourable insurance terms.
Summary: Standardisation Is Crucial When Managing Multiple Sites
To ensure safety efficiently across several facilities, standardisation is essential. This approach enabled our client to obtain complete and compliant documentation for eight sites and, at the same time, significantly strengthen safety — both through the implementation of specific protective measures and by training the team. All of this was achieved without spending money on incomplete studies or inadequate safeguards. It provides a solid foundation for further improving safety across the organisation.