Pyroban Group has converted two hybrid forklifts manufactured by Still GmbH.

Two hybrid forklifts with explosion protection are believed to be the "first of their kind" for energy-efficient use in potentially explosive atmospheres.

For the first time, the Pyroban Group has converted two hybrid forklifts manufactured by Still GmbH in Hamburg that combine diesel and electric power.

Robin Chapman, principal engineer for Pyroban's safe handling division, says forklift technology has become increasingly complex.

"Energy consumption and the environment are driving forklift design, leading to new and innovative handling technology," he says.

Chapman adds that converting equipment for use in an explosive atmosphere has become "progressively challenging".

"Increased electronics, controls and performance-enhancing components like turbochargers have led to continued investment in Pyroban's own technology to match requirements," he explains.

To complete the Still forklifts' conversions to ATEX 94/9/EC, Pyroban had to assess every component on the vehicles to identify potential causes of ignition through heat, sparks, static energy and other sources.

The naturally aspirated 1.9 VW diesel engines, all motors, brakes, electrics, the forks, the seat and other components were modified using explosion-protection techniques that included restricted breathing enclosures and surface temperature cooling.

"The trucks are required for zone 2 operation, so we were able to use Pyroban's System 5000 which combines gas detection and automatic truck shutdown with various protection methods," Chapman explains.

Pyroban's System 5000 incorporates an automatic calibration and gas test to ensure that the gas detection system is working daily.

"We have retained almost all the original characteristics of the truck including the exhaust system but more importantly, the overall environmental performance has not changed. I believe these are the first of their kind," Chapman says.

Pyroban Group Ltd provides explosion-proof safety and environmental solutions globally. The company was established in 1972 and has manufacturing facilities in the UK, the Netherlands and China. ATEX is the European Union legal framework for controlling explosive atmospheres and the standards of equipment and protective systems used in them.