How Do You Manage Combustible Dust and Process Safety Risks When Expanding Sugar Storage Capacity?

Summary: A large multinational food and beverage manufacturer engaged TEG Risk to complete a Hazardous Area Classification, Combustible Dust Risk Assessment and HAZOP review before commissioning a second sugar silo at an Australian manufacturing facility. Delivering the three studies as an integrated package ensured consistency of assumptions, findings and recommendations and gave the project team confidence that combustible dust and process safety risks had been appropriately considered before the system entered service.

What was the project and why did it require independent review?

A large multinational food and beverage manufacturer with factories across Australia and New Zealand was increasing sugar storage capacity at one of its Australian manufacturing facilities through the installation of a second sugar silo.

The new silo required integration into the existing sugar handling and production process. While combustible dust hazards already existed within the facility, the project modified the configuration of the sugar storage and transfer system and required review of the associated risks.

The manufacturer sought an independent review of the proposed design before commissioning. The objective was to identify process safety risks, combustible dust hazards and compliance requirements associated with the project, and to provide practical recommendations that could be incorporated during design and implementation.

Why does combustible dust risk matter in food manufacturing?

Combustible dust is often underestimated because it is a normal part of many manufacturing processes. However, when fine dust becomes airborne and an ignition source is present, the consequences can be significant.

Sugar is one of many food products capable of forming an explosive atmosphere under the right conditions. Activities such as conveying, filling, transfer and storage can generate airborne dust in sufficient concentrations to be hazardous and therefore require appropriate assessment and management.

For facilities expanding or modifying existing systems, it is important that hazardous area requirements are considered as part of the upgrade and that appropriate controls are implemented to manage both risk and compliance obligations.

Why was TEG Risk engaged for this project?

TEG Risk provides specialist expertise in hazardous areas, combustible dusts and process safety. The project required competency in Hazardous Area Classification to AS/NZS 60079.10.2, combustible dust risk assessment to AS/NZS 4745 and facilitation of a multidisciplinary HAZOP review.

TEG Risk was able to deliver all three studies as an integrated package, ensuring consistency of assumptions, findings and recommendations across the project.

TEG Risk personnel involved in the project held recognised hazardous area competency qualifications including Hazardous Area Classification & Design (UEEHA Certified) and Hazardous Area Classification (NZQA Unit Standard 17069 v2), together with extensive experience in hazardous area classification, combustible dust risk assessment and HAZOP facilitation.

TEG Risk has extensive experience supporting food and beverage manufacturers throughout Australia and New Zealand. The client required practical recommendations that could be incorporated into the project before commissioning.

What did the assessment involve?

TEG Risk was engaged to deliver three complementary studies:

• Hazardous Area Classification (HAC) in accordance with AS/NZS 60079.10.2, identifying potential dust release sources, establishing hazardous area zoning requirements, and producing hazardous area classification drawings and supporting source-of-release documentation.
• Combustible Dust Risk Assessment aligned with AS/NZS 4745, evaluating potential fire and explosion scenarios, ignition sources and explosion consequences associated with the new silo installation. Consideration was given to factors such as static electricity, hot work, mechanical failures, electrical equipment, housekeeping and explosion protection measures.
• Hazard and Operability Study (HAZOP), a multidisciplinary workshop involving operations, maintenance, engineering and safety representatives together with the equipment supplier, to identify process safety, operability and maintenance risks associated with the proposed design.

The review covered the proposed second sugar silo and associated equipment including dust collection, dehumidification and explosion protection systems.

What challenges did the project present?

The project involved three complementary studies that needed to align and produce a consistent set of recommendations. Multiple stakeholders were involved, including site operations personnel, maintenance representatives, project engineers and the equipment supplier.

Independent assessment required access to detailed design and operational information from a range of project participants and documentation sources. Recommendations needed to be practical, technically robust and capable of being incorporated into the project before commissioning.

The studies needed to balance compliance requirements, operational practicality and project delivery objectives.

What were the outcomes?

The manufacturer received an integrated review of hazardous area, combustible dust and process safety risks associated with the sugar storage expansion project. Key outcomes included:

• Identification and documentation of hazardous area zoning requirements prior to commissioning
• Assessment of combustible dust fire and explosion risks
• Review of process safety and operability considerations through a structured HAZOP process
• Development of a prioritised action list covering engineering controls, operational procedures, maintenance practices, training and hazardous area management
• Identification of compliance obligations and risk mitigation requirements

Importantly, the independent review provided confidence that combustible dust and process safety risks had been appropriately considered before commissioning.

The second sugar silo has since been commissioned and entered normal operation as part of the site’s expanded sugar storage capability. While implementation and commissioning remained the responsibility of the project team, the studies provided a structured and independent review of the design, helping the client understand relevant risks, compliance obligations and recommended controls before the system entered service.

The client subsequently advised TEG Risk that they were very happy with the outcome of the project.

Need support with a combustible dust or hazardous areas project?

Whether you are installing new equipment, modifying an existing process or seeking assurance that combustible dust risks have been appropriately managed, TEG Risk can assist with:

• Hazardous Area Classification (HAC)
• Combustible Dust Risk Assessments
• HAZOP Facilitation
• Machine Safety Assessments

Our team works with manufacturers across Australia and New Zealand to help identify risks early and provide practical, standards-based recommendations that support safe and efficient operations.

Talk to TEG Risk about your project.

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FAQ: Combustible dust and hazardous area classification

What is a Hazardous Area Classification (HAC)?

A Hazardous Area Classification identifies locations where explosive atmospheres may occur, establishes zoning requirements and produces documentation to support equipment selection, design review and hazardous area management. For combustible dusts, HAC is completed in accordance with AS/NZS 60079.10.2.

Why is sugar classified as a combustible dust hazard?

Sugar is one of many food products capable of forming an explosive atmosphere when fine dust becomes airborne in sufficient concentrations. Activities such as conveying, filling, transfer and storage can generate hazardous dust concentrations that require appropriate assessment and management.

What is a HAZOP and why is it used for process safety?

A Hazard and Operability Study (HAZOP) is a structured, multidisciplinary workshop that systematically examines a proposed or existing process to identify potential failure scenarios, operability issues and process safety concerns. It generates a prioritised action register for review and close-out by the project team.

What standards apply to combustible dust risk assessment in Australia and New Zealand?

Key standards include AS/NZS 60079.10.2 for Hazardous Area Classification involving combustible dusts and AS/NZS 4745 for combustible dust risk assessment. Compliance obligations may also apply under work health and safety regulations.

Why should combustible dust, HAC and HAZOP studies be done together?

Completing these studies as an integrated package ensures that assumptions, findings and recommendations are consistent across the project. This avoids gaps or contradictions that can arise when studies are completed separately by different providers at different times.