Intrinsically Safe Radios for Pharmaceutical Plants: Safe, Clean, Compliant

Why Pharmaceutical Plants Require Intrinsically Safe Radios

In pharmaceutical production environments, safety, cleanliness, and precision must be considered equally in high-risk operations. These companies often work in sterile areas, deal with volatile solvents, and must adhere to strict legal regulations such as GMP (Good Manufacturing Practices). Communication devices should be used without the risk of contamination or fire.

For safe and efficient communication to continue in such delicate areas, intrinsically safe radios are essential. In contrast to conventional two-way radios, intrinsically safe handheld radios are designed to avoid sparks, excessive surface heat, or circuit exposure—all of which are crucial characteristics in hazardous areas that are prone to explosions or contamination.

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Common Hazards in Pharmaceutical Plants

• •  Volatile solvents used in cleaning or formulation include acetone, isopropyl alcohol, and ethanol.

• •  Zone 22 Combustible Dust: During processing, powdered ingredients may fly into the air.

• •  Tight Hygiene Conditions: Resistance to harsh cleaning agents is necessary for cleanroom-grade operations.

• •  Electrostatic discharge is frequently observed in dry environments and on packaging lines.

  In such dangerous situations, standard communication tools are inappropriate. They might produce static, corrode, or shed particles, all of which are against ATEX/IECEx or GMP safety regulations.

Intrinsically Safe Radios Application Scenarios in Pharmaceutical Plants

Cleanroom Operations

• •  Used by operators in gowning zones, formulation rooms, and aseptic processing suites
• •  Must withstand frequent disinfection
• •  Surfaces must be sealed to prevent microbial growth or dust accumulation.

Areas for Weighing and Mixing

• •  Combustible dust may be released during the handling of active ingredients.
• •  There is a risk of ignition from static discharge from portable electronics.
• •  Reliability and spark-free communication are essential.

Inspection and Packaging Zones

• •  Continuous machine operation generates ambient noise.
• •  Real-time coordination is crucial without compromising sterile practices.

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Advantages and Trade-Offs of Intrinsically Safe Radios in Pharmaceutical Plants

Advantages

• •  ATEX/IECEx Certified: Completely approved for use in areas that are prone to dust and explosions
• •  Anti-Corrosion Housing: Safe for cleaning with ethanol and impervious to chemicals
• •  Dust/Water Resistance: In GMP settings, a high IP rating guarantees long-term dependability.
• •  Thermal Protection: Surface temperature stays below the threshold for ignition

Issues to Consider About

• •  Cost: Increased as a result of thorough certification and testing
• •  Periodic Validation: Inspections are necessary to preserve the integrity of certifications.

Retevis E2 Solutions for Pharmaceutical Plants Communication Safety

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• Surface corrosion or dust accumulation risks contamination

Challenge: Over time, residue may build up on cleanroom equipment due to frequent disinfection (e.g., alcohol sprays). Cracks or • corrosion may harbor particles and jeopardize hygienic conditions.

The Retevis E2 Explosion-Proof Radio Solution:

• IP68 protection: Complies with GMP-grade cleaning standards and can withstand repeated alcohol wiping and pressurized water spray.
• ABS+PC V0 housing: Able to withstand mild exposure to acids and alkalis, including diluted sodium hypochlorite and 75% ethanol.

• Hazards of dust infiltration and static discharge (Zone 22)

Challenge: Airborne particles and electrostatic buildup can jeopardize device function and safety in low-dust pharmaceutical environments.

Retevis E2 Digital Explosion-Proof Radio Solution:

Exic IIIC T100°C Dc certified: Safe for use in areas with flammable dust because the surface temperature stays below 100°C.

• Voice communication is unclear due to high ambient noise.

Problem: Acoustic noise produced by mixers, HVAC systems, and stainless steel equipment can obstruct voice communication.

Retevis E2 Intrinsically Safe Radio Solution:

• Compared to VHF, the UHF 400–480 MHz band provides superior penetration through metal walls, making it perfect for environments with a lot of stainless steel.
• A digital sensitivity of 0.25 µV (5% BER) guarantees steady reception and clarity even when the signal is weak.

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How to Choose the Right Radio for Your Pharma Operation

Before using handheld radios in a pharmaceutical plant, considering the following:

• •  Explosion-proof Certicified: Must meet ATEX Zone 1/2 or 21/22 standards

• •  IP68 Rating: Withstands alcohol and chlorine-based disinfectants

• •  Frequency Suitability: UHF preferred in metal-dense environments

• •  Safe Battery: Low heat generation with built-in protection circuits

• •  Group Communication: Support for zones, teams, and emergency broadcast

Conclusion

Pharmaceutical production environments demand both safety and sterility. Standard radios can compromise both. With certified intrinsically safe radios like Retevis E2, your facility ensures reliable communication without sacrificing regulatory compliance or workplace safety.