Protection against lightning and associated surges is a cornerstone of business continuity in the industrial sector, particularly within food processing. Production downtime caused by electrical system failures—or, even worse, ignition in areas at risk of explosion—can result in significant financial losses and compromise critical processes such as the cold chain.
This case study examines the thermal and electrical safety upgrade implemented in 2023 at the Fratelli Salmoiraghi S.r.l. facility in Gorla Maggiore (Varese), a company specializing in the butchering and portioning of pre-slaughtered meat.
The facility is located in a predominantly rural area—a geographical setting that historically exposes structures to a higher risk of direct and indirect lightning strikes due to the site’s isolation and flat topography. The industrial complex comprises four main functional zones:
- Office building
- Production building
- LPG storage area
- Vehicle refueling area
The Technical Challenge: ATEX Risk Analysis and Critical Issues
Designing the system required a careful risk assessment in compliance with strict current regulations (CEI EN 62305-1 and 2). The analysis revealed a varied structural situation:
- Building 1 (Offices and Residential): A two-level structure (ground floor offices, first-floor residence). Calculations regarding lightning strike exposure indicated that the building was *self-protecting* under the regulations. However, given its proximity to the production area, the client opted for a highly cautious approach, extending full lightning protection to this building as well to safeguard IT systems and ensure personnel safety.
- Building 2 (Production and ATEX Area): The production building was found *not* to be self-protecting. The primary risk factor lay inside the building: an area of approximately 20 m² used for charging electric forklifts, classified as ATEX Zone 1 and 21 due to the risk of explosion from the occasional presence of flammable gases (Zone 1) or dust (Zone 21).
- Outdoor Areas with Specific Risks: The company yard presented additional classified hazards: an LPG storage tank and a diesel dispensing pump for transport vehicles. These exposed elements required complete shielding against direct lightning strikes and their associated effects.
The challenge was twofold: eliminating the risk of fire and explosion in the ATEX zones and protecting production automation panels from transient overvoltages capable of damaging meat-processing machinery and disrupting operations.
The Solution Adopted: Euthalia Antimpatto® Technology
Two types of lightning protection currently exist on the market: devices designed to intercept and attract the leader channel—the discharge itself—and capacitor-based systems that continuously drain electrostatic charge in an attempt to inhibit the discharge from forming. Both approaches rely on receiving and dissipating the discharge, and neither can guarantee total protection, particularly during exceptionally intense weather events in highly exposed areas like the one in this case study.
To meet the highest safety standards, the Euthalia Lightning Protection System—featuring Ingelva’s Antimpatto® (Anti-Impact) Technology—was implemented in 2023.
Unlike those other systems, Euthalia technology employs a unique approach backed by over 70 years of experience, a track record of zero damage across all protected sites, and excellence in lightning protection standards.
Euthalia technology—the first of its kind globally—is designed to completely neutralize the formation of the discharge within the protected area, effectively preventing lightning from striking the protected zone.
This unique technology ensures a system characterized by “zero lightning strikes and zero energy consumption.”
Total Protection Against Direct Lightning Strikes and Surge Voltages
The capture and shielding of critical areas were achieved using five air terminals strategically positioned to cover the facility’s geometric volumes, in accordance with the protection angle and rolling sphere methods:
- 1 air terminal on the office building;
- 2 air terminals on the production halls;
- 1 air terminal protecting the LPG area;
- 1 air terminal covering the diesel refueling zone.
SCt filters (high-impedance filters for the grounding circuit) were installed between the air terminals and the grounding system; these serve to intercept induced or direct overvoltages entering via the grounding system—caused by indirect and upward discharges.
Protection was finalized by installing surge arresters upstream of every electrical panel to safeguard all electrical and electronic equipment against line overvoltages.
Results and Benefits for the Client
The integration of Euthalia’s comprehensive lightning and surge protection systems has enabled Fratelli Salmoiraghi S.r.l. to achieve exceptional safety standards:
- Complete securing of ATEX zones: Potential ignition sources—such as lightning strikes or sparks caused by voltage surges—have been neutralized in the forklift charging area and fuel/gas storage facilities.
- Guaranteed business continuity: Elimination of operational downtime risks caused by failures in industrial machinery electronic boards.
- Compliance: Bringing Building 2 into regulatory alignment has ensured the company meets workplace safety requirements (Legislative Decree 81/08).
Thanks to this project, the Gorla Maggiore facility stands as a prime example of how Euthalia’s lightning protection technology can be integrated into complex industrial environments, where operational continuity and safety within ATEX zones are non-negotiable requirements.
The Client:
- Company: Fratelli Salmoiraghi S.r.l.
- Location: Gorla Maggiore (VA)
- Sector: Meat processing and portioning (Industrial / Food Industry
- Installation period: 2023
Do you want to stop having to shut down production every time there’s a thunderstorm? Secure your business and your work today.
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