Drum Inspection in Ex Zones

Inspecting drums in filling, storage and handling facilities in the chemical, pharmaceutical and petrochemical industries places high demands on image quality, illumination and explosion protection. The ATEX-certified HD IP camera CVG-SAB-WCA-TF from Tippkemper-Matrix reliably inspects drum openings, fill levels, labels and codes – even in Ex zones 1, 2, 21 and 22. Combined with a 1000 lm continuous light source and a coaxial LED ring light, it delivers shadow-free, low-reflection images that are stable enough for automated evaluation.

Application – What drum inspection checks

Typical tasks include fill-level measurement in open 200-litre drums, detection of contamination, particles or foreign objects on the liquid surface, label verification, and reading batch and identification codes (QR code, EAN-13, Code 39, Code 128 and others). Lid, bung and seal checks, identification during inbound and outbound handling, and automated image comparison for pass/fail decisions are also common.

Why the CVG-SAB-WCA-TF for drum inspection?

The CVG-SAB-WCA-TF is a Raspberry-Pi-based HD IP camera designed specifically for high-resolution image inspection in hazardous atmospheres. It delivers full HD video streaming up to 1920×1080 at 30 fps and still images up to 8 MP (3280×2464 px), and ships with integrated code recognition for common 1D and 2D symbologies. Control runs over Modbus TCP, making PLC integration straightforward. The IP67 stainless-steel housing (1.4404) with Gorilla-glass window and M42 thread is robust and chemical-resistant, and the camera is powered via Power over Ethernet. Its Ex approvals II 2(1)G Ex db [op is Ga] IIC T4 Gb and II 2(1)D Ex tb [op is Da] IIIC T135 °C Db cover all relevant Ex zones around drum filling stations.

Lighting – 1000 lm continuous source plus ring light

The quality of any optical drum inspection depends on lighting. Two challenges are typical: reflections on glossy liquid surfaces and illumination reaching the bottom of deep 200-litre drums. Combining a continuous light source with a ring light solves both.

Ex continuous light source, 1000 lm

The ATEX-compliant continuous light source delivers 1000 lumens of stable white light and handles base illumination inside the drum. Continuous (non-pulsed) output means flicker-free images at high frame rates – ideal for live streams, video-based evaluation and drums moving on roller conveyors.

LED ring light coaxial to the lens

Mounted concentrically around the camera lens, the ring light provides axial, shadow-free illumination directly along the line of sight. Liquid meniscus, bung opening and inner labels are evenly lit, avoiding the hard side shadows that single-spot lighting tends to create.

How the combination works

Axial ring light plus angled continuous illumination produces soft, even light with reduced highlights – exactly what critical media such as solvents, oils, coatings or pastes require for reproducible results, whether the operator inspects manually on a monitor or the image is evaluated automatically by a PLC or edge system.

Typical setup

A proven setup uses the CVG-SAB-WCA-TF centered roughly 600 mm above the drum opening (matching the camera's fixed focus), a ring light mounted directly at the camera front, and a 1000 lm continuous source on a stainless-steel swing arm at the side. A single industrial Ethernet cable connects to a PoE switch in the safe area; the Modbus TCP interface handles process control and triggering – for example, capturing an image as soon as a drum reaches the inspection position.

Key benefits

Automating drum inspection with the CVG-SAB-WCA-TF, a continuous light source and a ring light replaces manual visual checks in hazardous areas, provides complete documentation with timestamp and code reference, reduces error rates during filling, labelling and identification, ensures reproducible results through consistent lighting, and is virtually maintenance-free thanks to stainless-steel hardware and ATEX certification.

Plan your drum inspection

Planning automated drum inspection in a hazardous area? Tippkemper-Matrix supplies the complete solution – Ex camera, Ex continuous light source and ring light – including advice on mounting, Modbus integration and image evaluation. Get in touch.