Prickly Pear Engineering

De-risk Your JourneyAccelerate Your Launch

We specialize in developing compliant products for explosive atmospheres, managing IECEx, ATEX, HazLoc, and global certifications to eliminate costly delays and free you to focus on your core business.

Explosive Atmosphere Engineering Excellence

Prickly Pear Explosive Atmosphere Solutions
ATEX
IECEx
HazLoc
UKEX
INMETRO
and others

We simplify your path to market in the highly regulated industry by transforming complexity into a clear, manageable process.

Proven Experience

With extensive leadership in product development, we've successfully guided products from initial concept to final certification.

Deep Standards Mastery

Our deep expertise in the IEC 60079 series of standards ensures your design is compliant from day one.

Global Partner Network

We leverage our network of trusted certification partners to navigate the process efficiently and avoid costly delays.

Our Services

A complete range of services for developing and certifying products for hazardous locations.

Global Certification, Simplified.
We define the most efficient and cost-effective certification strategy based on your specific target markets and product requirements.
Safety by Design, Not by Chance.
We integrate fundamental safety principles and the correct protection methods directly into your product's architecture from day one.
Engineered for Compliance.
We translate complex standards into precise engineering requirements to ensure your design is compliant upon first submission.
Documentation Done Right, First Time.
WWe prepare and assemble the complete technical file required by certification bodies for an efficient and successful review.
Quality That Passes Every Audit.
We set up robust quality systems so you scale with confidence.
Expert Technical Advisory.
We provide ongoing technical advisory and strategic guidance to help your team solve complex compliance challenges as they arise.

We integrate compliance and manufacturing requirements from day one.

This ensures you avoid costly surprises and stay on track for a successful launch.

Why Choose Explosive Atmosphere Specialists?

Explosive atmosphere compliance isn't just another engineering challenge, it's a specialized field requiring deep knowledge of hazardous area classifications, protection methods, quality management systems, and international certification processes. Our exclusive focus means you get experts who live and breathe this domain.

100%
Explosive Atmosphere Focus
IECEx
Foundational Expertise
Global
Standards Coverage
Prickly Pear Engineering

"In explosive atmospheres, one design oversight =$0+in recertification costs, $50,000 in engineering time, 6+ months of delays, and competitors beating you to market. We prevent all four."

Our core approach is prevention through preparation. We front-load the critical decisions, mapping every requirement before design begins. We architect for both certification AND manufacturing simultaneously, anticipating the pitfalls others discover too late. Your budget stays intact. Your timeline stays on track. Your market opportunity stays yours."

— Franco Fourie, Founder

A Proven Track Record of Global Success

Our founder brings over 5 years of specialized leadership in engineering products for explosive atmospheres, backed by a proven track record of successful global deployments and senior leadership roles within multinational organizations.

5+
Years of Specialized Ex Leadership
4
Products Certified Globally
70+
Countries with Market Access
Senior Leadership Experience

As the appointed Ex responsible person for a major multinational energy firm, our founder was directly entrusted with leading global product design, overseeing compliance strategy, and managing the certification process for the company's entire hazardous atmosphere portfolio.

Leadership in Action

Our experience is forged from leading complex, high-stakes projects from initial design to full global certification. Here are a few examples of our leadership in action:

Wireless Sensor System
Intrinsically Safe Design Leadership
Zone 0
Zone 20
Explosive Gas
Explosive Dust
Mining
Outcome: Unlocked Zone 0/20 certification in 4 months.
Led the design and certification of a compact wireless vibration and temperature sensor with distributed sensing capabilities for pressure monitoring in the harshest explosive environments.
  • Led intrinsically safe protection strategy development
  • Contributed to multi-parameter sensing design
  • Secured certification for Zone 0/20, unlocking access to the highest-risk markets
  • Collaborated on manufacturing optimization to improve production yield and scalability
Industrial Wireless Gateway
Ruggedized System Architecture
Zone 2
Zone 22
Explosive Gas
Explosive Dust
ISA100 Protocol
Cloud-Based
Outcome: Enabled deployment in hazardous industrial environments.
Led the certification of a ruggedized industrial wireless gateway connecting field sensors to cloud monitoring systems for explosive gas and dust environments.
  • Led ruggedized design strategy development
  • Secured certification for Zone 2/22, enabling deployment in hazardous industrial environments
  • Supported cloud integration architecture for real-time monitoring capabilities

Engineering That Drives Business Value

Our founder's unique approach combines deep technical expertise with strategic business thinking, delivering solutions that excel beyond traditional engineering boundaries.

Manufacturing Optimization
We don't just design for performance; we design for manufacturability. Our strategies reduce your production costs, improve scalability, and ensure long-term viability.
For example, by using thermodynamic modeling for one client, we were able to pre-approve a future cast-aluminum enclosure on their initial certificate, saving them thousands in future testing and recertification fees.
Component Obsolescence
We protect your product's future. By proactively managing the risk of component obsolescence through strategic design and supply chain planning, we save you from costly redesigns down the line.
We employ ingenious certification strategies, such as designing component-agnostic test procedures, that can make your product immune to obsolescence and eliminate future recertification costs entirely.
Quality Systems
Our deep expertise in ISO9001 and IECEx quality systems ensures your processes are robust, auditable, and built for excellence, reducing costly rework and guaranteeing market access.
A robust quality system means building a resilient supply chain, like having a pre-approved alternative component ready to go when a geopolitical event suddenly forces a critical part into obsolescence.

This is the Prickly Pear Advantage: forward-thinking engineering that protects your investment and maximizes your return.

About Prickly Pear Engineering

Inspired by resilience, adaptability, and unexpected beauty

Why Prickly Pear?

The prickly pear cactus embodies the qualities we bring to every engineering challenge. During my regular runs through the vineyard trails close to my home, I was constantly drawn to the prickly pears growing along the edges - these resilient plants that seemed to thrive effortlessly in conditions where most plants would struggle.

While the vineyard itself is well-maintained and fertile, these cacti had found their niche in the more marginal spaces - the rocky edges, dry slopes, and areas others might overlook. It was seeing these prickly pears flourish in spaces where they weren't expected that inspired both the name and philosophy behind Prickly Pear Engineering.

Like these remarkable plants that adapt to whatever conditions they find themselves in, we specialize in finding solutions where others see obstacles.

Resilience

Like the prickly pear that survives in extreme conditions, we tackle the most challenging engineering problems with persistence and innovative solutions.

Adaptability

Our process adapts to your specific needs. From flexible engagement models that match your project's scale and budget, to selecting the optimal protection architecture that fits your product's unique technical constraints, our solutions are never one-size-fits-all.

Unexpected Value

Just as the prickly pear produces beautiful flowers and nutritious fruit, we deliver solutions that provide value beyond the initial requirements.

Founder of Prickly Pear Engineering

Meet the Founder

Engineering Solutions, One Challenge at a Time

I founded Prickly Pear Engineering for a specific reason: to give startups and scaling companies direct access to the specialized expertise needed to succeed in the high-stakes world of explosive atmospheres. Large corporations have teams for this; my goal is to be that trusted, expert resource for you, providing practical, results-driven approaches that get your project moving forward safely and on budget.

My approach is simple: I combine deep technical knowledge of the standards with a pragmatic focus on what actually matters. Whether we're troubleshooting a complex compliance issue or planning a full certification strategy, I believe in clear communication and efficient, no-nonsense engineering.

When I'm not solving engineering challenges, you'll find me exploring vineyard trails, grilling with family, or just spending time in nature.

How We Work With You

Every significant project begins with a structured assessment to ensure mutual success. Our fixed-fee entry points provide the detailed scope necessary for confident project proposals.

Step 1: Start The Conversation

All new projects begin with a free discovery call to understand your goals and recommend the best approach.

100% FREE
45-Minute Discovery Call
A dedicated session focused entirely on your project. We listen to your goals, assess your challenges, and help you discover the most effective path forward.

Understand Your Goals

Assess Project Scope

Recommend Next Steps

Step 2: Choose Your Path

Following our discovery call, we recommend the ideal next step. Each path is a fixed-price engagement designed to de-risk your project and provide you with a clear, actionable roadmap.

Most Popular
Strategic Consultation
Get expert guidance and a clear development roadmap
$350 Fixed Fee

*Fully credited toward project if continuing within 30 days

What You Get:

  • Technical feasibility assessment
  • Detailed development roadmap
  • Written recommendations & next steps
  • Clear understanding of project requirements
Perfect For:
Early-stage projects needing direction and feasibility validation
For Full Projects
Rapid Feasibility Assessment
Comprehensive analysis for confident project proposals
$3,500 Fixed Fee

*The recommended first step for all major projects.

What You Get:

  • High-level project cost estimate
  • Complete technical architecture analysis
  • Detailed project timeline & milestones
  • Component sourcing & BOM cost estimation
  • Risk assessment & work breakdown structure
Essential For:
Clients ready for full project implementation and fixed-price quotes

Flexible Support & Expert Advisory

Whether you're continuing a project with us or just need an expert for a specific, smaller-scale challenge, our flexible hourly option provides the help you need, right when you need it.

Expert Consulting & Advisory
Your expert on-call for ongoing project support, quick technical questions, design modifications, standards interpretation, and strategic guidance for existing or new initiatives.
$150/hour

Minimum 4-hour engagement

Partnership Rate: $135/hour

Planning for the long term? We offer a partnership discount for 40+ hour engagements.

Save $15/hour • $600+ total savings on qualifying projects

Get Started Today

Tell us about your project goals. We'll review your details and schedule a discovery call to outline the most effective path to compliance.

Send us a message
Tell us about your project and we'll get back to you within 24 hours.
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Contact Information
Get in touch with us directly

Email

info@pricklypearengineering.com

Phone

Available upon request

Location

Global remote services

Response Time

Within 24 hours

What happens next?

  • 1
    We'll review your project details within 24 hours
  • 2
    Schedule a free discovery call to discuss your needs
  • 3
    Receive a tailored proposal with clear next steps

Note: Our process always begins with the free 45-minute discovery call to ensure a perfect fit before any project work starts.