How to prevent food factory fires with smarter machine monitoring

Factory fires can threaten food processing plants, causing disruption to productivity and endangering the workforce. Consequently, taking the necessary precautions — including using equipment capable of detecting and preventing fire-prone conditions — is essential to mitigate the risk.

In 2024, there were over two thousand recorded factory fires worldwide. The majority of these fires occurred in facilities within the United States, followed by incidents in India and Germany. Many of these fires took place in manufacturing-focused factories.

According to Resilinc, a supply chain risk management company, 59% of the factory fires analysed in 2021 were linked to faulty equipment. Common causes included improper installation, operation or maintenance; inadequate safety and cleaning procedures; and failure to replace outdated or worn-out equipment on time. Additionally, insufficient employee training, particularly a lack of awareness of key risks, was often a contributing factor.

Specific conditions on or around the production line can also increase the risk of a fire.

“Food processors need to be aware that combustible dust can contribute to fires when sparking occurs — and that almost every material can be combustible in dust form, including wood, metal, dyes, food and chemicals,” said John Bogart, Managing Director of Kett US, a manufacturer of a full range of moisture and organic composition analysers.

Bogart added that chemical plants face an increased fire risk when excessive friction occurs. Similarly, mechanical equipment can become a fire hazard if it is not properly cleaned, maintained and lubricated, leading to overheating and, in some cases, ignition.

Since many of these issues are largely preventable, industry professionals emphasise the importance of awareness and proactive measures.

“By prioritising equipment maintenance, providing comprehensive training and conducting regular safety inspections — even during periods of disruption — factories can significantly reduce the risk of fires and safeguard both employees and assets,” Bogart said.

In addition, he recommended equipping facilities with instruments that can detect hazardous conditions on the production line, which is essential for preventing fires and improving overall safety.

To address this need, industry OEMs have developed a variety of equipment specifically designed to prevent the hazardous conditions that can lead to factory fires. For example, Kett’s pulp and paper moisture meters line can prevent over-drying — an issue that may apply when producing certain food-grade packaging materials.

To keep friction — and overheating and sparking — from causing machinery-related fires, the OEM’s line of friction testers like the H94 Handheld Portable Friction Tester can evaluate machinery for friction and wear onsite.

The OEM’s engineers assist food processing facilities in selecting portable and inline laboratory-quality instruments to enhance safety and reduce fire risk. These instruments are designed for fast, efficient operation and are user-friendly, ensuring effective monitoring by any operator, regardless of who is onsite.

Factory fires pose a serious risk to workers, equipment and overall operations, yet many are preventable with the right precautions. Equipping food processing plants with advanced monitoring instruments ensures early detection of hazardous conditions, allowing for quick intervention before a fire can start.

By investing in reliable safety equipment, food processors can reduce fire risks, maintain productivity and protect both personnel and assets. Proactive safety measures, including proper training and routine maintenance, combined with the right detection tools, are essential for ensuring a safer, more resilient production environment.

Image credit: iStock.com/dulancristian