Major fire at a meat and sausage factory
Circumstances of the loss
A fire was detected in a deep-frying facility in unit 2 at about 11 a.m. Shortly afterwards, the automatic foam-extinguishing system was activated. Despite additional manual efforts to quell the fire, the flames could not be brought under control as the deep fryer continued to heat up. The fire brigade was alerted.
A large cloud of smoke had already risen over the factory by the time the firefighters arrived at the scene and the fire had spread to many other parts of the building. Efforts to extinguish the fire were considerably hampered by heavy fire loads and thick smoke. Parts of the steel structure buckled in the heat, passageways and roof sections collapsed, flames burst through windows, and deflagrations tore open doors. The firefighters risked having their retreat cut off at any time; a number of calls for reinforcements were necessary.
Loss
The factory comprises three manufacturing areas, together with administration buildings and old premises. Two of the manufacturing units were steel-frame structures with profiled-metal composite panels and foam insulation for the inner and outer walls. The units were linked by a 2.5-metre wide passageway with two crossings equipped with fire doors. A concrete ceiling separated the production area on the ground floor from the mechanical systems located underneath the roof. The roof structure was partly of trapezoidal plate with foam insulation and plastic film lining – also in composite panel design. A firewall separated unit 3 from unit 2.
The consequences of the fire were devastating. Unit 2 (with a usable floor area of approx. 7,000 m2) and the operating equipment were eventually a total loss, whilst unit 1 (with a usable floor area of some 10,000 m2) and the operating equipment were almost totally destroyed. Only the foundations and the basements of the two units remained.
A huge fire-fighting operation with around 400 firemen saved unit 3, which was protected by the firewall, and the adjacent administration building. Nevertheless, the damage caused by soot was extensive, as was the damage to stocks.
The business interruption loss was dramatic. After such a major loss, refurbishing the building and reaching full operability again may involve a downtime of up to a year, even taking account of increased production achieved by multiple shifts at subsidiaries and the procurement of goods and production capacity from outside firms. Notwithstanding business continuity planning, an insured business interruption loss of around €40m is to be expected.
Cause of loss
The fire was caused by a deep-frying tank overheating. Although automatic temperature monitoring with a maximum temperature control and spot protection had been installed, the frying unit’s control system was defective and caused the oil to overheat and ignite.
According to initial investigations, the extinguishing system for the deep-frying unit was properly activated. However, the oil continued to heat up and caught fire again. A test of the extinguisher system by experts suggested that a contactor had jammed. It was connected to the maximum temperature control (280°C), the temperature sensor, and the extinguisher activator, although from a safety point of view there should have been three separate contactors. It is vital to bear this in mind during risk inspections of similar operations.
Summary
As a result of the heavy structural and operational fire loads, coupled with large fire compartments, the fire spread with unusual rapidity before the fire brigade arrived at the scene. The materials used in construction were particularly detrimental – composite walls and roofs with combustible insulation. The loss is estimated at approx. €110m.
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