Smart detection and targeted extinguishing systems revolutionize fire safety

In the industrial sustainability conversation, waste reduction, resource conservation, and recycling are at the top of the agenda. But, ironically, the very facilities promoting circular economy practices face a major technological and environmental challenge: fires that threaten people, assets, and the environment.

An underestimated risk with global impact 

Data from the U.K., the U.S., Germany, and other countries shows that recycling facility fires are not isolated incidents. In the U.K. alone, 670 fire incidents were reported between 2019 and 2020. Many caused massive smoke and toxic emissions, strained emergency services, and led to long-term environmental damage.

At the core of the problem are lithium-ion batteries. Around 80 to 90 percent of documented recycling fires originate from energy cells, with heat, friction, sparks, and self-ignition adding to the risk.

Environmental damage from secondary effects 

What begins as an effort to protect the environment can, in a worst-case scenario, end in environmental disaster. This makes proactive fire risk control all the more important.

When a fire occurs, consequences extend beyond property loss:

• Air pollution from smoke, soot, and toxic gases
• Water contamination from firefighting runoff containing hazardous substances
• Loss of valuable secondary raw materials
• Production shutdowns, even for neighbouring facilities
• Regulatory penalties or license suspensions

Fire protection is environmental protection 

Preventing fires before they start relies on modern technology. Spark and ember detection systems are designed to identify ignition sources within milliseconds and neutralize them automatically before a fire can start.

These systems are now widely used and recommended by insurers — especially in high-risk areas such as shredders, dust extraction units, and conveyor systems. Unlike traditional sprinkler systems, they respond to early warning signs rather than waiting for a full-blown fire.

Intelligence where it matters 

Fagus-GreCon's Intelligent Extinguishing Module (IEM) elevates this approach. Continuously monitoring valves, nozzles, and pressure levels, the system detects wear, leaks, or irregularities at an early stage. This reduces unplanned downtime, extends maintenance intervals, and ensures system availability.

The IEM uses extinguishing agents only where needed and in the amount needed. Extinguishing agents are finely atomized and precisely targeted. This reduces water consumption and protects both the environment and stored materials. Due to integrated frost protection and smart heating, the system remains reliable even in freezing temperatures, which is essential for outdoor facilities.

More than a safety factor 

Fire protection systems don't just provide safety; they provide data. Integrated with control systems, they enable process evaluation, identify risk patterns, and guide targeted preventative measures. Fire protection becomes part of process optimization, turning safety into a core element of industrial sustainability strategy.

Prevention is essential 

The recycling industry must think in both economic and ecological terms. Smart, data-driven fire prevention safeguards operations, conserves resources, and reduces environmental risk. These technologies are proven and ready to meet today's challenges. Preventing fires doesn't just protect assets — it protects the planet. 

This article originally appeared in the 2025 Technology Special Edition of Recycling Product News.