The main cause of fire ignition is linked to the usage environment and grilling habits. Fires are typically caused by large amounts of grease at the bottom of the grill, which, when exposed to direct flames from the pellets, catch fire and spread to the grill grates, causing the surface coating on the bottom and part of the top of the grill to burn. This usually happens when the grill is not properly cleaned, especially when animal fats are not adequately removed (animal fat is highly flammable, and it needs both high temperature — around 350°C — and a certain amount of buildup to ignite after prolonged high heat).
- When pellets run out and the feed tube is empty, adding new pellets causes a delay in ignition as the igniter has already stopped. The pellets then accumulate, and after a few minutes, the igniter will light up again, causing a large amount of smoke and then a fire. The unburnt pellets that get blown out of the burner can catch fire and ignite the grease.
- When pellets in the hopper are damp (due to time or weather conditions), they may not ignite immediately when fed into the burner. This leads to a buildup of unburnt pellets, which then causes heavy smoke and ultimately a fire. Unburnt pellets may be blown out of the burner, igniting the grease.
- If the burner accumulates too much ash, it can cover the igniter, preventing it from lighting up properly. This leads to a pellet buildup and, eventually, a large fire. Unburnt pellets get blown out of the burner, bringing flames that ignite the grease.
Proper cleaning of the grill, particularly removing any grease and ash, can help avoid these issues and keep the grill working safely.
How to Handle Grease Fires in Your Grill
Grease Fire — Most Common A grease fire is a flare-up inside the barrel caused by accumulated grease on the drip pan igniting. This is different from the normal pellet fire in the firepot
- Keep the lid closed: Cutting off oxygen is the most effective way to control a grease fire.
- Do NOT spray water on a grease fire: Water will cause burning grease to splatter and spread.
- Run the shutdown cycle: If the controller is still accessible, running the shutdown cycle reduces airflow and helps starve the fire.
- If flames are visible from the chimney or lid gaps: Keep the lid closed and all vents shut until the fire dies down.
- Once fully cooled, Clean all grease from the barrel, drip pan, and grates before your next cook.
Prevention
- Line the grease drain pan with heavy-duty foil and replace it after every fatty cook (such as chicken, ribs, or pork shoulder).
- Never let grease accumulate — clean the drip tray every 3–5 cooks.
- Trim excess fat from very fatty cuts before placing them on the grill.
