How DLP Refilling Improved Fire Safety at a Manufacturing Plant

Fire safety is a critical concern for manufacturing plants, where equipment heat, electrical systems, and combustible materials increase fire risks. In such industrial settings, the maintenance of fire extinguishers and suppression systems cannot be overlooked. One powerful method that is transforming fire safety operations is Direct Low Pressure (DLP) refilling.

This blog highlights how the adoption of DLP refilling dramatically improved fire safety at a medium-sized manufacturing plant, reducing downtime, boosting safety compliance, and saving operational costs. If your facility is considering an upgrade in fire protection maintenance, this real-world example offers valuable insights.

Background: The Plant's Fire Safety Challenges

The manufacturing plant, located in the Midwest USA, specializes in automotive components production. The facility covers 150,000 square feet and operates 24/7. Prior to adopting DLP refilling, the plant faced several fire safety challenges:

• Inefficient manual refilling of extinguishers that took up to 3 days, requiring system shutdowns.

• Frequent over-pressurization incidents, causing wear and damage to expensive CO₂ and dry chemical extinguishers.

• Non-compliance issues during NFPA 10 audits, due to inaccurate pressure readings and refill inconsistencies.

• High maintenance costs from repeated valve replacements and agent wastage.

With nearly 200 extinguishers across multiple zones, these issues presented significant operational and safety risks.

What is Direct Low Pressure (DLP) Refilling?

Direct Low Pressure (DLP) refilling is a controlled fire extinguisher maintenance process, where agents such as ABC powder or CO₂ are refilled using low-pressure systems. Unlike traditional high-pressure refilling, DLP offers a safer, more precise, and eco-friendly approach to recharging extinguishers and suppression systems.

The DLP Refilling Implementation Process

To address its challenges, the plant partnered with a certified fire safety service provider specializing in DLP refilling. The implementation process included:

1. Initial Audit: Comprehensive assessment of fire safety systems and extinguisher placement.

2. Decommissioning Manual Refilling: Phasing out high-pressure, manual refilling procedures.

3. Deployment of DLP Equipment: Installing portable low-pressure refilling stations on-site.

4. Staff Training: Educating maintenance staff and safety managers on DLP processes and equipment handling.

5. Routine Scheduling: Creating a quarterly DLP refilling and inspection schedule to minimize downtime.

This systematic approach ensured seamless integration without disrupting daily plant operations.

Table: Pre-DLP vs. Post-DLP Refilling Results at the Plant

Key Benefits Realized Through DLP Refilling

1. Enhanced Operational Efficiency

DLP refilling significantly reduced the downtime required for fire safety maintenance. Rather than taking several days, the process was completed during off-shift hours, ensuring continuous production.

2. Improved Equipment Longevity

Low-pressure refilling eliminated over-pressurization stress on extinguishers and valves. This extended the lifespan of both portable and fixed suppression systems, reducing equipment replacement cycles.

3. Full Regulatory Compliance

The plant successfully passed two consecutive NFPA 10 compliance audits post-DLP implementation. Digital documentation generated during each refill cycle ensured compliance transparency.

4. Cost Savings

Through reduced component failures, faster maintenance, and lower agent wastage, the plant achieved an estimated 35% reduction in fire safety maintenance costs in the first year.

5. Enhanced Workplace Safety

The reduced risk of accidental agent release, combined with safer refill operations, protected both maintenance personnel and production workers from unnecessary hazards.

Technologies Used in the Plant’s DLP Refilling Program

The success of the project hinged on the deployment of advanced fire safety tools:

• Low-Pressure Fill Pumps: Ensured consistent agent transfer.

• Digital Pressure Gauges: Monitored fill levels with high accuracy.

• Vacuum Pumps: Removed air and moisture before refilling.

• Anti-Static Hoses: Prevented ignition risks during powder transfers.

• Portable Refilling Units: Enabled zone-based maintenance without relocating extinguishers.

Staff Training and Process Optimization

Beyond equipment, the project’s success was largely due to employee engagement and training. Technicians were taught how to:

• Inspect cylinders before and after refilling.

• Safely operate DLP systems without external support.

• Document maintenance activities for audit readiness.

• Identify early warning signs of extinguisher wear or leakage.

By creating a standardized maintenance playbook, the facility reduced human error in fire safety operations.

Sustainability Benefits

In addition to operational gains, the plant’s fire safety overhaul aligned with its corporate sustainability goals. DLP refilling reduced:

• Waste generation, as agents were transferred with minimal spillage.

• Energy consumption, due to the lower power requirements of DLP systems versus traditional compressors.

• Environmental impact, by preventing the release of chemical suppression agents into the air.

These improvements contributed to the plant’s ISO 14001 environmental management certification renewal.

Lessons Learned from the Case Study

This manufacturing plant’s journey with DLP refilling offers several lessons:

• Fire safety processes should evolve alongside manufacturing automation.

• Scheduled, preventive maintenance costs less than emergency repairs.

• Investing in the right tools enhances safety and business continuity.

• Fire safety compliance is easier to achieve when using data-driven maintenance systems.

Facilities across industries can replicate this approach to improve their fire safety operations without sacrificing productivity.

Conclusion

DLP refilling played a pivotal role in enhancing the fire safety culture at this manufacturing plant. By replacing outdated, manual refilling processes with a modern, low-pressure system, the plant achieved:

• Greater equipment reliability

• Faster, safer maintenance

• Lower environmental impact

• Full regulatory compliance

• Significant cost savings

If your business still relies on high-pressure or manual extinguisher refilling, now is the time to consider Direct Low Pressure refilling as a smarter, safer alternative. Partnering with a qualified fire safety service provider will streamline the transition and safeguard your facility for years to come.