FM Global

Property Loss Prevention Data Sheets 7-96

April 2010
Page 1 of 26

PRINTING PLANTS

Table of Contents
Page

1.0 SCOPE .................................................................................................................................................... 3

1.1 Changes ........................................................................................................................................... 3
2.0 LOSS PREVENTION RECOMMENDATIONS ........................................................................................ 3
2.1 Construction and Location ............................................................................................................... 3
2.2 Occupancy ........................................................................................................................................ 5
2.2.1 General Flammable/Combustible Ink and Solvent Handling ................................................. 5
2.2.2 In-Process Storage of Flammable/Combustible Inks and Solvents ...................................... 6
2.2.3 Paste Inks .............................................................................................................................. 7
2.2.4 Heat Transfer Fluid Systems .................................................................................................. 8
2.2.5 Hydraulic Systems and Plant Air Systems ............................................................................. 8
2.2.6 Solvent Recovery ................................................................................................................... 8
2.2.7 Parts Washers ........................................................................................................................ 8
2.2.8 Dust-Producing Operations .................................................................................................... 8
2.3 Protection ......................................................................................................................................... 9
2.3.1 General ................................................................................................................................... 9
2.3.2 Lithograph — Newspaper Press Protection ........................................................................... 9
2.3.3 Lithograph, Non-Newspaper Press Protection .................................................................... 12
2.3.4 Rotogravure and Flexograph Press Protection ................................................................... 12
2.3.5 Control Rooms, Computer Rooms, and Motor Control Centers .......................................... 13
2.3.6 Manual Protection ................................................................................................................ 13
2.3.7 Sound Enclosures ................................................................................................................ 15
2.3.8 Baler Rooms ......................................................................................................................... 15
2.3.9 Ducts .................................................................................................................................... 16
2.3.10 Carbon Bed Adsorbers ....................................................................................................... 16
2.3.11 Dust Collection Systems .................................................................................................... 16
2.4 Equipment and Processes ............................................................................................................. 16
2.4.1 General ................................................................................................................................. 16
2.4.2 Dryers ................................................................................................................................... 16
2.5 Maintenance ................................................................................................................................... 18
2.6 Human Factors ............................................................................................................................... 18
2.6.1 Flammable/Combustible Liquid Handling Procedures ......................................................... 18
2.6.2 Combustible Dust Handling .................................................................................................. 19
2.6.3 Housekeeping ...................................................................................................................... 19
2.6.4 Emergency Response .......................................................................................................... 20
2.7 Ignition Source Control ................................................................................................................... 20
3.0 SUPPORT FOR RECOMMENDATIONS ............................................................................................... 21
3.1 Construction/Location ..................................................................................................................... 21
3.1.1 Noncombustible Construction .............................................................................................. 21
3.1.2 Fire Hazard Isolation ............................................................................................................ 21
3.1.3 Explosion Hazard Isolation .................................................................................................. 22
3.2 Occupancy ...................................................................................................................................... 22
3.2.1 Flammable/Combustible Liquids .......................................................................................... 22
3.2.2 Paste Inks ............................................................................................................................ 22
3.2.3 Combustible Dusts ............................................................................................................... 23
3.3 Protection ....................................................................................................................................... 23
3.3.1 Automatic Sprinkler Protection ............................................................................................. 23
3.3.2 Special Protection ................................................................................................................ 23

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3.4 Maintenance ................................................................................................................................... 24

4.0 REFERENCES ...................................................................................................................................... 24
4.1 FM Global ....................................................................................................................................... 24
4.2 Other ............................................................................................................................................... 25
APPENDIX A GLOSSARY OF TERMS ...................................................................................................... 25
APPENDIX B DOCUMENT REVISION HISTORY ...................................................................................... 26

List of Figures
Fig. 1. Press room design and layout ........................................................................................................... 4
Fig. 2. Rotogravure press fed by piping from storage/mixing room to press sump ..................................... 5
Fig. 3. Solvent dispensing station .................................................................................................................. 6
Fig. 4. In-process storage of paste ink in small containers, metal tote tanks, and metal tanks .................. 7
Fig. 5a. Automatic sprinkler protection for shielded areas of a single level newspaper press ................... 10
Fig. 5b. In-press automatic sprinkler protection for a multilevel newspaper press ..................................... 11
Fig. 6. Carbon dioxide and automatic sprinkler system protection for a rotogravure press
using flammable/combustible inks ..................................................................................................... 14
Fig. 7. Carbon dioxide and automatic sprinkler system protection for a central impression (CI)
flexography press with six printing decks using flammable/combustible inks .................................. 14
Fig. 8. Carbon dioxide and automatic sprinkler system protection for a stack-type
flexography press using flammable/combustible inks ...................................................................... 15
Fig. 9. Carbon dioxide protection for a six-color, in-line flexograph press using
flammable/combustible inks ............................................................................................................. 15
Fig. 10. Typical exhaust system design for rotogravure press with recirculated dryer atmosphere into burner
combustion chamber ...................................................................................................................... 17
Fig. 11. Areas where Class I, Div 1 and 2 classified electrical equipment is needed
for a flexography press using low-flash point flammable/combustible inks ................................... 20
Fig. 12. Areas where Class I, Div 1 and 2 classified electrical equipment is needed
for a rotogravure press using low-flash point inks, and where Class II, Div 2
classified electrical equipment is needed within and below the folder sound enclosure .............. 21

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1.0 SCOPE
This data sheet contains fire protection and fire prevention recommendations for printing plants.

1.1 Changes
April 2010. The following changes were made:
1. Separated flammable/combustible liquid protection into three categories: (1) low flash-point (below 200°F
[93°C]), (2) high flash-point (200°F [93°C] and above), and (3) paste inks.
2. Added guidance on when to protect a printing occupancy as an flammable/combustible liquid-use area
in accordance with Data Sheet 7-32, Flammable Liquid Operations.
3. Added recommendations for in-process storage of roll paper in the press room.
4. Added recommendations for housekeeping in newspaper offset lithograph press operations.
5. Added details on the location and type of automatic fire protection for single and multiple-level lithograph
presses.
6. Added details on local-application CO2 system installation to promote better understanding of the system
design.
7. Added requirements for proper testing and maintenance of CO2 systems.
8. Added recommendations for control and computer room protection, carbon bed adsorbers, plate washers,
solvent recovery, lube oil, hydraulic, pneumatic, and heat transfer fluid (HTF) systems.
9. Added recommendations for dryers, exhaust ducts, and thermal oxidizers where design variations for
printing plant installations are different than those covered in existing standards.

2.0 LOSS PREVENTION RECOMMENDATIONS

2.1 Construction and Location

2.1.1 Use noncombustible or FM Approved Class 1 building materials for exterior and interior construction.
2.1.2 Stage and store roll stock (e.g., roll paper, roll plastic, etc.) as follows:
A. Separate bulk storage of roll stock from the pressroom and from other production areas with a one-hour
fire wall (see Figure 1). Design the wall to resist potential mechanical impact damage from material
handling operations (e.g., fork truck). See Data Sheet 1-19, Fire Walls, Subdivisions and Draft Curtains,
for further details.
B. Provide floor drainage in roll paper storage areas in accordance with Data Sheet 8-21, Roll Paper
Storage.
C. Limit in-process roll paper storage in the press room to 200 ft2 (18.6 m2) in area and a maximum of
10 ft (3 m) high. Ensure roll paper storage is a minimum of 25 ft (7.6 m) from presses and other combustible
materials.
D. Limit in-process roll plastic storage in the press room to 200 ft2 (18.6 m2) in area and a maximum of
5 ft (1.5 m) high. Ensure the roll plastic is a minimum of 25 ft (7.6 m) from presses and other combustibles.
2.1.3 Cut off flammable/combustible ink and paste ink operations (e.g., storage, mixing, parts washers, solvent
recovery, etc.) from other areas of the facility (e.g., press hall, roll paper storage, finished goods storage).
Arrange, evaluate, and protect in accordance with Data Sheets 7-32, Flammable Liquid Operations; 7-29,
Flammable Liquid Storage in Portable Containers; 7-2, Waste Solvent Recovery; 7-88, Flammable Liquid
Storage Tanks (see Fig. 1).
2.1.3.1 In printing operations that only use paste ink, uncut inks can be stored in the press hall and other
areas. See Section 2.2.1.3 for more guidance. Locate and handle blanket wash in accordance with its closed
cup flash point.
2.1.4 Provide a one-hour fire wall for baler rooms to isolate them from other plant areas.

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Fig. 1. Press room design and layout

2.1.5 Ensure sound/dust enclosures provided around slitter operations on the press are constructed of
noncombustible or FM Approved Class 1 materials. The provision of small clear plastic windows to allow visual
inspection of the process is acceptable.
2.1.6 Provide one-hour-rated fire separations for motor control centers, electrical/mechanical rooms, and
mail rooms. Provide positive pressure filtered air supplies to these rooms.
2.1.7 Protect openings in fire-rated floors and walls with FM Approved fire doors. Seal any penetrations
caused by piping, electrical cables, etc. with FM Approved penetration seals.
2.1.8 In dust-producing occupancies within printing plants (e.g., slitter enclosures, baler rooms, finishing
operations involving corn starch application to printed media, etc.), do the following:
A. Evaluate the dust exposure using Data Sheet 7-76, Prevention and Mitigation of Combustible Dust
Explosion and Fire.
B. Install and arrange dust collection systems designed to prevent any dust accumulation inside plant
areas in accordance with Data Sheet 7-73, Dust Collectors and Collection Systems. Always locate dust
collection equipment (e.g., cyclones, bag collectors, etc.) outside. Provide adequate explosion isolation
between the dust collection equipment and the building.
C. Provide automatic sprinkler protection in bag-type dust collectors.
D. If a dust collector is located inside, provide damage-limiting construction designed to direct the products
of a deflagration (i.e., fire, pressure, and unburned dust) outside the plant or use a properly designed
and installed FM Approved explosion-venting system.
E. Provide building designs that minimize horizontal surfaces where dust can accumulate.

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2.2 Occupancy

2.2.1 General Flammable/Combustible Ink and Solvent Handling

2.2.1.1 Hard pipe all inks, solvents, thinners, and washes from their appropriately isolated storage tanks or
mixing rooms to the individual presses (see Figure 2). In cases where regular color changes prevent the
use of a piped ink delivery system, use 6.5 gal (25 L) metal containers to transfer ink to the presses from
the mixing room. Arrange piped ink transfer systems as follows:
A. Use welded steel pipe or tubing. Do not use piping that could fail under fire exposure, such as plastic
piping, rubber hose, or copper pipe with sweat-soldered joints.
B. Limit flanged or screwed fittings to the minimum needed for equipment repair/replacement.
C. Provide high-level alarms and high-high-level alarm and pump shutoffs for ink reservoirs.
D. Use braided metal hose when flexible piping is needed.
E. Arrange the transfer system to shut down all liquid flow in the event of fire by installing FM Approved
safety shut-off valves at the liquid source and at the point of use. Interlock the valves to close upon
detection of a fire or activation of a fire protection system. Also interlock all pumps to shut down as well.
F. Ensure the transfer system is properly bonded and grounded per Data Sheet 5-8, Static Electricity.

Fig. 2. Rotogravure press fed by piping from storage/mixing room to press sump

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2.2.1.2 In cases where more than 55 gal (208 L) of solvent is needed at a press for normal operations,
hard-pipe solvent from a properly arranged cut-off room or tank per Section 2.2.1.1 to the point of use on
the press, and arrange in accordance with Data Sheet 7-32. In cases where manual handling is needed,
arrange the solvent dispensing stations as follows (see Fig. 3):
A. Locate the dispensing station at least 15 ft (4.6 m) from a press, and 25 ft (7.6 m) from any in-process
storage.
B. Design the system to use the minimum flow rate necessary for normal operations, but do not exceed
1 gpm (3.7 L/min) and 1⁄2 in. (13 mm) diameter pipe/tubing.
C. Provide containment at the dispensing point and design it to hold at least 20 gal (76 L) of solvent.
D. In addition to the safety shut-off valve at the point of use, provide an FM Approved, normally closed,
spring-loaded valve at the dispensing point for regular dispensing operations.
E. Provide mechanical, low-level ventilation adjacent to the dispensing point and design it to keep any
flammable vapor concentration below 25% of the solvent’s lower explosive limit (LEL).
F. Provide properly arranged bonding and grounding in accordance with Data Sheet 5-8, Static Electricity.
2.2.1.3 Do not store or dispense inks or solvents in storage areas (roll paper warehouse, signature storage
areas, etc.).

Fig. 3. Solvent dispensing station

2.2.2 In-Process Storage of Flammable/Combustible Inks and Solvents

Note: For paste inks, see Section 2.2.1.3.
2.2.2.1 Limit quantities of flammable/combustible ink and solvent to 70 gal (265 L) in each fire area. Define
a fire area by determining a separation distance that would prevent a spill from the largest container in one
area from exposing containers in the next area.
A. A single FM Approved flammable liquid cabinet can be used in a fire area if more than 70 gal (265 L)
is needed for normal operations.

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B. The cabinet approval is intended for sealed stored drums only.

C. If a drum is provided with a drum pump, have only one 55 gal (208 L) steel drum in the cabinet, and
provide forced mechanical ventilation to outside the building.
D. If drums are sealed, up to two drums can be stored in properly sized cabinets.
E. Sealed small containers, up to the cabinet liquid volume rating, are acceptable.
2.2.2.2 Stage ink and solvent at least 25 ft (7.6 m) from presses, and 35 ft (10.7 m) from other in-process
storage in the press area. (See Section 2.2.3 for paste ink staging on the press room floor.)
2.2.2.3 Use sealed metal containers when transporting and storing inks or solvents. Transfer inks to the press
using FM Approved safety cans or drum pumps.

2.2.3 Paste Inks

Paste inks are high-viscosity fluids that have to be transferred from the container by means of a trowel,
scraper, or high-pressure pumping system (see Fig. 4). Paste inks will flow under pressure or shear. Paste
inks have flashpoints higher than 200°F (93°C). Automatic sprinkler protection will be effective on a pool
fire. Press-room protection as recommended in this data sheet is expected to control a fire involving paste
ink.
2.2.3.1 Stage paste inks in combustible containers at least 10 ft (3 m) from all press units, and 25 ft (7.6
m) from other combustible storage. Stage paste ink in steel IBCs at least 10 ft (3 m) from all press units or
other combustible storage.
2.2.3.2 Limit in-process staging of small containers of paste ink (5 gal [19 L] or less) to areas no larger than
200 ft2 (18.6 m2). Limit storage height for small containers on pallets to one pallet high. Limit storage height
on metal shelves to 5 ft (1.5 m) high.
2.2.3.3 Do the following for staged portable metal paste-ink tanks:
A. Limit storage to two high in racks or two high palletized.
B. Protect in accordance with Section 2.3.1.2.

Fig. 4. In-process storage of paste ink in small containers, metal tote tanks, and metal tanks

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2.2.4 Heat Transfer Fluid Systems

2.2.4.1 Protect systems in accordance with Data Sheet 7-99, Heat Transfer by Organic and Synthetic Fluids.
Ensure the following are provided for systems up to 100 gal (380 L) in capacity:
A. Isolate the HTF heater and use area from other occupancies with at least a 1-hour rated fire wall.
B. Provide metal covers for rotary couplings to direct leaks and sprays to a properly designed containment
area.
C. Provide nonabsorbent insulation on piping.
D. Provide safety shut-off valves at all use points, and interlock HTF pumps, safety shut-off valves, and
the HTF heater burner to shut down in the event of a fire or activation of a protection system.
E. Provide liquid containment for the HTF heater cut-off room designed to contain the volume of the
expected spill plus 2 in (5 cm) of freeboard. Use a minimum curb height of 4 in (10 cm).
F. Vent the expansion tank to a safe location outside the building.

2.2.5 Hydraulic Systems and Plant Air Systems

Many presses have hydraulic systems and plant air for controlling rollers on the press. The hydraulic systems
are usually part of the press and can vary in size from 30 gal (110 L) to over 100 gal (379 L). A press fire
involving its hydraulic oil system will severely damage the press regardless of the system size. A press fire
that is fanned by the release of compressed air will burn hotter, causing increased damage.
2.2.5.1 Interlock all hydraulic oil systems, regardless of size, and plant air systems to shut down in the event
of a fire. Where possible, use FM Approved hydraulic fluids (see recommendation 2.3.1.3).
2.2.5.2 Do not use PVC piping for compressed air distribution systems. Within the United States, PVC piping
is prohibited by OSHA from being used as air-distribution piping.

2.2.6 Solvent Recovery

Solvent recovery operations are usually needed for rotogravure and flexograph presses. They can represent
a fire hazard and potentially an equipment and/or room explosion hazard, depending on the design of the
equipment and solvents being used. A vacuum still may not present an explosion hazard due to the recovery
process, but the impact of the solvent would still need to be evaluated from a room explosion and fire hazard
standpoint. Any solvent recovery process needs to be fully evaluated in accordance with the applicable
standards. If the solvents are flammable/combustible liquids, OS 7-32, Flammable Liquid Operations, needs
to be used to evaluate potential explosion hazards.
2.2.6.1 Design and protect solvent recovery systems in accordance with the recommendations in Data Sheet
7-2, Waste Solvent Recovery, and Data Sheet 7-32, Flammable Liquid Operations.

2.2.7 Parts Washers

Parts washing operations are usually needed for rotogravure and flexograph presses. They can represent
a liquid fire hazard and potentially an equipment and/or room explosion hazard depending on the design of
the equipment and solvents being used.
2.2.7.1 Design and protect parts washing operations in accordance with Data Sheet 7-97, Metal Cleaning,
and Data Sheet 7-32, Flammable Liquid Operations.

2.2.8 Dust-Producing Operations

2.2.8.1 Provide dust-collection systems for all operations that produce combustible dust (see
Recommendation 2.1.8).
2.2.8.2 Design the dust-collection system to ensure no dust is released into the facility during normal plant
operations.

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2.3 Protection

2.3.1 General
2.3.1.1 Install wet automatic sprinklers throughout printing press facilities. Extra care needs to be taken to
ensure all concealed spaces with combustible materials around presses or below mezzanines are adequately
covered by sprinkler protection.
2.3.1.2 Design automatic sprinkler systems as follows:
A. Design ceiling sprinkler protection for press rooms with no in-process storage to provide a 0.30 gpm/ft2
(12 mm/min) over 3,000 ft2 (279 m2) using 165°F (74°C), quick-response sprinklers.
B. Design ceiling sprinkler protection for press rooms with limited quantities of in-process storage as
described in Sections 2.1.2(B), 2.1.2(C), and 2.2.2 to provide a 0.30 gpm/ft2 (12 mm/min) over 3,000 ft2
(279 m2) using 286°F (141°C) sprinklers.
C. Design ceiling sprinkler protection for press rooms with excess amounts of in-process storage of roll
stock or flammable/combustible liquids in accordance with the appropriate data sheet. Protect the entire
press room area for the highest hazard.
D. Protect paste-ink storage and staging as follows (see Figure 4):
1. Design ceiling sprinklers over small container storage (not more than 6.5 gal [25 L]) of paste inks in
accordance with Data Sheet 8-9 using the protection criteria for a cartoned unexpanded plastic.
2. Design ceiling sprinklers over metal tote storage to provide at least a 0.30 gpm/ft2 (12 mm/min) over
2,000 ft2 (186 m2) using 165°F (73°C) sprinklers.
C. Provide in-rack sprinklers over the first tier of a tote storage rack using a horizontal spacing of 8 ft
(2.4 m) located at each rack upright. Use quick-response, K ≥ 5.6 (80), 165°F (73°C) automatic in-rack
sprinklers. Design for operation of up to eight sprinklers at a flow rate of 30 gpm (115 L/min) and balance
with the provided ceiling sprinkler system.
2.3.1.3 Interlock the following press systems to automatically shut down upon activation of a fire protection
system:
• Ink, solvent, thinner, and blanket wash pumping systems
• Vacuum systems
• Hydraulic oil systems
• Lube oil systems
• Pneumatic systems
In addition to the automatic interlocks, provide a remotely accessible manual shut-off.

2.3.2 Lithograph — Newspaper Press Protection

The protection recommended for newspaper presses is intended to confine a fire to one press unit for both
single-unit-high presses and multiple-unit-high (tower) presses.
2.3.2.1 Provide protection for reel rooms as follows:
A. Locate an automatic sprinkler between each reel stand, or locate a standard sidewall sprinkler on one
side of the press between each unit discharging across and under the press units (see Figures 5a and
5b). Locate standard sidewall sprinklers as high as possible to ensure they are exposed to the heat plume
from the fire. This is to prevent damage to press supporting members and the press itself.
B. Provide automatic sprinklers under metal skirts surrounding the press at the top of the reel level.
C. Locate automatic sprinklers over collection pans that contain oil or ink residues.
D. Design in-press sprinklers for the operation of 7 sprinklers at 22 gpm (83 L/min). Use K ≥ 5.6 (80),
quick-response, 165°F (74°C) temperature-rated sprinklers (consider the ambient temperature in the areas
where the sprinkler will be installed and ensure the temperature rating of the sprinkler is at least 50° above
ambient).

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2.3.2.2 Provide protection for single-unit-high presses shielded from ceiling sprinkler protection as follows:

Fig. 5a. Automatic sprinkler protection for shielded areas of a single level newspaper press (not shown is automatic sprinkler
protection for shielded areas on the opposite side of the press); for multiple press levels the protection shown above is
repeated at each level of the press

A. Provide automatic sprinklers under all platforms or walkways, regardless of width between press units.
Installation at the center of a platform (along centerline of press) is preferable; however, the sprinkler may
need to be located at the side of the platform due to obstructions or web break. If the web runs under
the platform, a web break could wrap around the sprinkler.
B. Provide automatic sprinkler protection under catwalks adjacent to the press when any of the following
conditions exist:
1. Catwalks are above a press unit operating level, or
2. Catwalks are 4 ft (1.2 m) or more in width, or
3. There are combustibles under the catwalk, including flammable/combustible liquid-piping or electrical
cable.
C. Provide automatic sprinkler protection in sound enclosures around folders.
D. Design in-press sprinklers at the operating level for single-high presses for 7 sprinklers operating at
22 gpm (83 L/min). Use K ≥ 5.6 (80), quick-response, 165°F (74°C) sprinklers. Operation of in-press
sprinklers does not need to be balanced with the ceiling sprinkler system (consider the ambient
temperature in the areas where the sprinklers will be installed and ensure the temperature rating of the
sprinklers is at least 50˚ above ambient).

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Fig. 5b. In-press automatic sprinkler protection for a multilevel newspaper press

2.3.2.3 Provide one of the following types of fixed fire protection for multiple-unit-high (tower) presses as
follows:
A. Provide automatic sprinkler protection below platforms, catwalks, and in archways.
1. Provide automatic sprinklers for multilevel presses at all operating levels as described in Sections
2.3.2.2(A) through 2.3.2.2(D).
2. Provide 165°F (74°C) quick-response automatic sprinklers to protect all archways (doghouses) of
press towers to limit vertical fire spread.
3. Design in-press sprinkler protection for 14 sprinklers (seven sprinklers on each of two levels)
operating at 22 gpm (83 L/min). Use K ≥ 5.6 (80), quick response, 165°F (74°C) sprinklers. In-press
sprinklers do not need to be balanced with ceiling sprinklers (consider the ambient temperature in the
areas where sprinklers will be installed and ensure the temperature rating of the sprinklers is at least
50˚ above ambient).
B. Provide an automatic fixed water spray system designed as follows:
1. Arrange FM Approved open nozzles around each press level, with the nozzles pointed into press
openings.

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2. Design the water spray system to provide 22 gpm (85 L/min) with a minimum discharge pressure
of 7 psig (0.5 barg) using solid cone, spray nozzles with a maximum discharge angle of 120°. The deluge
system does not need to be balanced with the ceiling sprinkler system.
3. Provide a separate deluge valve for each tower tied to a heat detection system located above that
tower, or use automatic zone valves tied to a heat-detection system located above a tower and a single
deluge valve.
4. Provide a water supply adequate for the water-spray systems in two adjacent towers.
2.3.2.4 Use a cage around any installed sprinklers if there is a possibility that mechanical damage could
result in their operation.
2.3.2.5 When used, install pre-action automatic sprinkler systems in accordance with Data Sheet 2-0,
Installation Guidelines for Automatic Sprinkler Systems. Ideally, use line-type heat detection wrapped around
the sprinkler piping, or use spot heat detectors located no more than 12 in. (30.5 cm) from each automatic
sprinkler to ensure prompt water delivery. Usually, pre-action sprinkler systems are not recommended or
needed for this occupancy.

2.3.3 Lithograph, Non-Newspaper Press Protection

2.3.3.1 Protect vertical web presses in accordance with the recommendations in Section 2.3.2 and the
following:
A. Provide sprinkler protection below solid or grated mezzanines between stacked horizontal presses.
B. Use K ≥ 5.6 (80), quick-response 165°F (74°C) temperature-rated sprinklers.
C. For solid mezzanines, design for 0.20 gpm/ft2 (8 mm/min) over 3000 ft2 (278.7 m2) or the area of the
mezzanine, whichever is smaller.
D. For grated mezzanines, design sprinkler protection below the mezzanine for seven sprinklers operating
at 22 gpm (83 L/min).
E. The in-press sprinkler system does not need to be balanced with the ceiling sprinkler system.

2.3.4 Rotogravure and Flexograph Press Protection

2.3.4.1 Protect rotogravure presses (see Figure 6) likely to contain flammable/combustible liquids with a
closed-cup flash point higher than 200°F (93°C) (e.g., ink or solvent) and/or combustible deposits as follows:
A. Provide automatic sprinkler protection in the following areas:
• Both sides of the roll stacks
• Floor area under the press
• Ink carts, ink reservoirs, or ink viscosity control equipment
• Dryers
• Exhaust ducts
• Folders, if part of the press line; use automatic sprinkler protection if folder is in a separate enclosure
B. Use K ≥ 5.6 (80), quick-response 165°F (74°C) temperature-rated sprinklers designed to provide 22
gpm (83 L/min) out of seven sprinklers. Press sprinklers do not need to be balanced with the ceiling
sprinkler system.
2.3.4.2 Protect flexograph presses likely to contain flammable/combustible liquids with a closed-cup flash
point higher than 200°F (93°C) (e.g., ink or solvent) and/or combustible deposits as follows (see Fig. 7):
A. Provide automatic sprinkler protection in the following areas:
• Printing stations
• Rollers
• Ink, ink viscosity control equipment, and solvent tanks

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• Dryer
• Exhaust ducts
B. Use K ≥ 5.6 (80), quick-response 165°F (74°C) temperature-rated sprinklers designed to provide 22
gpm (83 L/min) out of seven sprinklers. Press sprinklers do not need to be balanced with the ceiling
sprinkler system.
2.3.4.3 Provide a combination of automatic sprinklers and special protection systems for any presses using
low-flashpoint flammable/combustible inks (i.e., closed-cup flashpoint lower than 200°F [93°C]).
2.3.4.3.1 Install/design automatic sprinklers as follows:
A. Provide sprinkler protection below solid or grated mezzanines and in concealed spaces within the press
(see Figs. 7, 8, 9, and 10).
B. Use K ≥ 5.6 (80), quick-response 165°F (74°C) temperature-rated sprinklers.
C. Design sprinkler protection for seven sprinklers operating at 22 gpm (83 L/min).
D. The in-press sprinkler system does not need to be balanced with the ceiling sprinkler system.
2.3.4.3.2 Design/install special protection systems as follows:
A. Protect unenclosed presses with a FM Approved local application CO2 system designed in accordance
with Data Sheet 4-11N, Carbon Dioxide Extinguishing Systems.
B. Protect enclosed presses with an FM Approved total flooding CO2 system in accordance with Data
Sheet 4-11N, Carbon Dioxide Extinguishing Systems.
C. Design local application systems so the full quantity of agent needed to meet the design concentration
is discharged within 30 seconds.
D. Arrange the special protection systems so they can be manually activated by press operators and
automatically activated by fire detection. Use FM Approved flame detection or heat detection.
E. Interlock the fire detection system to shutdown press, exhaust system, ink and solvent supply, and
pneumatic and hydraulic systems associated with press operation.
F. Design press protection to either discharge to protect the entire press line at one time or subdivide
into zones. In the latter case, provide adequate agent for a full discharge for all press units.
Fixed special protection with adequate detection is the first line of defense. Automatic sprinkler protection
is intended to contain a fire and prevent it from getting beyond the press in the event of re-ignition.
2.3.4.4 Protect presses that switch between flammable/combustible and non-flammable/combustible inks
as though they used flammable/combustible inks all the time.
2.3.4.5 Provide web-break detection and interlocks to shut down the press to prevent burning or solvent/
ink-soaked material from being pulled through the press.

2.3.5 Control Rooms, Computer Rooms, and Motor Control Centers

2.3.5.1 Provide automatic smoke detection in the room and below raised floors with an alarm to a constantly
attended location.
2.3.5.2 Provide automatic sprinkler protection.
2.3.5.3 Protect the computer room in accordance with Data Sheet 5-32, Electronic Data Processing.
2.3.5.4 Protect motor control centers in accordance with Data Sheet 5-19, Switchgear and Circuit Breakers.
Prohibit combustible storage within these rooms.

2.3.6 Manual Protection

2.3.6.1 Provide small hose connection or small hose stations in press rooms and reel rooms. Use of carbon
dioxide hose lines are an acceptable substitute where low-pressure bulk storage carbon dioxide systems
are used.

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Fig. 6. Carbon dioxide and automatic sprinkler system protection for a rotogravure press using flammable/combustible
inks

Fig. 7. Carbon dioxide and automatic sprinkler system protection for a central impression (CI) flexography press with six
printing decks using flammable/combustible inks

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Fig. 8. Carbon dioxide and automatic sprinkler system protection for a stack-type flexography press using flammable/
combustible inks

Fig. 9. Carbon dioxide protection for a six-color, in-line flexograph press using flammable/combustible inks (where the
press is in an enclosure, sprinklers would be provided within the enclosure)

2.3.6.2 Provide portable fire extinguishers rated for the occupancy in accordance with Data Sheet 4-5,
Portable Extinguishers. Locate within 20 ft (6.1 m) of the press and where they would be accessible during
a fire.

2.3.7 Sound Enclosures

2.3.7.1 Provide automatic sprinkler protection within and under sound enclosures. Provide a density of 0.20
gpm/ft2 (8 mm/min) over and under the area of the enclosure up to 3,000 ft2 (279 m2).
2.3.7.2 Ensure combustible dusts are properly controlled (see Sections 2.1.8, 2.2.7, and 2.3.11).

2.3.8 Baler Rooms

2.3.8.1 Provide automatic sprinkler protection and hydraulic system interlocks in baler rooms (see Data Sheet
7-98, Hydraulic Fluids).
2.3.8.2 Locate fans downstream of the cyclone to reduce dust emission into the baler room.
2.3.8.3 Ensure combustible dusts are properly controlled (see Sections 2.1.8, 2.2.7, and 2.3.11).

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2.3.9 Ducts
2.3.9.1 Design, construct, and protect ducts in accordance with Data Sheet 7-78, Industrial Exhaust Systems.
Provide automatic sprinkler protection for metal ducts if there are accumulations of oily residue and paper
dust. Inspect ducts every six months.

2.3.10 Carbon Bed Adsorbers

2.3.10.1 Design, construct, and protect carbon bed adsorbers in accordance with Data Sheet 7-2, Waste
Solvent Recovery.

2.3.11 Dust Collection Systems

2.3.11.1 Provide automatic sprinkler protection in dust collection systems in accordance with Data Sheets
7-73, Dust Collectors and Collection Systems, and 7-76, Prevention and Mitigation of Combustible Dust
Explosion and Fires.

2.4 Equipment and Processes

2.4.1 General
2.4.1.1 Provide hard-wired safety circuits, or install PLCs or other programmable electronic systems in
accordance with Data Sheet 7-45, Instrumentation and Control in Safety Applications.
2.4.1.2 Provide low-level local ventilation for rotogravure and flexograph presses using low-flashpoint inks
for normal operation and when shut down for cleaning. Ensure ventilation rates are 1 cfm/ft2 (0.3 m3/min m2).
Extend ventilation to cover dispensing of liquids with flashpoints lower than 200°F (93°C). Provide supervision
for the ventilation and alarm on loss of ventilation.

2.4.2 Dryers
2.4.2.1. Design purge, ventilation, and fuel train interlocks for dryers, thermal oxidizers/fume incinerators,
carbon bed adsorbers or other emission control systems in accordance with Data Sheets 6-9, Ovens and
Dryers; 6-11, Fume Incinerators; and 7-2, Waste Solvent Recovery. Ensure the burner system is interlocked
to automatically shut down on operation of process safety controls associated with this equipment.
2.4.2.2 Provide adequate safety ventilation to prevent solvent concentrations in the dryer and associated
ducting from exceeding 25% of the lower flammable limit (LFL). Ensure safety ventilation is adequate for
solvent concentrations measured during blanket wash. Test and confirm the exhaust ventilation design during
equipment commissioning.
2.4.2.3 Provide FM Approved LFL detectors directly on the dryer to minimize the length of sampling tubes.
Sampling tubes with extended lengths can delay notification, increasing response time. Test and maintain
detectors in accordance with OEM specifications. If a flammable calibration gas is needed for the detection
system, locate cylinders outside of important buildings and follow guidance in Data Sheet 7-50, Compressed
Gases in Cylinders.
2.4.2.4 Do the following where dryers are operated above 25% of the LFL:
A. Interlock detectors to alarm at a maximum of 45% and trip at 50%. Arrange the trip to shut off burners,
lift the press imprint roller, and stop the web (fast stop), open ventilation dampers, and increase fan speed.
B. Test and confirm safety ventilation at least annually.
C. Calibrate LFL detectors semi-annually.
2.4.2.5 Interlock the imprint roller with exhaust ventilation on flexograph and rotogravure presses using
low-flashpoint inks. Conducting imprint roller color checks with the dryer ventilation system off could result
in an explosion in the dryer.
2.4.2.6 Arrange damper settings so minimum exhaust ventilation is maintained based on ink application rate
or automatic solvent wash, whichever is greater. Provide dampers with proximity (position) switches so
minimum exhaust ventilation is maintained. An acceptable alternative is to provide mechanical stops on the
dampers arranged to ensure the minimum needed exhaust rate will be maintained (see Fig. 11).

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Fig. 10. Typical exhaust system design for rotogravure press with recirculated dryer atmosphere into burner combustion
chamber; the figure shows LFL detectors for the dryer, explosion venting for the dryer and ductwork, and damper
arrangement set for minimum exhaust ventilation based on ink application rate or auto solvent wash, whichever is greater

2.4.2.7 Provide damage-limiting construction for dryers that are direct fired and/or handle flammable/
combustible solvents (See Data Sheets 6-9, Ovens and Dryers; 7-32, Flammable Liquid Operations; and
1-44, Damage Limiting Construction, for design information). Provide explosion venting for exhaust ducts in
accordance with Data Sheet 6-11, Fume Incinerators. The ducts include dryer exhaust and recirculation ducts
where dryer or oven atmosphere is re-circulated to the combustion chamber.
2.4.2.8 Provide separate exhaust ventilation for each dryer and the thermal oxidizer/fume incinerator, where
possible, so each can be independently purged to atmosphere during startup or process upset conditions.
2.4.2.9 Do the following where there is a common exhaust system supported by a variable-speed exhaust fan
downstream of the dryer or other vapor generating equipment that provides a constant negative exhaust
system pressure:
A. Prevent operation of the RTO/fume incinerator, or shut it down and vent the dryer exhaust to atmosphere
if a hazardous condition exists. Provide LFL detection in the dryer and exhaust ducts connected to the
RTO.
B. Provide direct airflow measurement in the duct connecting dryers to the central exhaust system.
Interlock to shut down dryers and RTO. Do not use a negative exhaust pressure interlock; this is not
effective because the variable speed fan is designed to maintain a constant negative pressure.
C. Provide proper damper controls to ensure adequate ventilation of dryers, exhaust ducts, and RTO.
D. Do not allow re-circulation of exhaust from one dryer to other dryers.
E. Ensure the oxidizer is in operation before dryers are purged and the startup cycle is initiated.
F. Shut off the burner for the dryers and stop the press imprint roller and web if the thermal oxidizer trips.

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2.4.2.10 Do the following where press designs allow modification of re-circulation rates for the dryers:
A. Verify there has been no change in safety monitoring interlocks (air flow, air pressure switches, damper
proximity switches) following a modification of recirculation rate.
B. Develop a formal procedure to confirm the change in recirculation rate will not result in hazardous vapor
concentrations in the dryer and associated ductwork.
2.4.2.11 Provide a direct method of measuring exhaust ventilation from the oven, or interlock the damper
system with a proximity switch set at the minimum exhaust air flow rate for the dryer.
2.4.2.12 Interlock direct-fired dryers (or dryers that operate at a temperature high enough to ignite the printed
material) to shut down when the press is stopped. For rotary web press, the web could be automatically
removed on press shutdown.

2.5 Maintenance
2.5.1 Clean and test the static eliminator system periodically.
2.5.2 Establish a formal preventive and predictive maintenance program for press unit bearings, drive motors,
clutches, gearboxes, dryer fans, and combustion blowers.
2.5.3 Establish a formal preventive maintenance and testing program for all fuel-fired equipment burner safety
controls.
2.5.4 Establish a formal preventive maintenance, testing, and calibration program for LFL detection systems
and interlocks on press dryers and thermal oxidizer units in accordance with OEM specifications.
2.5.5 Maintain dryers and thermal oxidizing equipment in accordance with OEM specifications and Data
Sheets 6-9, Industrial Ovens and Dryers, and 6-11, Fume Incinerators.

2.6 Human Factors

2.6.1 Flammable/Combustible Liquid Handling Procedures

2.6.1.1 Develop a formal procedure to transfer flammable/combustible liquids to press room areas. The
following are examples of what to include:
• Allow no open containers.
• Establish a short route from storage to use (not through warehousing areas).
• Ensure product containers are properly secured.
• Allow no transport when building fire protection is impaired.
• Transport a maximum of one pallet load at a time.
2.6.1.2 Use the following flammable/combustible-liquid handling procedures at all times:
A. Do not clean up spilled ink with low-flashpoint solvents. Instead, use processes such as dry-ice
blast-cleaning that can remove dried ink without the addition of solvents.
B. If solvent cleaning is used, follow procedures to control the amount of solvent, ignition sources,
flammable vapor generation, and waste rags. At a minimum, include the following in any procedure:
1. Use safety cans to transport and dispense solvent.
2. Never use a mop to disperse the solvent.
3. Use rags or other materials that can be wetted with solvent.
4. Do not pour solvent on the floor.
5. Ensure low-level mechanical ventilation is provided to limit solvent vapor accumulation to 25% or
less of the solvent’s lower explosive limit (also known as lower flammable limit).
6. Properly dispose of rags in sealed metal containers.
7. Strictly control all ignition sources in the area.

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8. Provide a properly rated portable fire extinguisher in the area.

9. Where possible, use a solvent with a closed-cup flash point higher than 140°F (60°C).
C. Do not pour solvent on the web.
D. Use FM Approved safety cans and limit solvent use to no more than 5 gal (19 L).
2.6.1.3 Allow hot surfaces to cool before cleaning them.
2.6.1.4 When a manual wash is conducted on a lithograph press, have the web removed and the dryer shut
down, but maintain safety ventilation.
2.6.1.5 Establish cleaning frequencies for automatic blanket and cylinder washes. Base frequencies on OEM
recommendations as a minimum and change them if needed, based on observations of residue accumulations
during use).
2.6.1.6 Maintain automatic blanket wash per the press OEM specifications so they continue to operate
properly. Always visually check the press for unusual conditions, such as fire, before initiating an automatic
blanket wash using flammable/combustible wash solvent.
2.6.1.7 Establish a formal procedure for manual application of blanket wash to the press in accordance with
the dryer manufacturer’s specifications.

2.6.2 Combustible Dust Handling

2.6.2.1 Inspect dust-producing areas in the facility weekly for dust accumulations.
A. When dust accumulations are found, immediately clean them up with a vacuum-type system. Never
blow down dust with compressed air.
B. Identify the source of the leak in the dust-collection system and promptly repair it.
2.6.2.2 Examine ducts and areas above suspended ceilings every six months for accumulations of paper
or other combustible dust (e.g., starch, which is used for some plastic film/sheet printing operations).
A. When dust accumulations are found, immediately clean them up with a vacuum-type system. Never blow
down dust with compressed air.
B. Identify the source of the leak in the dust collection system and promptly repair it.
2.6.2.3 Monitor pressure drop across filters of press dust collection systems to replace filters that have
become plugged. Plugged filters reduce air flow and increase dust loading on the press and in the duct.

2.6.3 Housekeeping
2.6.3.1 Keep equipment that generates combustible dust, such as paper and starch, and the surrounding
areas as dust-free as possible using automatic dust-collection equipment. In the event of an accidental dust
release, only use vacuuming for cleaning up the dust. (See Data Sheet 7-73, Dust Collectors and Collection
Systems, for further protection guidelines.)
2.6.3.2 Establish cleaning schedules for (a) presses, (b) ink troughs, (c) folders, (d) dryers, (e) slitters, (f)
dust collection ducts, (g) baler rooms, (h) areas below the press, and (i) oil-collection pans.
2.6.3.3 Do not allow continuous residue accumulations between press units of greater than 1/16 in. (1.6 mm)
high-density dust to 1⁄8 in. (3.2 mm) low-density dust above or below the press operating floor. Record
cleaning frequencies.
2.6.3.4 Prevent the accumulation of paper scrap, flammable/combustible liquids, and cleaning rags.
2.6.3.5 Examine ducts, areas above suspended ceilings, and all pit areas at least every six months for
accumulations of ink mist. Clean as necessary. Redesign of the ventilation system may be needed where
frequent cleaning is required.

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2.6.4 Emergency Response

2.6.4.1 Ensure press operators and plant emergency response personnel are trained in the manual
activation/operation of any special protection systems, isolation of all flammable/combustible liquid systems
(e.g., ink, solvent, wash solvent, hydraulic systems, HTF system, etc.), shutdown of electrical systems and
compressed air systems. Provide prompt public fire service notification for any fire regardless of in-plant efforts
to control or extinguish it.
2.6.4.2 Develop a pre-fire plan in partnership with the public fire service that includes: all emergency response
actions; plans for evacuating smoke from the building of fire origin directly outside the building; and a plan
to reduce moisture content within plant buildings along with actions to dry and oil any equipment in areas
exposed to smoke to reduce post-fire corrosion. See Data Sheets 10-1, Pre-Incident Planning With The
Public Fire Service, and 10-2, Emergency Response, for additional pre-fire planning and emergency response
guidance. generation. Any printing press exposed to smoke generated during a fire needs to be promptly
dried to

2.7 Ignition Source Control

2.7.1 Provide hazardous-area-rated electrical equipment in areas with flammable vapors/gases or
combustible dusts. Use Data Sheets 5-1, Electrical Equipment in Hazardous Locations, 7-32, Flammable
Liquid Operations, and Figures 11 and 12 to determine what type of equipment rating is needed and where
the equipment is needed. Ensure the equipment chosen is appropriate for the hazard.

Fig. 11. Areas where Class I, Div 1 and 2 classified electrical equipment is needed for a flexography press using low-flash
point flammable/combustible inks

Class I Rated Equipment – Flammable vapors or gases

Division 1 or 2
Zone 0, 1, or 2
Class II Rated Equipment – Combustible dusts
Division 1 or 2 (US)
Zone 20 or 21 (IEC)
2.7.2 Provide wiring for presses in compliance with local jurisdictional electrical codes (in the United States,
use the National Electric Code). Many presses are pre-wired to be suitable for the specific application. Install
wiring in metal raceways or conduits where they might be otherwise be exposed to mechanical damage.
Provide FM Approved fire stopping in all vertical raceways between press levels.
2.7.3 Provide a means to eliminate static electricity for all press types. See Data Sheet 5-8, Static Electricity.
Copper tinsel (tacker bars) have been found effective on presses. Use bonding and grounding when
transferring any flammable/combustible liquid that is at or above its closed-cup flash point. Establish a formal
procedure on static electricity control and prevention.

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Fig. 12. Areas where Class I, Div 1 and 2 classified electrical equipment is needed for a rotogravure press using low-flash
point inks, and where Class II, Div 2 classified electrical equipment is needed within and below the folder sound enclosure

2.7.4 Establish a housekeeping program. Pay special attention to potentially hot areas such as bearings,
drive motors, and gearboxes.
2.7.5 Observe standard ignition-source prevention practices with regard to hot work and smoking.

3.0 SUPPORT FOR RECOMMENDATIONS

Most printing equipment operates at high speed and produces high-quality printed products from newspaper
to bottle labels. The equipment is complicated and requires precise tolerances. In most cases, protecting
the building envelope against the collection of fire hazards that exist in this occupancy is done using
ceiling-level automatic sprinklers. Unfortunately, ceiling sprinklers alone will not necessarily protect the
equipment from the high temperatures and nonthermal damage associated with a fire. To achieve the level
of protection against a fire or explosion that is really needed in a printing occupancy, efforts must be aimed
at eliminating/minimizing potential exposures to the printing equipment, in addition to providing local area
protection within the equipment.

3.1 Construction/Location

3.1.1 Noncombustible Construction

Plastics create severe fire hazards and large amounts of nonthermal damage (smoke); using plastics for
equipment enclosures directly exposes printing equipment to both. Using expanded plastic materials for
sound-deadening significantly increases the fire challenge by creating the potential for a fast-growing, severe
fire within close proximity to press electronics, air tubing, and hydraulic lines.

3.1.2 Fire Hazard Isolation

The fire hazard within a printing press is tied to the media being printed to (paper, plastic film), the
inks/solvents, hydraulic systems, heat transfer fluid (HTF) systems, pneumatic systems (plant air), electrical
wiring, and potential combustible deposits created by dust and ink residue. Very few scenarios involving
any of these exposures will result in thermal damage or water damage to adjacent presses, which should
limit severe press damage to a single press. Rolled stock (paper or plastic film) storage creates a significant
fire hazard that will produce large quantities of smoke and water. Flammable/ combustible liquid storage

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and mixing operations also create severe fire hazards that will produce extreme temperatures, black smoke
and, because they are liquids, can spread fire across large areas. Using walls, curbs, and drains will eliminate
the potential exposure created by either of these hazards to the printing equipment.

3.1.3 Explosion Hazard Isolation

Explosions create thermal, nonthermal, water, and pressure damage. The overpressures created during an
explosion can easily cause improperly designed walls and roofs to fail. Movement of a roof or floor will result
in damage to automatic sprinkler protection. The isolation of explosion hazards can only be accomplished
though the use of properly designed damage-limiting construction. Similar protection is also needed for
equipment that can explode. In most cases, the potential for an explosion is inherent to a process and using
protection measures such as ventilation can only reduce the likelihood of an explosion. Data Sheet 7-32,
Flammable Liquid Operations, and Data Sheet 7-76, Prevention and Mitigation of Combustible Dust Fire and
Explosion Hazards, provide guidelines for defining explosion hazards in buildings and equipment.
Printing occupancies create many potential explosion hazards, including the following:
• Ovens drying flammable/combustible inks or solvents
• Direct-fired ovens
• Press operations involving or generating combustible dusts (e.g., printing, cutting, slitting, folding)
• Operations collecting combustible dusts (e.g., dust collectors, cyclones)
• Parts-washing operations
• Solvent recovery (e.g., solvent recovery stills, carbon bed absorbers, thermal oxidizers)
• Flammable/combustible ink mixing operations
In many cases, ventilation and exhaust systems are used to control the accumulation of flammable
vapors/gases or combustible dusts during normal operations. However, upset conditions will cause any
provided ventilation design to fail, and the use of proper damage-limiting construction is the only way to ensure
the products of a combustion explosion (heat, flame, pressure) are directed to a safe location.

3.2 Occupancy

3.2.1 Flammable/Combustible Liquids

One significant hazard in many printing occupancies is the use of liquids that will burn (i.e., “flammable/
combustible liquids” or ignitable liquids). These liquids create severe growing fire hazards if they are not
controlled. A printing press alone can contain flammable/combustible inks, solvents, hydraulic oils, lube oils,
and HTF liquids. Most are pumped to/within the press and must be shut down in the event of a fire or damage
to the press will be severe because there are no fire protection systems that can extinguished a flowing liquid
fire. In most cases, shutting down the flow of flammable/combustible liquid to/within the press will allow
provided protection to limit thermal and nonthermal damage at the press.
Another hazard that is often overlooked is a pneumatic system (e.g., plant air). Many presses use air to control
various aspects of their operation and the air is delivered in flexible hoses. If a hose melts through during
a fire and the air is not shut down, the pressurized air will provide extra oxygen to the fire and increase its
severity.
Many printing occupancies store or stage large quantities of flammable/combustible inks and solvents
adjacent to the presses. This storage/staging creates a significant flammable/combustible liquid fire hazard
in the press hall that must be protected in accordance with Data Sheet 7-29, Flammable Liquids Storage
in Portable Containers, or Data Sheet 7-32, Flammable Liquid Operations. Failure to adequately control and
protect these liquids exposes multiple printing presses to a severe fire scenario that could consume all
electrical equipment and potentially warp the press frame.

3.2.2 Paste Inks

Paste inks are high-viscosity liquids that have to be transferred from their storage containers by means of
a trowel, scraper, or high-pressure pumping system. Paste inks will flow under pressure or shear. Paste inks
have flashpoints higher than 200°F (93°C). Automatic sprinkler protection will be effective on a pool fire.

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Press-room protection recommended in this data sheet is expected to control a fire in paste ink as long as
it has not been cut with an flammable/combustible solvent.

3.2.3 Combustible Dusts

Accumulations of combustible dust inside a building create the potential for a dust explosion. All dust-handling
equipment create the potential for dust explosions within the equipment and outside the equipment if the
equipment vents into a building.

3.3 Protection

3.3.1 Automatic Sprinkler Protection

Automatic sprinklers provide the best level of protection against a fire. In printing occupancies, the greatest
challenge is getting fire protection water to fires concealed within presses, ovens, ducts, and concealed
spaces around or below presses. Ceiling sprinklers alone will not adequately protect most printing presses,
requiring the installation of sprinklers in/around the presses. However, sprinklers will not operate if they are
not directly above/within the fire. Therefore, protecting a printing press has two parts: first, getting sprinklers
near/around concealed spaces, and second, locating the sprinklers inside the press/concealed space to
ensure it actually operates. Sprinklers located around press units can stop the horizontal spread of fire, but
will not impact its vertical growth because they will not operate until the fire spreads horizontally. Unfortunately,
getting automatic sprinklers where they need to be is challenging at best due to the moving web and press
designs.
The best way to protect a printing press is to use an automatic water spray system with heat detection located
over the individual printing units. This approach allows the installation of spray nozzles around press units
aimed into the units. Currently this approach is not used and installing multiple deluge valves can be
expensive; however, when balanced against the cost of refurbishing or replacing a printing press, the costs
are justified. Automatic water-control zone valves could reduce the costs by limiting the number of deluge
valves needed for a press. There are currently no FM Approved automatic water-control zone valves.

3.3.2 Special Protection

Loss experience indicates that special protection systems can significantly decreases property damage and
business interruption for printing presses. Unfortunately, if these systems are not properly designed, installed,
tested, and maintained, they will not work.
Local-application systems are used when the press or coater is not enclosed. CO2 systems and water-mist
systems are presently the only gas agent system FM Approved for local application. CO2 is the only
local-application system used for press protection to date. There is guidance in Data Sheet 4-11N, Carbon
Dioxide Systems, for designing of local-application systems. Systems are designed on a rate-by-area or
rate-by-volume method. General guidance is that (a) nozzle discharge patterns should overlap, and (b) the
agent must be discharged within 30 s (as opposed to 60 s for total flooding systems).
The area method defines the hazard as 2-dimensional; for example, a pan of ink supplying a rotogravure
press. The CO2 system nozzles are then arranged to discharge directly onto the surface of the ink. The type
of nozzle and the nozzle location are based on (a) the potential for splashing, and (b) the FM Approval listing,
and (c) the quantity of agent for high-pressure systems should be 1.4 times that calculated.
The volume method defines an imaginary enclosure plus 2 ft (0.6 m) around the hazard. CO2 nozzles and
agent application rate are arranged to fill the enclosure using a substantial safety factor.
Both the rate-by-area and rate-by-volume method may be used to protect different areas within the same
hazard.
CO2 systems protecting press stands are also installed to protect dryers and exhaust ducts associated with
the press. The design concentrations in dryers are 65% unless temperatures exceed 200°F (93°C). Where
higher temperatures are encountered, concentrations are increased. If dryers are large enough nozzles may
be located within the dryer. Where the size of the dryer or obstructions prevent internal installation, nozzles
may be arranged to discharge into the dryer opening with exhaust air drawing in the CO2. Exhaust ducts
are protected between the dryer and the first automatically closing damper in the duct. Nozzles are also
arranged on the upstream side of the damper to block fire spread past the damper.

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Local application CO2 systems are the most widely used special protection systems in printing plant
operations.
One of the major factors affecting the proper operation of CO2 systems is reliance on manual operation.
Operators attempt to control and extinguish the fire with portable extinguishers and, if not successful, then
activate the CO2 system. In many incidents, this was effective. In some incidents, however, the delay in
operation resulted in surface temperatures high enough to reignite ink when concentrations of CO2
decreased. Another factor is lack of proper inspection, testing, and maintenance of protection systems. In
one incident, a fire occurred on a rotogravure press. Sprinklers operated, operators left the area in anticipation
of the CO2 system actuating, but the system did not operate. Failure to shut down an flammable/combustible
liquid spray fire will also cause a CO2 system to fail to extinguish a fire.
In a recent 8-year period there were 14 fires where CO2 systems were provided and were described as
operating effectively. CO2 protection was provided in eleven incidents for rotogravure and flexograph presses,
and in two incidents for offset lithograph presses. There were seven incidents where CO2 was not provided
where needed, and there were three incidents where an installed CO2 system failed to limit damage.

3.4 Maintenance
There are two types of maintenance for presses: preventive and predictive.
Preventive maintenance consists of regularly scheduled tests, measurements, adjustments, and parts
replacement performed specifically to prevent faults from occurring.
Predictive maintenance is condition-driven. Oil changes and sump cleaning are conducted as described
above; however, rather than replacing the bearing on a regular schedule, instruments are used to monitor
the mechanical condition and other parameters in an attempt to determine the approximate time of failure so
the bearing can be replaced before it fails.

4.0 REFERENCES

4.1 FM Global
Data Sheet 1-19, Fire Walls, Subdivisions and Draft Curtains
Data Sheet 4-1N, Fixed Water Spray Systems for Fire Protection
Data Sheet 4-5, Portable Extinguishers
Data Sheet 5-1, Electrical Equipment in Hazardous Locations
Data Sheet 5-8, Static Electricity
Data Sheet 5-32, Electronic Data Processing Systems
Data Sheet 6-9, Industrial Ovens and Dryers
Data Sheet 6-11, Fume Incinerators
Data Sheet 7-2, Waste Solvent Recovery
Data Sheet 7-29, Flammable Liquid Storage in Portable Containers
Data Sheet 7-32, Flammable Liquid Operations
Data Sheet 7-45, Instrumentation and Control in Safety Applications
Data Sheet 7-73, Dust Collectors and Collection Systems
Data Sheet 7-78, Industrial Exhaust Systems
Data Sheet 7-88, Storage Tanks for Flammable Liquids
Data Sheet 7-98, Hydraulic Fluids
Data Sheet 7-99, Heat Transfer by Organic and Synthetic Fluids
Data Sheet 8-9, Storage of Class 1, 2, 3, 4 and Plastic Commodities
Data Sheet 8-21, Roll Paper Storage

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FM Global Property Loss Prevention Data Sheets Page 25

4.2 Other
American National Standards Institute (ANSI). Safety Standard – Printing Press Systems. ANSI B65.1-1995.
American National Standards Institute (ANSI). Binding and Finishing Systems. ANSI B65.2-1999.
Gravure Association of America, Inc. “Gravure Process Glossary.” http://www.gaa.org/technical-resources
/tech-downloads.html (accessed June 2, 2008).
National Fire Protection Association (NFPA). Guide for Fire and Explosion Investigation. NFPA 921. Latest
edition.
National Fire Protection Association (NFPA). National Electrical Code. NFPA 70. Latest edition.

APPENDIX A GLOSSARY OF TERMS

FM Approved: References to ‘‘FM Approved’’ in this data sheet mean the product or service has satisfied
the criteria for Approval by FM Approvals. Refer to the Approval Guide, an online resource of FM Approvals,
for a complete listing of products and services that are FM Approved.
Ballard shell: A thin skin of copper plated separately over the surface of a base cylinder. The base cylinder
is ground and polished before treatment with one of several liquid parting agents, which prevents the copper
layer from bonding directly to the base surface. The copper skin may be engraved and used for printing, after
which it is easily stripped from the base cylinder; a new copper skin may be plated onto the base cylinder
after the cylinder has been retreated with a parting agent.
Base cylinder: A gravure cylinder prior to copper plating.
Broke: Printed or unprinted paper or paperboard resulting from trimmings or make-ready sheets, generally
reusable in papermaking.
Color management:Controlling the matching of colors between an original image, scanner, monitor, color
printer, and final press sheet.
Combustible liquid: See flammable/combustible liquid.
Cylinder: Round, cylindrical copper or chrome-plated roller that carries etched image on the printing press,
revolving in a fountain of ink and being wiped by the doctor blade, prints on the moving web or substrate.
Flat-bed cylinder presses are sheet-fed and used mainly for short-run work such as booklets, folders, catalogs,
and labels. The quality of paper can vary widely from coarse to coated paper. Fine register multicolor work
also may be done, each color requiring a separate printing operation. The maximum press speed is 5,000
impressions per hour.
Flammable liquid: See flammable/combustible liquid.
Flammable/combustible liquid: Any liquid, or the liquid phase of any material, that is capable of fueling a
fire, including a flammable liquid, combustible liquid, or any other material that can be liquefied and burned.
These liquids can also be called “ignitable” liquids which is defined in NFPA 921.
Intermediate bulk container (IBC): Defined by the U.S. Department of Transportation in CFR Title 49, Part
178, Subpart N, dated October 1, 1997, and the United Nations Recommendations on the Transport of
Dangerous Goods, Ninth Edition, Chapter 16. The container size is limited to 3000 L or 793 gal There are no
other specific requirements on the design or material of construction. All IBCs must pass the required
performance-based testing designed to evaluate their resistance to leakage during transport. No existing test
requirements evaluate the container’s performance when exposed to fire. The IBC category also includes
the containers previously defined as portable tanks or tote tanks. Some limitations on the type of liquid storage
allowed in an IBC used for transportation do exist. However, for most commonly transported flammable/
combustible liquids, there are few limitations.
Lacquer: Clear varnish with a plastic film-former base (originally used to denote nitrocellulose-type fast-drying
inks and varnishes).
Laser engraving: The application of image information directly onto a zinc layer by the thermal energy of a
pulsating laser beam. Every laser pulse creates one cell by local evaporation of the zinc material. Because of
the pulse repetition rate of the laser beam, 70,000 cells per second can be generated.

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Page 26 FM Global Property Loss Prevention Data Sheets

Paste ink: An ink with a closed cup flash point greater than or equal to 200°F (93°C) that in an unsheared
condition at room temperature will not pour or readily flow. There is no definition for paste ink in the printing
industry.
Platen presses: Platen presses are the most flexible type of letterpress, capable of printing on a wide range
of paper products from thin paper to heavy cardboard, and from coarse to high-gloss paper. Fine register
multicolor work can be done, each color requiring a separate printing operation.
Process colors: The four colors (cyan, magenta, yellow, and black) that are controlled to print a wide range
of colors. When blended, these reproduce only a small portion of all the colors found in nature, but they can
reproduce the widest range with the fewest number of inks.
Sealed container: This term refers to a container that is tightly covered. An example is a container that is
ready for shipment versus a container that has a loose fitting cover provided.
Secondary colors:Colors created by combining two primary colorants of a color system (also referred to as
overprint colors). Example: red would be the secondary color produced with magenta and yellow.
Tote Tank: Heavy steel cylindrical tank generally used for paste ink storage, dispensing, and shipping. They
range in size from 200 gal (750 L) to 400 gal (1510 L). The tanks are designed for pressurized dispensing
of paste ink.
Web: Material to be printed and/or processed in roll form.
Web guide: Device that keeps the web traveling straight or true through the press.

APPENDIX B DOCUMENT REVISION HISTORY

April 2010. The following changes were made:
1. Separated flammable/combustible liquid protection into three categories: (1) low flash-point (below
200°F [93°C]), (2) high flash-point (200°F [93°C] and above), and (3) paste inks.
2. Added guidance on when to protect a printing occupancy as an flammable/combustible liquid-use
area in accordance with Data Sheet 7-32, Flammable Liquid Operations.
3. Added recommendations for in-process storage of roll paper in the press room.
4. Added recommendations for housekeeping in newspaper offset lithograph press operations.
5. Added details on the location and type of automatic fire protection for single and multiple-level
lithograph presses.
6. Added details on local-application CO2 system installation to promote better understanding of the
system design.
7. Added requirements for proper testing and maintenance of CO2 systems.
8. Added recommendations for control and computer room protection, carbon bed adsorbers, plate
washers, solvent recovery, lube oil, hydraulic, pneumatic, and heat transfer fluid (HTF) systems.
9. Added recommendations for dryers, exhaust ducts, and thermal oxidizers where design variations
for printing plant installations are different than those covered in existing standards.
January 2000. The document was reorganized to provide a consistent format.

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