Grilling our readers results in a recall

You gotta hand it to a guy who would drive all the way from Columbus, Indiana to Yonkers, New York to deliver a used grill to our testing labs. That's what John Heathcote did after we contacted him to learn more about a Perfect Flame grill that was giving him trouble. Because we only test new products, our normal testing protocols hadn't picked up on problems that John and other Perfect Flame owners were having after using their grills for awhile. Problems like lids catching fire and burners becoming dangerously deteriorated. (That's John, in shorts, at right showing his grill to Don Mays.)

John's grill was one of two donated for our tests but he gets the award for coming the farthest. (He also got a replacement grill and gas money.) What we got was more information to argue for the grill to be recalled. And yesterday it was—665,000 Perfect Flame SLG series grills in fact.

Not only do we listen to our readers but we act on your complaints. When we're told about safety hazards, we enter the information into a database that we monitor to uncover and address emerging problems. 
 
Readers started telling us about issues with Perfect Flame grills in 2007. We analyzed their complaints and wrote about them on this blog in August 2008. We questioned whether an earlier Perfect Flame grill recall  went far enough since it hadn’t include other hazardous models that our readers complained about—specifically the SLG2006, SLG2007 and SLG2008 series grills. 

We also reported our concerns to the compliance office of the Consumer Product Safety Commission and followed up with a written request for an investigation and recall. We sent the CPSC a list of 136 complaints we'd received, most citing uncontrolled fires, melting and poor burner quality for their SLG model grills. One user had been burned while trying to extinguish a fire and two homes had suffered property damage. Clearly, the CPSC should have addressed this hazardous product immediately.
 
But it didn't and we kept getting complaints at the rate of more than two per week.  By the beginning of this August, we'd received 77 complaints of fires, resulting in 11 injuries including burns to the hands, arms and legs. The injuries included two reports of breathing complications from inhalation of noxious gasses, and some 60 problems with burners cracking and rusting and/or shooting out irregular flames.

After reading so many complaints we wanted to test the older grills ourselves. That's where John came in. We put his grill and one from another volunteer through tests cooking fatty hamburgers and juicy steaks.  Although there were unusual flame patterns and out-of-control flare ups, we didn’t see any molten metal or lid fires. (It’s perplexing, though common, to get different results in a lab from those that turn up in the real world.)
 
When John got home he wrote to us again. “I truly hope that acquiring my grill will help in your research. I too believe there is something wrong with the Perfect Flame grills, either with the materials, the design or a combination of both," he said. "You have no idea how much I appreciate getting a replacement grill and how good it makes me feel knowing that I may help resolve an issue with a dangerous product.”

Finally, a full 14 months after we first brought Perfect Flame's imperfect flames to the CPSC's attention, the grill was recalled yesterday. “CPSC commends Consumers Union and Consumer Reports for the in-depth laboratory testing and research done in regard to this product," the agency's spokesman Scott Wolfson told us.  "Now that the recall is out, it's time for consumers with these dangerous grills to respond immediately to the recall to avoid any more fires or injuries.”
 
So it pays to report your safety concerns to us. That way we can warn readers, tweak our testing programs and push government agencies, manufacturers and retailers to get unsafe products off the market and out of consumers’ homes. To report a problem, fill out a form on our Web site. You can also report unsafe products to the CPSC.

Hats off to John Heathcote and to the rest of you who wrote.—Don Mays

Fires and burns prompt recall of 665,000 Perfect Flame grills sold at Lowe's

After reports of fires and some injuries, Perfect Flame has recalled its SLG series of grills -- totaling 665,000 grills sold at Lowe’s retail outlets nationwide over the past four years. Perfect Flame has received about 40 reports of fires from the burners deteriorating and about 23 reports of the lids catching fire. The company is aware of one report of an eye injury requiring surgery and 21 incidents of minor burns to the hands, arms or face.

After writing about these grills in August 2008, we have been hearing from readers about their problems with Perfect Flame grills and have taken our concerns to the Consumer Product Safety Commission.

Today we'd like to get the word out on the recall but we'll be weighing in with more information in the coming days.

This recall includes 10 model numbers with the years 2006, 2007 and 2008 in the model number. (See the recall notice for the full list.) According to the notice, the burners can deteriorate causing irregular flames and the lids of some models can catch fire, posing fire and burn hazards to the consumer.

The CPSC is advising owners to stop using the grills. Perfect Flame is offering owners replacement lids and/or burners, depending on the model. Grill owners should contact the company at (888) 840-9590  or visit www.lowes.com for more information.

Based on the comments from our readers who have had a variety of good and bad experiences trying to get their damaged grills replaced, we'll be interested to see how the company handles this recall.

After nine deaths, retailer recalls more chenille clothing

After nine deaths related to robes catching fire Blair, a Pennsylvania store and online retailer, has recalled all chenille clothing made by one of its suppliers because it does not meet flammability standards. This is the company's third recall. The first two involved 162,000 chenille robes but today's was expanded to include three other styles of chenille clothing made by CA-One Textile & Towel, of Karachi, Pakistan—totaling 300,000 garments in all.

In April 2009, Blair recalled 162,000 chenille robes after it learned of three robes catching on fire, including one report of second degree burns. Blair then received several reports of deaths allegedly due to robes catching fire. This prompted a second recall in June 2009 to alert consumers to the burn hazard for the chenille robes. After the re-announcement, Blair received four additional reports of deaths due to the robes catching fire. Three of the victims were cooking and a fourth was tending a pellet stove. All nine reported deaths occurred prior to the April 2009 announcement of the recall.

Today's recall was prompted by a report of another chenille garment made by CA-One Textile & Towel catching fire although no injuries were suffered in that incident.

The clothing was sold through Blair's catalogs and Web site, and in its stores in Warren, Pa., Grove City, Pa., and Wilmington, Del., from July, 2000, through April, 2007. Blair has been very aggressive in trying to reach customers who purchased the robes and has offered them a full refund or $50 gift certificate. It has mailed letters to every catalog and internet customer who purchased a robe and then followed up with letters and e-mails to those who did not respond. The company also called 63,000 customers who had not yet returned the recalled robes. A safety notice posted on Blair's Web site reads, "If you haven’t yet returned your robe to us, we urge you rethink your decision to keep it."

Blair is also offering refunds to those who purchased the items in today's recall. For more information, call Blair toll-free at (877) 392-7095 between 9 a.m. and 9 p.m. ET Monday through Saturday, visit the firm’s Web site at www.blair.com/recall, or contact the firm by e-mail at blairproductrecall@blair.com.

Fire safety week: Sparked by the Chicago fire

This is time of year when we observe Fire Prevention Week. But first let's clear up a popular misconception: The cow didn't do it—start the Great Chicago Fire of 1871 that is. The myth that the fire began when Mrs. O'Leary's cow kicked over a lantern was busted long ago.

A positive legacy of the blaze has been the observance of fire safety week, which occurs every year during the week in which Oct. 9 falls. The Chicago fire began October 8 but most of the damage occurred the following day. In all, the fire killed more than 250 people, left 100,000 homeless, destroyed more than 17,400 structures and burned more than 2,000 acres.

As bad as it was, the Chicago fire wasn't the worst inferno to occur on those two days. Far worse was the Peshtigo Fire, the most devastating forest fire in American history, according to the National Fire Prevention Association. The fire blazed through Northeast Wisconsin, burning down 16 towns, killing 1,152 people, and scorching 1.2 million acres before it ended. Historical accounts of the fire speculate that it began when railroad workers clearing land for tracks unintentionally started a brush fire.

Forty years after the Chicago fire, the Fire Marshals Association of North America (now the International Fire Marshals Association), decided to mark the event not with a celebration but with an annual public safety campaign about fire prevention.

At Consumer Reports we report on fire safety year round. In fact, we have new Ratings and recommendations (for subscribers) of smoke alarms and carbon monoxide detectors, a must for every home. We've also written recently about kitchen fires, which the NFPA is highlighting this week, childproofing your stove, fire safety on campus, and grilling safety, among many other related topics.

Last year fire departments responded to 1,451,500 fires in the U.S. that resulted in 3,320 civilian deaths. More than 80 percent of those deaths occurred at  home. With that in mind, take a moment this week to review fire safety with your family. The NFPA has lots of good information on its Web site, including the exoneration of Mrs. O'Leary's cow.

This week in safety: Home hazardous home

Each year more than 18,000 Americans die accidental deaths at home. In fact, the home is the second most common place for such mishaps, following the car, according to the Home Safety Council. To get the word out, Meri-K Appy, the council's president, talked to U.S. News recently about the five leading causes of unintentional home injury deaths and how to prevent them.

According to Appy, these are the five leading home injuries and the number of lives they claim each year.

1. Falls: 6,000
2. Poisoning: 5,000
3. Fires and burns: 3,000
4. Airway obstruction: 1,000
5. Drowning: 800

Headlines
Lead-tainted toys linger on shelves despite law
NPR. org
At many discount toy stores in this country, products that test at dangerously high levels for lead are still on the shelves — despite a new federal law to protect children. Read more ...

Legal life: Watching out for the consumer
The New York Times.com
Earlier this summer I bought a new gas barbecue grill at Lowe’s. I had used it only a handful of times when one morning as I blankly stared at the Star-Ledger, I noticed a line of print announcing a recall of Blue Ember barbecue grills. Read more ...

After snowmobilers killed, parents push for greater safety
The Journal Times (Racine, WI)
For six months after Nathan and Jennifer Kender went out for a morning snowmobile ride in northern Wisconsin and never made it home, their parents have wanted to know why the crash happened. Read more ...

Infant car seats can restrict babies oxygen levels
CNN.com
Infant car safety seats can—and do—save newborns' lives in traffic accidents. However, these seats, which require infants to be placed in an upright position, can also cause breathing problems when babies sleep in them. Read more ...

When food safety fails: E. coli victim fights to survive
The Los Angeles Times
Linda Rivera's mute state, punctuated only by groans, is the latest downturn in the swift collapse of her health that began in May when she curled up on her living room couch and nonchalantly ate several spoonfuls of Nestle Toll House cookie dough. Read more ...

Don't miss these recalls

• 1,400 children’s animal masks and pendants (lead)
• 24,000 SRAM bicycle chains with PowerLock connector links (fall hazard)
• 500 Grizzly Industrial bandsaws (shock hazard)
• 2,300 La Jolla Sport hooded sweatshirts (strangulation hazard)

Safety news from the CR blogs

• Babies & Kids: Dishwasher dangers
  
• Babies & Kids: Safe sleep tips
• Cars: National child passenger safety week
• Cars: Toyota and Volkswagen recalls
• Cars: How to prevent car theft
• Home: Can nonstick pans make you sick?
• Health: Latisse -- long lashes, long list of risks

Maytag reissues refrigerator recall after more fires

After more reports of fires and property damage, Maytag has expanded an earlier recall of 1.6 million refrigerators by an additional 46,000 units because of an electrical failure. The recall includes six brands: Maytag, Jenn-Air, Amana, Admiral, Magic Chef, Performa by Maytag and Crosley.

When the recall was first announced in March, Maytag had received 41 reports of the relays catching fire, including 16 that resulted in property damage ranging from smoke damage to extensive kitchen damage. Since then the company has received 23 additional incident reports including four with property damage. The defect is in the relay, the component that turns on the refrigerator's compressor, which can overheat.

The recall involves both side-by-side and top-freezer refrigerators but not those with bottom freezers. (Check the first and second recall notices for serial and model numbers.) They were sold at department and appliance stores and by homebuilders nationwide from September 2000 through May 2004 for between $350 and $1,600.

Owners of the units should contact Maytag to determine if their refrigerator is included in the recall and if so, to schedule a free in-home repair. Consumers should not return the refrigerator to the retailer where it was purchased. For more information, contact Maytag toll-free at (866) 533-9817 anytime, or visit the Maytag Web site.

Home Depot and Sam's Club recall generators that pose fire hazard

Big box retailers Home Depot and Sam's Club have recalled 51,750 generators because the fuel gauge can leak excessive amounts of gasoline, posing a fire hazard to consumers, the Consumer Product Safety Commission announced today.

The Homelite and Husky (Home Depot) and Black Max (Sam's Club) brand generators were distributed by Homelite, a South Carolina firm. They were sold from July 2008 through May 2009 for between $480 and $1,600. Check the recall notice for model numbers and date codes.

The CPSC is advising consumers to stop using the generators and contact Homelite Consumer Products (Homelite and Husky brands only) or Black Max (Black Max brands only) for a free repair kit. For more information regarding Homelite or Husky generators, contact Homelite Consumer Products at (800) 242-4672 between 8 a.m. and 5 p.m. ET Monday through Friday, or visit www.homelite.com. Owners of the Black Max brand generators can contact Black Max at (800) 726-5760 between 8 a.m. and 5 p.m. ET Monday through Friday or visiting www.blackmaxtools.com.

Our take: As we've reminded readers in the past generators, even when working properly, can pose risks from carbon-monoxide (CO) poisoning, fire and electrocution. Owners of generators should not only heed this recall but follow these essential safety steps as well.

For more tips, watch our video on generator safety.

After reported injuries, Fiesta again recalls Blue Ember grills

After getting more reports of injuries and incidents, Fiesta is again recalling its Blue Ember grill because the hose of the gas tank can get too close to the firebox and cause a fire hazard, the Consumer Product Safety Commission announced today. The company has received 192 reports of grill fires, resulting in nine injuries, including two incidents of major burns on different parts of the body, six incidents of minor burns, and an incident involving temporary hearing loss. The recall includes 88,000 units in the U.S. and 25,000 in Canada.

The recall involves three U.S. models (FG50045, FG50057, FG50069) and two Canadian (C1072-30744, C1072-30754). The serial numbers can be found on the U.S. and Canadian recall notices. In October, Fiesta recalled 47,000 Blue Ember grills including some of the same model numbers. Two months before that, Consumer Reports had asked the CPSC to issue a safety alert about the grill after discovering that it could be assembled incorrectly.  At the time, Fiesta said it had made design changes that reduced the risk of incorrect routing of the burner hose, which created the fire hazard.

This time around, Fiesta is asking consumers to stop using the grill and call the company to obtain a free replacement grease pan assembly and instructions for installing the pan and the gas tank. The grill should not be used until the new grease pan assembly and the gas tank have been installed correctly. Consumers should also inspect the gas burner hose and regulator, which will be replaced free of charge if there are signs of damage. Call Fiesta at 866-740-7849 between 7 a.m. and 5 p.m. CT Monday through Friday, e-mail mnorman@fiestagasgrills.com or visit the company's Web site.

Made in China, the grills were sold in various home centers and by national retailers from November 2006 through June 2008 for between $400 and $500 in the United States and from November 2006 through May 2009 for between $400 and $600 in Canada.

Our take:  We are growing increasingly concerned that the recognized safety standard on gas grills does not go far enough to capture the fire hazards that occur under regular use.

Today's recalls: Faulty smoke alarms and tea kettles

The Consumer Product Safety Commission today announced recalls of two products found in many homes because they can pose burn or fire hazards. Recalled were 94,000 Kidde smoke alarms because they may fail to sound an alert and 142,000 Copco tea kettles with ill-fitting lids. A number of second-degree burn injuries have been associated with the tea kettles.

Copco Harmony tea kettles
Wilton, the distributor of the Copco kettles, has gotten reports of  25 incidents of lids coming loose, some which resulted in burns to hands and fingers. The recall includes stainless steel kettles with both brushed and polished finishes and enamel kettles in red, white, black, turquoise, orange, yellow and blue. The kettles were sold by retailers nationwide from March 2006 through June 2009 for about $30.

The company is offering two different remedies depending on which type of kettle a consumer has. Owners of the stainless kettles should contact Wilton for a free replacement lid that fits more snugly. Wilton is offering owners of the enamel tea kettles a free replacement tea kettle or a refund.

For more information, contact Wilton Industries at (800) 794-5866 or visit the firm’s Web site at www.copco.com.

Kidde dual sensor smoke alarms
Kidde is recalling its PI 2000 alarms because an electrostatic discharge can damage the unit, causing it to fail. Kidde has received two reports of smoke alarm malfunctions involving electrostatic discharge during installation. No injuries have been reported.

The recalled alarms can be identified by two buttons: “Hush” and “Push and hold to test weekly”  located on the front/center of the alarm. The model number and date code are on the back of the smoke alarm. Only date codes 2008 Aug. 01 through 2009 May 04 are included in this recall. The alarms were sold at retail, department, and hardware stores and through electrical distributors nationwide from August 2008 through May 2009 for between $30 and $40.

The CPSC is advising consumers to contact Kidde to receive a free replacement smoke alarm. For more information, contact Kidde at (877) 524-2086 or visit the firm’s Web site at www.kidde.com.

Do you have a Perfect Flame gas grill? Then read this

Owners of Perfect Flame gas grills should be especially cautious as they fire them up for the July 4th weekend … or at any other time for that matter. What appeared to be a limited fire and burn hazard with some models may be much wider than anyone realized.

Last August, the Consumer Product Safety Commission announced the recall of one model, the Perfect Flame GAC3615, due to fire and burn hazards. The cooking chamber of those grills can "melt or ignite” according to the recall notice.

But our readers are telling us that’s not the only volatile model. In fact, after our August 13, 2008 blog post "Does the Perfect Flame grill recall go far enough?" suggesting that the recall was too narrow, we received more than 100 responses from readers who own the Perfect Flame SLG2006 and the SLG2007 models. Their grills have also melted or caught on fire.

The number of complaints and severity of the incidents we’ve heard about are very concerning.  We are currently collecting additional information that we hope will be used to address the hazards with these grills. In the meantime, take these precautions before using your Perfect Flame SLG2006 or SLG2007 grill:

• Check the burner tubes for holes or cracks. If you find any, replace the necessary parts before using the grill.
• When cooking, watch the grill at all times. Do not leave it unattended even just to preheat.
• Look for unusual flame patterns. If you notice anything out of the ordinary, shut off the gas and step away from the grill until it cools down.

Some of our readers have reported that when the grill catches on fire the flames can produce bright white light indicative of burning magnesium.  If that happens, be careful—water and carbon dioxide fire extinguishers will not put out a fire containing burning magnesium. Instead, you must either use a Class D dry chemical fire extinguisher or cover the fire with sand.  Better yet, call the fire department.

If you’ve experienced problems with the Perfect Flame or with fires, melting or deformation of any gas grill, please comment on this posting and be sure to report it to us as well as to the CPSC. The CPSC's recall system relies heavily on consumer complaints and without them many problem products wouldn't be recalled. Sharing this information with Consumer Reports can help us accomplish our mission of reducing the number of unsafe products in the marketplace and help protect consumers from serious injury.

Grill safety
No matter what grill you are using, follow this safety advice:

• Replace cracked or brittle propane hoses or gas lines.
• Check hoses for gas leaks by applying a mixture of dishwashing soap and water. Bubbles indicate a leak.  Replace as needed.
• Do not attempt to repair the valve on a gas tank or the grill yourself.  Take the grill to a liquid-propane dealer or qualified appliance-repair service.
• Regularly empty grease pans, trays, or receptacles to minimize fire hazards.
• Never start a charcoal fire with gasoline.
• Never add lighter fluid to a charcoal fire after the fire has started; the flame can follow the stream of fluid to its source.
• Never use an outdoor grill indoors or in a garage, breezeway, carport, porch, or under a surface that can catch fire. Also, keep the grill at least 10 feet away from your house and other structures.

For more on grills, read our gas grill buying guide (with Ratings for subscribers).—Molly Glauberman