Each year, the grain industry looks to Purdue University’s dust explosion report to better understand the risks associated with combustible dust in agricultural facilities. The latest report from Purdue University’s Dr. Kingsly Ambrose highlights both progress and ongoing concerns when it comes to grain dust explosions in the United States.
While the number of incidents declined slightly in 2025, the report underscores an important reality: dust explosions remain one of the most serious hazards in grain handling and feed manufacturing.
Key Findings from the 2025 Purdue Report
According to Dr. Kingsly Ambrose, Professor at Purdue University, there were 7 grain dust explosions reported in the United States in 2025.
This represents a slight decrease compared to 9 explosions in 2024 and is below the 10-year average of 8.5 incidents per year.
Despite the lower number of explosions, the severity of incidents increased. The 2025 explosions resulted in:
- 4 fatalities
- 10 injuries
These numbers serve as a sobering reminder that even a small number of incidents can have devastating consequences for workers, families, and operations.
Where the Explosions Occurred
The explosions occurred across a variety of agricultural processing facilities, including:
- 1 feed mill
- 2 grain elevators
- 1 seed processing plant
- 1 biofuel plant
- 1 flour milling plant
- 1 farm-operated grain elevator
These facility types highlight how combustible dust hazards extend across the entire grain supply chain, from farms to processing facilities.
Geographically, the incidents occurred in five states:
- Texas (2 incidents)
- Ohio (2 incidents)
- Minnesota
- North Dakota
- Nebraska
What Caused the Explosions?
Investigators were able to identify several probable ignition sources, including:
- Smoldering grain
- Equipment maintenance work
- An overheated bearing
- A dust fire
- Three incidents with unknown ignition sources
Fuel sources were also identified in most cases:
- 5 explosions involved grain dust
- 1 involved wood dust
- 1 fuel source was unknown
These findings reinforce what safety professionals have long understood: grain dust in suspension combined with oxygen, confinement, and heat or ignition sources can create explosive conditions very quickly.
Understanding the Combustible Dust Hazard
Grain dust becomes dangerous when it accumulates on surfaces or becomes suspended in the air. When the right conditions exist, (fuel, oxygen, dispersion, confinement, and an ignition source) the result can be a powerful explosion.
In grain facilities, potential ignition sources may include:
- Overheated bearings
- Welding or cutting work
- Equipment malfunctions
- Friction from misaligned belts
- Smoldering grain caused by spoilage
Because these hazards are often part of normal operations, strong prevention practices and employee awareness are essential.
Preventing Grain Dust Explosions
The Purdue report reinforces several important prevention strategies used across the grain and feed industries:
Housekeeping and Dust Control
Dust accumulation is the fuel for explosions. Routine cleaning and dust management programs significantly reduce risk.
Preventive Maintenance
Equipment failures, such as overheated bearings or belt misalignment, can generate the heat needed to ignite dust.
Hot Work Controls
Maintenance work such as welding or cutting must be carefully managed to avoid ignition hazards.
Employee Training and Hazard Recognition
Employees must understand how dust explosions occur and how to recognize hazardous conditions before they escalate.
Strengthening Prevention Through Training
Education plays a critical role in preventing combustible dust incidents. When employees understand the risks associated with grain dust, they are better equipped to recognize and control hazards in their daily work.
Safety Made Simple offers several training programs that address these critical risks, including:
- Housekeeping and Combustible Dust This course helps employees understand how combustible dust hazards develop in industrial and agricultural environments. Participants learn how dust accumulations create explosive conditions and how proper housekeeping, ventilation, and hazard awareness can prevent incidents.
- Grain Dust Explosions: Prevention This course focuses specifically on grain handling environments, teaching workers how explosions occur, how ignition sources develop, and what practical steps can reduce risk in elevators, feed mills, and processing facilities.
Together, these courses help organizations strengthen safety awareness while reinforcing operational practices that protect employees and facilities.
Learning from the Data
While the number of explosions decreased slightly in 2025, the increase in fatalities highlights why continued attention to combustible dust safety is essential. Every incident reported in the Purdue study represents an opportunity for the industry to learn and improve.
Dust explosions are preventable when facilities prioritize maintenance, housekeeping, and employee training.
Because at the end of every shift, the goal remains the same: Together, we send them home safely.