Beware of Loose Bristles on Worn Out Grill Brushes Causing Illnesses

Essential safety tips for grill brush use in North Carolina backyards

Multiple reports have surfaced across the United States of serious injuries after accidental ingestion of metal bristles from worn out grill cleaning brushes. According to a 2024 survey by the Hearth, Patio & Barbecue Association, 74 percent of North Carolina households own a barbecue grill and use it at least once a month. That translates to over two million active grillers in the state alone. United States Senator Charles E. Schumer (D-NY) has formally requested that the Consumer Product Safety Commission (CPSC) and the U.S. Food and Drug Administration (FDA) launch a full investigation into the safety of wire brushes used on backyard grills. As of today, no federal recall has been issued, but safety experts warn all consumers in North Carolina to take proactive steps to avoid this hidden hazard.

Understanding the hazard

Wire grill brushes rely on stiff metal bristles to scrape char and grease from grill grates. Over time, repetitive brushing weakens bristle bases and causes individual wires to detach without visible warning. Loose wires can embed themselves in food or fall onto uncovered grill surfaces. If swallowed, a bristle can lacerate the throat, perforate the stomach or intestines, and cause internal bleeding. Many cases require emergency surgery to remove embedded metal fragments and repair organ damage. Even minor incidents can lead to dangerous infections or lengthy hospital stays.

Incidents reported nationwide and in North Carolina

In the past year, at least 25 confirmed cases of bristle ingestion have been reported to the CPSC from 15 states, including clusters of hospitalizations in South Carolina and eastern North Carolina. One tragic incident in Durham involved a mother who experienced sharp abdominal pain hours after a weekend cookout. Doctors at Duke University Hospital discovered and removed a bristle that had perforated her small intestine. In Charlotte, a father of three spent two days in Atrium Health Carolinas Medical Center after an emergency endoscopy revealed embedded metal fragments in his stomach lining. Local emergency departments report seeing these injuries with increasing frequency, underscoring the need for immediate preventive measures.

Government and industry response

Senator Schumer’s request, submitted on July 28, 2025, asks the CPSC to review hospital data trends and determine whether a mandatory recall of certain wire brushes is needed. The FDA has been asked to update labeling standards and require clear warnings about potential bristle hazards. As of early August 2025, the CPSC spokesperson confirmed that an initial review is under way and that the agency expects to issue a safety bulletin by late fall.

At the state level, North Carolina Representative Erica Smith introduced House Bill 456 on March 12, 2025, which would require prominent warning labels on all grill cleaning brushes sold in the state and mandate that retailers offer metal-free alternatives. The bill is currently under consideration by the General Assembly and may reach a committee vote this fall.

On the industry side, major grill brush manufacturers – including Weber, Char-Broil and Grill-Pro – have issued voluntary guidelines advising consumers to replace wire brushes after six months of moderate use or three months of heavy use. They are also testing new brush designs with reinforced bristle bases and exploring nonmetallic bristle options. The American National Standards Institute (ANSI) and ASTM International are evaluating voluntary safety standards for grill cleaning tools, with draft guidelines expected in early 2026.

Choosing and maintaining safe grill brushes

Selecting the right tool and inspecting it regularly can greatly reduce the risk of loose bristles. Follow these recommendations:

• Pick high quality materials such as stainless steel bristles with solid rivet attachments or consider brass or nylon bristle brushes designed to resist wear.
• Inspect before each use by running a gloved finger along the bristles to check for any loose wires or irregular gaps.
• Replace brushes on a schedule Replace wire brushes at minimum every six months if used weekly, or every three months if used daily. Mark your purchase date on the handle for easy tracking.
• Store brushes properly keep them hanging in a dry place away from rain and humidity to prevent rust that can accelerate bristle failure.
• Dispose of worn brushes safely wrap old brushes in newspaper or seal them in a plastic bag before discarding to contain any loose wires.

Alternative cleaning methods

Wire brushes are not the only way to keep grates clean. Consider these effective, bristle free options:

• Grill stones pumice based scrubbers that remove residue without metal wires.
• Balloon scrubbers reusable silicone scrubbers shaped like a ball that scrub evenly when rolled over grates.
• Nylon bristle brushes heat resistant up to 400°F and far less likely to shed wires.
• Chemical grill cleaners non caustic sprays and gels that loosen stuck on food for easy wiping, follow manufacturer safety instructions.
• Half onion method skewer and rub a halved onion over hot grates to naturally break down grease.
• Steam cleaning preheat grill, place a pan of water inside, close lid for 10 minutes to steam off residue, then wipe with a heat resistant cloth or nylon brush.

Reporting injuries and filing complaints

If you suspect ingestion of a grill brush bristle or experience related symptoms, seek medical attention immediately. After treatment, file complaints with federal and state agencies to help track this hazard and push for safety actions. North Carolina residents can follow these steps:

• Call the FDA Consumer Complaint Coordinator for North Carolina at the Raleigh District Office: 919-875-4820.
• Submit an online complaint via the FDA’s Report a Problem with Food or Cosmetic Products portal: FDA Consumer Complaint.
• Contact the NC Department of Agriculture & Consumer Services at 1-800-206-9333 to report safety concerns or misleading product information.
• Notify the NC Attorney General’s Consumer Protection Division Phone: 1-877-566-7226 (1-877-5-NO-SCAM) or file online: ncdoj.gov/consumer-complaints.
• Report to your local county health department to support tracking of foodborne and foreign object hazards.
• Alert the NC Poison Control Center Hotline: 1-800-222-1222 for emergency guidance on ingestion incidents.

Resources for North Carolina consumers

Stay informed and connected with these local resources on grill safety and product recalls:

• NC State University Extension Food Safety Program offers articles, videos and workshops on safe grill cleaning: food-safety.ces.ncsu.edu.
• NC Department of Health and Human Services Food and Lodging Section publishes guidelines on safe cooking and cleanliness: epi.dph.ncdhhs.gov.
• Local fire departments often host summer safety fairs with live grilling demonstrations and safety checks.
• North Carolina Barbecue Society regional chapters share best practices at monthly meetups across the state.
• Consumer Reports regularly tests grill brushes and cleaning tools for durability and safety – check their latest reviews online.

Key takeaways and best practices

As grilling season heats up, safety must come first. Remember to:

• Inspect and replace grill brushes on a strict schedule to prevent loose bristles from contaminating food.
• Consider bristle free alternatives like nylon brushes, grill stones or chemical cleaners.
• Choose high quality products and follow manufacturer instructions for safe use.
• Report any bristle injuries or loose bristle discoveries to federal and state agencies promptly.
• Monitor proposed legislation and safety bulletins from the CPSC and NC General Assembly.

By adopting these precautions and leveraging North Carolina specific resources, backyard chefs can grill confidently and reduce the risk of bristle related injuries. NCCC will continue to track developments and report new findings as they emerge.