Large-Scale Food Manufacturing Plant Coating
Complete food manufacturing facility coating by certified American food safe coating contractor - multi-zone FDA/NSF/USDA compliance, diverse coating systems across 750,000 square feet.
Comprehensive American Food Safe Coating for Multi-Zone Manufacturing
A major food manufacturer operating a 750,000 sq ft multi-product facility required comprehensive coating system upgrades across 12 distinct processing zones. The facility produces shelf-stable foods, frozen entrees, sauces, and packaged goods across wet processing areas, dry ingredient handling, cooking zones, cold storage, and high-speed packaging lines.
As a certified American food safe coating contractor, we developed a comprehensive zone-specific coating strategy incorporating NSF/ANSI 51 certified epoxy systems for wet processing, antimicrobial urethane coatings for packaging areas, thermal shock-resistant systems for cooking zones, and moisture-tolerant coatings for cold storage. The complex 24-week phased installation coordinated with production schedules across all zones, maintaining 90%+ capacity throughout the project while upgrading critical food contact surfaces to achieve full FDA, NSF, and USDA compliance.
Multi-Zone Compliance Achieved
- ✓ FDA 21 CFR 175.300 Compliant
- ✓ NSF/ANSI 51 Certified Systems
- ✓ USDA-Approved Coatings
- ✓ 12 Distinct Processing Zones
- ✓ 90%+ Production Maintained
Challenges & Solutions
Key Challenges
- • Multi-zone facility with 12 distinct processing areas requiring different coating systems
- • FDA/NSF/USDA compliance across wet processing, dry storage, and packaging zones
- • Diverse substrate types: concrete, metal, block, existing coatings
- • Active 24/7 production with strict line changeover scheduling
Our Solutions
- ✓ Comprehensive American food safe coating strategy with zone-specific system selection
- ✓ NSF/ANSI 51 certified epoxy, urethane, and specialty coatings
- ✓ Advanced surface preparation protocols for substrate-specific adhesion
- ✓ 24-week phased installation maintaining 90%+ production capacity
Zone-Specific Coating Systems
Wet Processing Zones
- • Seamless epoxy systems
- • High-pressure washdown rated
- • Antimicrobial protection
Cold Storage Areas
- • Thermal shock resistant
- • Moisture-tolerant primers
- • Flexible formulations
Packaging Lines
- • Fast-cure urethane systems
- • High-traffic durability
- • Easy-clean surfaces
Project Results
"Moorhouse Coating's expertise as a certified American food safe coating contractor was essential for our complex multi-zone facility. Their zone-specific coating strategy addressed the unique requirements of each processing area - from high-temperature cooking zones to cold storage and wet processing. The comprehensive FDA/NSF/USDA compliance documentation streamlined our audits. Maintaining 90%+ production capacity during the 24-week project was critical for our business. The coordinated phasing across 12 zones was flawlessly executed."
Frequently Asked Questions
How do you manage coating different zones with varying requirements?
Our American food safe coating contractor team conducts comprehensive zone assessments identifying specific requirements: wet vs. dry processing, temperature extremes, chemical exposure, traffic levels, and regulatory standards (FDA, NSF, USDA). We develop zone-specific coating specifications and phased installation schedules that coordinate with production calendars, ensuring each zone receives appropriate systems while maintaining operational continuity.
Can you maintain production during large-scale facility coating projects?
Yes, our phased approach for large food manufacturing facilities typically maintains 85-95% production capacity. We section the facility into zones, coating 1-2 zones per week while others remain operational. Fast-cure systems allow weekend coating with Monday production resumption. For this 750,000 sq ft facility, we completed 12 zones over 24 weeks while maintaining 90%+ capacity - minimizing revenue impact while upgrading critical infrastructure.
What compliance documentation is provided for multi-zone food facilities?
We provide zone-specific compliance packages including: NSF/ANSI 51 certification letters for all food contact coatings, FDA 21 CFR 175.300 compliance statements, USDA approval documentation where applicable, Certificate of Conformance with batch/lot traceability by zone, application records with cure times and DFT measurements, and photographic documentation. This comprehensive approach ensures audit readiness for FDA, third-party food safety audits (SQF, BRC, FSSC 22000), and customer facility inspections.
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