Shamrock Foods Processing Facility
Complete food processing facility coating with USDA/FDA compliance, antimicrobial surfaces, and zero operational downtime across 600,000 square feet.
Project Overview
Shamrock Foods, one of the largest foodservice distributors in the Southwest, required a complete coating system upgrade for their Phoenix processing facility. The project demanded strict adherence to USDA and FDA regulations while maintaining continuous 24/7 operations.
Our team implemented NSF-certified food-safe coatings across production floors, processing areas, cold storage rooms, and loading docks. Special attention was given to creating antimicrobial surfaces that meet the highest food safety standards while providing long-term durability in demanding conditions.
Challenges & Solutions
Food processing facilities present unique coating challenges requiring specialized expertise and compliance knowledge.
Key Challenges
- USDA and FDA compliance requirements for food contact surfaces
- Active 24/7 food processing operations
- Temperature-controlled zones from -20°F to 90°F
- Strict sanitation protocols and cleanroom standards
- Multiple surface types including stainless steel, concrete, and block
Our Solutions
- NSF-certified food-safe epoxy coating systems
- Phased execution coordinating with production schedules
- Antimicrobial additives for bacteria-resistant surfaces
- Specialized primers for extreme temperature zones
- GMP-compliant application procedures
Food-Safe Coating Systems
Specialized coating systems designed for food processing environments with strict regulatory compliance.
NSF Certified Coatings
- • NSF/ANSI 51 food zone approved
- • USDA-compliant formulations
- • FDA CFR Title 21 compliant
- • Zero VOC emissions
Antimicrobial Protection
- • Built-in antimicrobial additives
- • 99.9% bacteria reduction
- • Mold and mildew resistant
- • Long-lasting protection
Extreme Durability
- • Chemical resistant surfaces
- • High-pressure washdown rated
- • Thermal shock resistant
- • 15+ year service life
Project Results
Successful completion with full regulatory compliance and measurable operational improvements.
Client Testimonial
"Moorhouse Coating understood the complexities of working in an active food processing environment. Their knowledge of USDA requirements and NSF-certified coatings was impressive. The project was completed on schedule with zero impact to our operations, and we passed our USDA inspection with flying colors."
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Learn More →Frequently Asked Questions
Common questions about food processing facility coating projects
What does USDA and FDA compliance mean for coating systems?
USDA and FDA compliance means coatings must meet strict standards for food contact and food zone areas. We use NSF/ANSI 51 certified products that are approved for both direct and indirect food contact. These coatings are formulated without harmful substances that could contaminate food products. All materials comply with FDA CFR Title 21 regulations and are documented for inspection purposes. We maintain complete traceability of all products used.
How do you work around 24/7 food processing operations?
We develop detailed phasing plans that coordinate with your production schedules and sanitation windows. Our teams work during planned maintenance periods, line changeovers, and scheduled shutdowns. We can section off areas using containment barriers while other zones remain operational. Fast-cure coating systems allow for rapid turnaround — many areas can return to production within 12-24 hours. Our project managers coordinate closely with your operations team to minimize any impact.
How effective are antimicrobial coatings in food processing facilities?
Antimicrobial coatings contain built-in additives that continuously inhibit bacterial growth on coated surfaces. Independent testing shows 99.9% reduction in common bacteria including E. coli, Salmonella, and Listeria. The protection is built into the coating itself, not just applied on the surface, so it remains effective throughout the life of the coating. This provides an additional layer of protection beyond your regular sanitation protocols and helps maintain food safety between cleaning cycles.
Can coatings withstand extreme temperature zones in food processing?
Yes, we use specialized coating systems formulated for extreme temperature ranges. For cold storage and freezer areas (-20°F to 35°F), we apply flexible coatings that resist cracking during thermal cycling. For hot processing areas (up to 200°F), we use heat-resistant epoxy systems. These coatings are also designed to handle thermal shock — rapid temperature changes that occur during washdowns. We select specific products based on each zone's temperature profile and operating conditions.
What documentation is provided for health department inspections?
We provide comprehensive documentation packages including NSF certification letters, product specification sheets, VOC compliance certificates, and material safety data sheets (SDS). All documentation clearly identifies the coating products used, their NSF ratings, and FDA compliance status. We include application records, cure times, and coating thickness measurements. This documentation is formatted specifically for health department audits and USDA inspections, making your compliance verification process straightforward.
Need Food-Safe Coating Solutions?
Our team specializes in USDA and FDA compliant coating systems for food processing facilities. Let's discuss your project requirements.