The Essential Role of Cleanroom Coatings in Food & Beverage Production

Clean Environment Assurance

In food processing cleanrooms, controlling contamination is a central focus.

Cleanrooms play a critical role in preventing the growth of bacteria, molds and other potential pathogens. Microbial contamination can lead to foodborne illnesses, which pose significant health risks to consumers and can result in costly recalls and damage to a company’s reputation.

The sterile environment of a cleanroom minimizes the risk of contamination, help to ensure the safety, shelf life and integrity of food products. These facilities help mitigate risks by providing a controlled environment where air quality, temperature, humidity and particulate levels are tightly regulated. This is essential in processes such as the packaging, filling and handling of ready-to-eat foods, dairy products, beverages and other perishable items.

Determining the appropriate type of cleanroom to meet these guidelines hinges on a range of factors – taking into account industry standards, regulations, cleaning feasibility, particulate concentration and others.

The International Organization for Standardization (ISO) has established specific cleanroom classifications to suit various cleanliness needs under the ISO 14644-1 standard. These nine classification levels are based on the maximum number and size of particulates allowed per cubic meter, with a Class 1 designation being the cleanest. Food and beverage cleanrooms typically adhere to ISO Class 7 or 8 standards, balancing the need for cleanliness with practical considerations for food production environments.

Surfaces within these cleanrooms are often treated with antimicrobial coatings that prevent the growth and spread of harmful microorganisms. Continuous monitoring of microbial load and airborne particulates ensures that the cleanroom environment remains within acceptable limits.

Adhering to ISO standards helps promote compliance with food safety regulations – essential for successful food and beverage operations. In the United States, the Food Safety Modernization Act (FSMA) – enacted and enforced by the U.S. Food and Drug Administration (FDA) – focuses on preventing contamination rather than responding to it. Properly constructed and operated cleanrooms –ones that implement preventive controls, including maintaining sanitary conditions, proper hygiene practices and environmental monitoring – are instrumental in not running afoul of the FSMA.

Many operations adopt an approach centered on Hazard Analysis and Critical Control Points (HACCP), a systematic approach to food safety that identifies potential hazards and implements critical control points to mitigate risks.

In addition, the ISO 22000 standard specifies the requirements for a food safety management system up to the point of final consumption. Cleanrooms help organizations meet these ISO requirements by maintaining stringent control over environmental conditions and implementing robust cleaning and sanitation protocols.

By adhering to these guidelines, laws and standards, facilities can ensure their cleanrooms are effective and compliant. This proactive approach not only safeguards public health but also enhances a facility’s operational efficiency and credibility.

Cleanroom Coating Systems

In food and beverage cleanrooms, the choice of coatings is critical to maintaining a hygienic environment.

Antimicrobial coatings contain agents that disrupt the cellular functions of microorganisms, effectively preventing their growth on walls, floors and other surfaces. This is particularly important in areas where food contact is possible, as it helps maintain a sanitary environment.

Coatings certified for food contact surfaces meet stringent safety standards and are free from harmful substances that could contaminate food. Regulatory agencies, including the FDA, provide guidelines and approvals for such coatings, ensuring they are safe for use in these environments.

These coatings are also formulated to withstand rigorous and frequent cleaning protocols – often with strong disinfectants – and maintain their integrity and effectiveness over time. Cleaning processes also often involve high-pressure washdowns for thorough sanitation, demanding that coatings resist degrading or peeling.

Coatings must also prevent cross-contamination from allergens, which is a significant concern in food processing. This involves using non-porous, easy-to-clean coatings that do not harbor residues. In addition to allergens, coatings should act as barriers against pathogens. Smooth, seamless coatings that eliminate crevices where bacteria and other microorganisms can hide are ideal.

By selecting coatings that meet these specific requirements, food and beverage facilities can ensure their cleanrooms remain compliant with industry standards, safe for processing and effective in maintaining a contaminant-free environment.

Food-Safe Flooring

Flooring systems play a pivotal role in maintaining a sanitary environment – and ensuring the safety of both products and personnel – while enduring the harsh conditions typical in product processing areas.

Subjected to frequent cleaning with strong disinfectants and detergents, flooring must be resistant to chemical exposure to prevent degradation, ensuring a long-lasting hygienic surface.

Smooth, seamless resinous flooring systems – both epoxies and urethanes, and combinations of the two – must be impervious to moisture to prevent water ingress. With no crevices or joints where dirt and microbes can accumulate, these systems facilitate easy and thorough cleanings without suffering long-structural damage.

A key component often utilized in food and beverage cleanroom flooring systems is a cove base (Figure 1), which creates a seamless transition between the floor and wall surfaces. This feature not only enhances aesthetic appeal but facilitates an ease of cleaning by ensuring that no gaps or crevices are present at wall-to-floor transitions.

In wet and potentially slippery environments, flooring must offer slip resistance to protect personnel from accidents. Textured or specially coated surfaces can provide the necessary traction to prevent slips and falls. Some cleanrooms require a moisture vapor barrier (MVB) as a line of defense against moisture vapor transmission that can be detrimental to the safety and integrity of a cleanroom environment.

Scratch-resistance is also a key quality that promotes longevity, reducing the potential for surface damage that could compromise cleanliness standards. This resilience contributes to the overall durability of the cleanroom environment. By cutting down on repairs and replacements, these systems also help save costs and promote sustainability efforts.

Figure 3. ESD flooring mitigates shock risks by dissipating static charges through the flooring via a direct, uninterrupted connection between copper tape embedded within the flooring and an existing electrical outlet (top) or another grounding point such as a steel post (bottom).

Hygienic Wall Solutions

In food and beverage cleanrooms, walls must withstand various forms of wear and tear – including exposure to moisture, impacts, abrasion and chemicals.

High-performance wall systems are crucial for protecting against long-term damage in these environments. They provide essential functions such as imperviousness, ease of cleaning, and resistance to moisture and microbial growth (Figure 4).

Fiber-reinforced epoxy resin systems create a protective barrier against contaminants. Specifically designed for application to walls and ceilings, these systems offer exceptional durability, ease of application and excellent performance – including resistance to UV light, which is not typical of traditional epoxy systems.

Smooth wall coating systems with no pinholes or gaps are relatively easy to sanitize and maintain, with options for power washing and resistance to vaporized hydrogen peroxide (VHP). Seamless surfaces eliminate crevices where grime can accumulate, inhibiting the collection of dust, dirt, fluids and microbes.

These systems should consist of multiple layers, including epoxy and urethane topcoats, engineered to resist the cleaning regimens required. They help control humidity, minimize outgassing and prevent particle infiltration by being impermeable. Fiberglass-reinforced coatings can be included for added impact resistance.

Cleanroom ceilings should also offer the resilience to withstand daily washdowns. These systems may include two-component, water-based urethanes and a single-component, low-VOC, UV-resistant acrylic clear coat, providing protection against corrosion from sanitizing agents.

A breathable, water-based epoxy intermediate coat on ceilings can enhance durability and longevity. These ceiling coatings proactively address maintenance needs, helping to minimize downtime and ensure continuous compliance with food safety standards.

Fireproofing Considerations for Cleanrooms

Fire safety is a critical aspect of maintaining safe and compliant food and beverage facilities. Given the potential presence of flammable ingredients, high-heat equipment and various other fire hazards, implementing effective fireproofing measures is of utmost importance. These measures must not only protect against fire risks but also ensure they do not compromise food safety.

Many food processing operations involve the use of flammable ingredients, such as oils, alcohols and certain chemicals used in cleaning or preservation. Additionally, ovens, fryers and stoves can pose significant fire risks if not properly managed.

When constructing or renovating food and beverage facilities, using fire-resistant building materials – such as fire-rated drywall, ceilings and flooring – can provide an additional layer of protection. Utilizing fire-resistant insulation and barriers around high-risk areas can prevent the spread of fire to other parts of a facility.

Steps taken to fireproof cleanrooms mainly focus on protecting the steel structure. The selection and application of fireproofing materials and systems should not introduce contaminants that could jeopardize sensitive food- and beverage-related processes.

These materials must be non-toxic, especially in environments where they might come into contact with food or food preparation surfaces. Materials should be chosen that do not emit harmful fumes or leave residues that could contaminate food products.

Traditional cementitious spray-applied fire-resistive materials (SFRMs) – while commonly used in other environments – can pose challenges in food and beverage facilities due to the risk of creating dust. Generally, epoxy coatings are cleaner and more effective in these settings. Unlike SFRMs, epoxy coatings do not outgas or release airborne particulates, thus minimizing contamination risks.

Specialized passive fire protection (PFP) solutions, including intumescent fire-resistive materials (IFRMs), are often preferred choices for their cleanliness and effectiveness (Figure 5). In addition, the coatings can be applied offsite (Figure 6), enhancing the quality of applications, minimizing overlap with other trades at the construction site and enabling faster project completions.

By integrating effective fireproofing strategies and materials that prioritize both fire safety and food safety, facility owners can significantly reduce the risk of fire-related incidents. This dual focus ensures the protection of personnel, the facility and the food products themselves, maintaining a safe and compliant operation.

Figure 4. In sterile environments such as food and beverage cleanrooms, wall systems must be highly cleanable to minimize contamination risks and durable enough to endure rigorous cleaning protocols, impacts and abrasions.

Figure 5. Intumescent fire–resistive materials (IFRMs) meet requirements for outgassing, low dusting and environmental tolerances in cleanroom environments.

Figure 6. Off-site application of epoxy intumescent fireproofing before constructing a food and beverage cleanroom environment eliminates potential numerous on-site challenges.