Optimizing Food & Beverage Facility Management with High-Performance Coatings
Correct Coatings Choices are a Central Consideration in Maximizing Performance and Safety in Food and Beverage Environments
by Feraas Alameh, Market Segment Manager - Food & Beverage, Sherwin-Williams Protective & Marine
In manufacturing and processing industries – especially those in the food and beverage sectors – facility managers are at the forefront of maintaining operational efficiency and regulatory compliance, as well as upholding the highest standards of safety and hygiene.
These facilities face unique challenges, including frequent exposure to moisture, harsh cleaning chemicals and high levels of traffic – including heavy equipment like forklifts and bins – all of which can compromise the integrity of the infrastructure. As such, facility managers are tasked not only with keeping systems functional but also with safeguarding surfaces from the wear and tear inherent in food production and processing environments.
One of the most effective tools in facility managers’ arsenal is the strategic use of advanced protective coatings. These high-performance coatings are specifically designed to withstand the rigorous demands of food and beverage facilities, enhancing durability, cleanliness and compliance with strict industry regulations.
By applying coatings to floors, walls and steel structures, facility managers can protect against contamination, improve hygiene and extend the lifespan of key assets (Figure 1). In addition, these coatings reduce the need for frequent repairs, helping facilities maintain smooth operations and lower maintenance costs.
Proper selection and application of coatings can also promote compliance with federal food safety standards, such as the Hazard Analysis and Critical Control Points (HACCP) system, and regulations by the U.S. Food and Drug Administration (FDA) and the U.S. Department of Agriculture (USDA). When applied correctly, various coatings contribute to a safer, more efficient working environment, minimizing risks of foodborne illnesses and contamination while promoting long-term success for food and beverage facilities.
Designing Durable Spaces for Food and Beverage Manufacturing
Manufacturing and production areas typically encompass large, open spaces that must be carefully designed and maintained.
The nature and utility of these environments demands robust flooring – in addition to wall and steel coating systems – that can withstand rigorous use while maintaining a high standard of safety and quality.
Flooring must be tailored to activities and traffic expected. For instance, areas exposed to foot traffic and rubber wheeled carts may require a moderate-duty, three-coat system (approximately 20-40 mils). However, areas subjected to heavy forklift traffic or other heavy machinery may need a thicker solution, such as a five-coat epoxy mortar system (approx. 250 mils) (Figure 2).
These considerations are also important when it comes to flooring systems for new or smooth concrete slabs, versus an existing, older eroded or pitted slab that may require resurfacing.
Flooring system topcoats must also exhibit chemical resistance properties – qualities that reduce maintenance requirements and extend longevity – in manufacturing areas due to various chemicals that could spill during operations or cleaning.
Slip resistance is a key consideration, too. Floors must have the appropriate texture to prevent slips and falls, which account for a significant number of workplace injuries. In 2021, according to the U.S. Bureau of Labor Statistics, 18% of all nonfatal work injuries resulting in days away from work were from slips, trips and falls. As part of a company-wide safety program, flooring with suitable surface traction can help facility managers meet operational goals.
The correct use of safety colors and floor marking provides visual cues to help prevent these accidents as well. Light-reflective floor finishes can enhance the overall brightness of an area. Amplified room illumination can increase visibility, contributing to a safer work environment and improved production outcomes.
Walls and ceilings require special attention in these environments as well. Brightly coated walls and ceilings create a well-lit environment, potentially reducing the need for additional lighting fixtures and improving energy efficiency. These coatings can also contribute to a cleaner and more professional appearance, which is important for areas frequently visited by customers or subject to audits.
Importantly, steel structures need protection against corrosion, which aids in the structural integrity and longevity of these assets. Simply painting steel surfaces is often insufficient for the harsh conditions often found in manufacturing and production facilities. Advanced protective coatings can sufficiently shield steel from the corrosive effects of moisture, chemicals, cleaning solutions and other factors.
Maintaining manufacturing and production areas is a complex task for food and beverage facility managers. A comprehensive strategy for proactive maintenance includes setting inspection schedules, recognizing signs of wear, implementing preventive measures and preparing ready-to-go repair strategies to quickly address any surface issues.
The number of choices can be daunting, but experienced coatings specialists can provide valuable support, allowing managers to focus on operations.
Wet and Dry Considerations for Food and Beverage Facilities
In the food and beverage industry, wet and dry processing areas pose unique challenges that require tailored facility management approaches. These environments demand easy-to-clean, moisture-resistant surfaces that minimize contamination risks while supporting the strict hygiene standards necessary for food safety.
Due to the distinct operational requirements of wet and dry processing, facility managers must implement specialized maintenance and protective measures to preserve the integrity of the production process and the safety of products, all while complying with new and existing health regulations.
In dry processing areas, maintaining controlled temperature and humidity levels is necessary for the proper handling and preservation of food products. Flooring systems in these areas must be impervious to moisture to prevent contamination. Resinous flooring systems are an ideal solution, offering seamless, non-porous surfaces that resist moisture infiltration. These floors maintain their integrity under fluctuating temperatures while providing the strength to withstand heavy mechanical loads and the high temperatures often encountered in food drying or baking processes.
Resinous floors in dry areas promote hygiene by minimizing the potential for bacteria or contaminants to settle into cracks or seams, thus supporting cleanliness and food safety compliance. Their durability reduces the frequency of repairs, allowing facilities to maintain continuous operations with minimal disruption.
Wet processing environments – such as those used for washing, cooking or beverage production – rely heavily on water for daily operations, which requires flooring systems to be highly resistant to constant moisture exposure and cleaning protocols (Figure 3).
Resinous flooring systems with textured finishes are particularly well-suited to wet environments, as they enhance slip resistance and reduce the risk of workplace accidents due to slips and falls. They must also be impervious to harsh cleaning agents, sanitizers and process-related chemicals – all of which are frequently used to maintain cleanliness and hygiene.
Walls in both wet and dry processing areas must also be protected by advanced coatings to handle the specific conditions of each environment. In dry processing areas, wall coatings need to be durable and moisture-resistant, protecting against impacts, abrasions and temperature fluctuations while preventing contamination buildup. These coatings allow for easy cleaning and help maintain a hygienic environment.
In wet processing areas, the demands on wall coatings are even more stringent. Constant moisture, harsh cleaning procedures and chemical exposure are daily challenges. Advanced protective coatings allow walls to be properly sanitized, preventing the growth of mold and mildew – key concerns in damp environments.
Steel surfaces are also vulnerable to damage from moisture, chemicals and temperature variations. In dry processing areas, protective coatings for steel must resist corrosion while withstanding fluctuating temperatures. These coatings create a protective barrier that preserves the structural integrity of steel components, reducing maintenance and preventing costly equipment failures.
In wet processing areas, where steel is regularly exposed to water and aggressive cleaning agents, the risk of corrosion and degradation is significantly higher. Advanced anti-corrosion coatings protect steel surfaces from rust and maintain functionality. By extending the lifespan of steel surfaces, these coatings contribute to the overall efficiency and reliability of food and beverage processing operations.
Figure 1. High-performance coatings applied strategically to floors, walls and steel structures in manufacturing and production areas can help mitigate wear and tear, reduce maintenance costs, extend facility asset lifecycles, support regulatory compliance and promote safer, more efficient working environments.
| Figure 2: Robust floor, wall and steel coating systems are required in manufacturing, production and storage areas to withstand rigorous use while maintaining a high standard of safety and quality. |
Figure 3. Wet processing areas require flooring systems that are highly resistant to constant moisture exposure and aggressive cleaning protocols. Such systems often feature textured finishes to enhance slip resistance and reduce the risk of slips and falls.
Fortifying Surface Protection in Food and Beverage Chemical Zones
Chemical zones within food and beverage processing facilities are some of the most challenging environments to manage. These areas are regularly exposed to harsh cleaning agents, sanitizers, solvents and acids used in routine sanitation and processing operations.
Flooring systems must be exceptionally resilient to withstand exposure to a range of cleaning chemicals, food byproducts and other aggressive substances. Resinous flooring systems – specifically designed to endure the unique conditions in food production – provide a durable, non-porous surface that resists splashes, spills and immersion in various food-grade acids, alkalis and sanitizers. These systems bond aggressively to the substrate, offering long-term protection against chemical attacks, mechanical damage and wear from heavy traffic.
Secondary containment areas – often found near chemical storage or sanitation stations – play an important role in capturing and containing chemical spills that could otherwise provide sources of contamination. These containment zones require highly durable lining systems that are resistant to caustic cleaning agents and chemicals, preventing leakage that could lead to safety hazards. The linings must be seamless and impermeable to ensure that no chemicals collect in hidden crevices.
Tanks used in food and beverage processing for storing cleaning agents, acids or food ingredients require specialized linings to protect both the tanks and their contents. Solvent- and acid-resistant linings help prevent the corrosion and degradation of storage vessels, which keep the chemicals used in cleaning or food-safe solvents from contaminating food products. These linings provide a long-lasting barrier that withstands frequent exposure to cleaning agents and food-grade chemicals, thus maintaining sanitary conditions.
Coatings experts and specialized installers can guide food and beverage facility managers in choosing protective coatings that are ideal for meeting the rigorous demands of chemical zones within their operations. Working with manufacturers who can deliver products and services quickly during unplanned shutdowns helps facilities avoid extended periods of inactivity.
Safety & Sterility in Food and Beverage R&D
Research and development (R&D) laboratories and cleanrooms in the food and beverage industry require the highest standards of cleanliness, sterility and environmental control. These spaces are used for food science research, product development and quality assurance testing, where contamination can jeopardize food safety, product consistency and regulatory compliance. The right protective coatings promote sterile spaces – safeguarding both the integrity of food research and the quality of the products being developed.
Resinous flooring systems are particularly well-suited for food and beverage R&D labs due to their seamless and non-porous nature, which eliminates any joints or cracks where bacteria, allergens or contaminants can accumulate. These flooring systems are easy to sanitize and can withstand the severe cleaning protocols required to maintain sterile environments needed for food safety testing and development (Figure 4). They can also handle heavy equipment and traffic in busy lab environments.
Electrostatic dissipative (ESD) flooring may also be necessary in certain food and beverage cleanrooms where sensitive electronic equipment is used for testing and quality control. It reduces the risk of static discharge, which can disrupt sensitive experiments or damage equipment.
Wall and ceiling coatings in food and beverage labs must be equally durable and resistant to frequent cleaning and exposure to chemicals used in sanitation. These smooth, non-porous coatings create a hygienic barrier that prevents the buildup of food particles, dust and bacteria. This is especially important in environments where food allergens are tested or new ingredients are developed, as any contamination can potentially compromise the results or lead to safety risks.
Figure 4. Adding an integral cove base where flooring interfaces with a vertical surface provides a seamless transition that helps direct water and cleaning agents toward floor drains, minimizing standing water and bacteria harborage points.
In addition to contamination control, fire safety is a priority in food R&D labs, where the use of heat and chemicals in testing or equipment may pose fire hazards. Fire-resistant coatings applied to structural elements help protect the facility and its personnel.
Traditional commercial paint and coatings are generally insufficient for these environments, due to their lack of durability and chemical resistance. Advanced industrial-grade coatings – specifically designed for high-demand environments like food and beverage laboratories – provide the longevity, resilience and sanitary qualities needed to maintain a compliant, sterile and safe environment.
Safeguarding Water Systems in Food and Beverage Facilities
Water plays a starring role in many food and beverage processes – including cleaning, cooling, food production and waste management. To protect the infrastructure that handles this valuable resource, using anticorrosive epoxy or polyurethane coatings and linings is part of an effective strategy to safeguard water processing systems.
Water treatment in the food and beverage sector must address several areas:
- Water Storage Tanks: High-performance coatings are necessary to prevent contamination and maintain the safety and quality of the potable water used in food manufacturing and also for cleaning equipment.
- Wastewater Storage: During food processing, large quantities of wastewater are generated, often containing organic matter, oils, fats, chemicals and other substances. Tanks used for wastewater storage require protective linings that can withstand aggressive chemicals and biological materials, preventing leaks and corrosion that could lead to environmental contamination and regulatory violations.
- Process Water Storage: Many food and beverage production processes require water that has been mixed with various chemicals. Tanks storing this process water need chemical-resistant linings to prevent corrosion and protect the integrity of the tanks, which aids efforts to avoid cross-contamination.
- High-Purity Water Systems: Certain food and beverage operations – particularly those involving beverages, dairy products or sensitive food ingredients – require high-purity water. Coatings for high-purity water systems must provide an impermeable barrier.
To address these needs, a range of chemical and erosion-resistant epoxy linings can be used in water treatment applications. Epoxy coatings protect the concrete and steel structures from corrosive substances. Polyurethane linings offer additional flexibility, abrasion resistance and low permeability – making them ideal for environments exposed to harsh chemicals and physical wear, such as wastewater tanks and secondary containment areas.
For food and beverage facilities, anticorrosive coatings and linings in water treatment infrastructure extend the lifespan of water processing systems. By preventing leaks, corrosion and structural failures, these coatings help maintain the safe, sanitary and efficient operation of water systems, which in turn safeguards food safety.
Protecting water treatment systems also supports sustainability efforts by reducing the need for frequent repairs and replacements – promoting responsible water management in food production.
Warehousing, Storage and Shipping Solutions for Food and Beverage Facilities
Warehousing, storage and shipping areas are hubs for receiving raw materials, storing ingredients and intermediate products, as well as preparing finished goods for distribution. These environments face constant traffic, mechanical impacts and exposure to a variety of chemicals.
Floors must withstand equipment such as forklifts, pallet jacks and automated guided vehicles. Resinous flooring systems provide exceptional resistance to abrasion, extending the life of concrete surfaces under heavy traffic (Figure 5). Resinous flooring systems are ideal – providing excellent resistance to abrasion and extending the life of concrete surfaces subjected to continuous movement.
In addition to withstanding physical impacts, the flooring must also be resistant to spills from vehicle fluids, cleaning agents and other commonly used chemicals. Chemical-resistant coatings protect surfaces from these hazards, resulting in a facility with safe and easy-to-clean floors. What’s more, their high compressive and tensile strengths allow them to support the substantial weight of equipment and stacked goods without cracking or deforming.
High-visibility coatings can be applied to designate pedestrian pathways, loading zones and hazard areas, helping lower the risk of accidents in busy shipping and storage zones. These markings are especially valuable in facilities where the quick and safe movement of goods is a key component of meeting production and distribution timelines.
Figure 5. Heavy-duty industrial grade flooring is needed in warehousing, storage and shipping areas to help protect concrete substrates from potential damage inflicted by heavy moving equipment, high traffic, abrasion and impact.
Walls and steel structures are also subject to damage from moving equipment, stored goods and frequent impacts. In food and beverage facilities, where hygiene and safety are top priorities, these surfaces should remain intact and easy to clean. Applying durable protective coatings to walls helps them resist impacts and abrasions while preventing the buildup of dust, dirt and contaminants. Similarly, steel structures – such as racking systems and support beams – benefit from corrosion-resistant coatings that protect against moisture, spills and temperature variations.
The food and beverage industry often requires specialized solutions for loading docks and shipping areas, where heavy traffic, wet conditions and potential spills can be a daily challenge. Slip-resistant flooring in these areas helps reduce the risk of injuries, particularly where water or other liquids may be present. ESD flooring is also beneficial in some processing and storage areas where workers handle packaging materials sensitive to static electricity.
Facade Fortification for Food and Beverage Facilities
The exterior of a facility plays a role in protecting the operations inside – serving as the first line of defense against environmental elements and helping safeguard the building’s structural integrity. Exposure to harsh weather conditions – such as rain, humidity, heat, snow, UV radiation and salt – can gradually wear down exterior surfaces, which may compromise both the hygiene and safety of the facility over time.
Impermeable coatings offer waterproofing benefits, protecting the building from water infiltration that could lead to freeze-thaw damage or internal moisture issues.
Precast concrete walls are commonly used in food and beverage processing plants due to their strength and durability. However, even concrete is vulnerable to damage from environmental factors. Protective coatings specifically designed for concrete help mitigate these risks by providing weather resistance and preventing cracking, spalling and other forms of deterioration caused by extreme temperatures, moisture and UV exposure. In food production, where hygiene is paramount, these coatings also contribute to a clean and professional exterior appearance.
Steel structures – such as exterior support beams, frameworks and cladding – are especially prone to corrosion, particularly in coastal or industrial environments. The constant exposure to moisture, chemicals and temperature fluctuations can accelerate corrosion, leading to structural issues and repairs. Anti-corrosion coatings shield steel from rust and degradation, helping maintain a facility’s infrastructure. UV-resistant coatings provide additional protection by preventing damage from prolonged sun exposure, which can weaken steel over time.
Energy consumption is a significant concern for food and beverage facilities, where temperature control is necessary for food safety and operational efficiency. High energy costs – driven by the need to cool large processing and storage areas – can significantly impact a facility’s bottom line. Older buildings or those with traditional roofing systems may absorb substantial amounts of heat, leading to increased cooling demands.
Facility managers can mitigate these energy costs by applying reflective, energy-efficient roofing coatings. These coatings reduce the roof surface temperature and minimize the amount of heat transferred into the building – making it easier to maintain temperatures. Lower cooling costs can translate into significant savings while also contributing to sustainability efforts by reducing the facility’s energy footprint.
Protective roof coatings also provide waterproofing benefits. Fluid-applied seamless coatings form a continuous barrier against precipitation, preventing leaks and condensation from air conditioning units. Maintaining a dry, controlled environment helps prevent drivers of contamination.
Partnership for Problem Prevention
Facility managers face a unique set of challenges. They must balance stringent regulatory compliance, maintain operational efficiency, create safe products and protect the well-being of their workforce – all while managing the maintenance demands of a facility that is constantly exposed to harsh conditions. The key to success lies not just in reacting to issues as they arise, but in proactively fortifying the facility with advanced protective coatings.
Partnering with experts in protective coatings allows facility managers to move beyond reactive maintenance and adopt a proactive approach that prioritizes the integrity and safety of their operations.
By embracing coating technologies tailored to the food and beverage sector, facility managers can create environments that are not only compliant and safe, but also resilient and prepared for future conditions. Whether safeguarding the high-traffic floors of processing areas, protecting steel and concrete structures in wet and dry zones, or optimizing energy efficiency through reflective roofing systems, the right coatings promote durability, cleanliness and long-term performance across every square foot of the facility.
ABOUT THE AUTHOR
Feraas Alameh is the Market Segment Manager – Food & Beverage for Sherwin-Williams Protective & Marine. He is a seasoned business professional with nearly 15 years of experience in the coatings industry, leading various market segments with an emphasis on front-end innovation and business and market strategy. He earned his bachelor’s degree from Cleveland State University and has completed continuing education programs at the Weatherhead School of Management at Case Western Reserve University and the Fisher College of Business at the Ohio State University. Contact: FAlameh@sherwin.com
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