Resinous Flooring Supports Hershey’s First New U.S. Facility in a Generation

In Hershey, Pennsylvania, a major investment in chocolate manufacturing recently came to fruition. Next to the landmark H.B. Reese Candy plant, The Hershey Company has constructed a new 250,000-square-foot facility – its first ground-up U.S. production site in more than 30 years.

This state-of-the-art plant is designed to expand Hershey’s production capabilities and give the company the flexibility needed to meet rising demand and shifting consumer trends. It also reinforces Hershey’s long-standing commitment to its hometown – a community that remains central to its growth and legacy.

From the beginning, flooring emerged as a key part of the facility’s infrastructure strategy. Chocolate manufacturing brings intense daily demands, including heavy forklift traffic, repeated high-temperature washdowns and routine exposure to strong cleaning agents. The floor systems selected needed to deliver long-term durability, safety and cleanability – standing up to constant use without compromise.

Designing for Demands

By late 2022, after detailed collaboration between general contractor Whiting Turner, the design team and key project stakeholders, flooring specifications were finalized for the new plant. Production zones would receive a seamless, high-performance resinous system designed to handle the facility’s heaviest traffic and most punishing conditions. In employee areas such as corridors and locker rooms, a decorative quartz system was chosen to provide both visual appeal and long-term durability.

The installation was led by Pennsylvania-based Durex Coverings – a flooring contractor with deep experience in food and beverage environments. Their approach combined two proven systems to deliver a facility-wide solution that balanced form and function across all zones.

“It’s the unrelenting nature of food manufacturing that makes flooring selection – throughout a facility – so critical,” said Bryan DeCarlo, Division Vice President at Durex. “Even small cracks or worn patches can become major sanitation or safety hazards.”

From the start, Durex worked closely with Sherwin-Williams High Performance Flooring to develop specifications tailored to the unique demands of chocolate production. The planning process accounted for thermal and chemical exposure, frequent washdowns and slip resistance – along with slope-to-drain design to support effective cleaning protocols.

“When you combine large volumes of ingredients, frequent spills and daily cleaning, you need a floor that can withstand punishment without losing integrity,” said DeCarlo.

From Prep to Topcoat

To protect the facility’s highest-traffic production zones (Figure 1), the project team specified Poly-Crete MD, a robust urethane cement system applied at 1/4-inch thickness. Designed for aggressive food and beverage environments, SL45 stands up to repeated forklift traffic, heavy loads and daily thermal cycling. It resists the cracking and delamination that can occur in standard epoxy floors when exposed to steam or hot water – due to its ability to expand and contract with the concrete substrate.

Installation began with detailed surface preparation, including shot blasting and grinding to achieve a concrete surface profile (CSP) of 3 to 4. After priming and thoroughly cleaning the substrate, crews applied the self-leveling SL45, using gauge rakes and trowels (Figure 2) to create uniform coverage and a lightly textured finish for slip resistance.

Once cured, installers added a grout coat of Resuflor™ 3569, building an additional 20 to 30 mils of thickness to fully seal the urethane base. To further improve traction, installers broadcast an anti-skid additive while the epoxy was still tacky – embedding the texture into the surface before final cure.

The system was completed with Accelera™ 4850, a durable polyurethane topcoat formulated for fast return-to-service and resistance to chemicals, abrasion and UV exposure. Applied at 5 to 7 mils, the Accelera finish created a seamless, non-porous barrier with excellent cleanability – essential for daily sanitation protocols. Together, the flooring system (Figure 3) reached a finished thickness of approximately 3/8 inch, delivering durable, hygienic performance in demanding food-production conditions.

Managing the Elements

Maintaining the right installation conditions was a persistent balancing act – especially in the face of Pennsylvania’s unpredictable seasonal weather. With high-performance resinous flooring systems, environmental control is a top consideration. Application temperatures, substrate conditions and cure rates all influence final film integrity and performance.

During the summer months, surface temperatures climbed well above 90°F, speeding up working times and forcing crews to adjust on the fly.

“In such conditions, you’re effectively racing the curing process,” said DeCarlo. “Every minute counts when you’re placing these coatings in 90-degree heat – especially if the surface is even hotter.”

To keep the project on track, crews adapted mix times, batch sizes and application speed based on real-time environmental readings. Installers used temporary heating systems during colder months to maintain substrate temperature and promote a complete cure – for both coating adhesion and lasting performance.

Careful sequencing, tight coordination and responsive jobsite adjustments helped avoid rework and kept installation phases moving despite the changing conditions.

Design Meets Durability

While the production zones required maximum toughness, the facility’s locker rooms and corridors posed a different challenge: combining appearance with performance. These areas needed to be safe, seamless and easy to sanitize – while also reflecting the facility’s modern design. The team selected Resuflor™ Deco Quartz, a decorative quartz flooring system that merges long-term durability with visual sophistication.

Resuflor Deco Quartz is built to handle high foot traffic, frequent cleaning cycles and occasional chemical exposure. The system uses multi-colored quartz aggregate broadcast into epoxy resin layers, creating a dense, decorative surface that resists abrasion, impact and moisture while delivering a vibrant speckled finish.

Installation began with Resuprime® 3579, a moisture-tolerant epoxy primer that penetrates and seals the substrate while promoting adhesion for subsequent layers. Crews then applied two body coats of Resuflor™ 3561, a high-build epoxy binder that encapsulates the quartz aggregate broadcast after each coat, ensuring even distribution and texture.

To finish the system, applicators used a clear topcoat of Resutile™ Aqua 4410/4411 or Accelera 4850, depending on cure time and environmental conditions. Resutile is a water-based catalyzed epoxy known for breathability and chemical resistance – well-suited for floors prone to moisture vapor transmission. Accelera 4850, a fast-curing aliphatic polyurethane, offers UV stability, chemical durability and excellent gloss retention for high-visibility spaces.

Installers also integrated an integral cove base (Figure 4) that curled the floor system upward several inches along the wall. This continuous surface design improves sanitation by eliminating seams and reducing buildup points in corners – an advantage in hygiene-sensitive areas.

To align design across employee spaces, the project team used the Sherwin-Williams High Performance Flooring Visualizer to select a consistent palette. They chose “Suit & Tie – Resuflor Topcoat Metallic,” a sleek blend of grays that adds visual interest while maintaining a polished, professional look.

Orchestrating Installation

Coordinating flooring installation across nearly 4,000 square feet of active construction demanded constant communication and flexibility. Multiple trades moved through the facility installing processing equipment and completing envelope work – which meant flooring crews had to mobilize and stage work around active trades, avoiding surface contamination or delays.

While the Durex crew typically operated with a team of six, that number doubled during peak phases to manage multiple zones simultaneously. Still, crews often adjusted their work plans daily, based on access, cleanliness and progress from other trades.

“With so many moving pieces, sequencing was everything,” said DeCarlo. “We had to stay nimble, coordinate with other contractors and be ready to shift plans when conditions changed.”

Sherwin-Williams High Performance Flooring representatives played an active role throughout – supporting field troubleshooting, advising on application techniques and confirming that surface prep and environmental conditions met system requirements. Their input proved valuable when substrate issues arose, such as high moisture readings or an uneven concrete profile.

“This entire project showcases what’s possible when you combine the right products with skilled craftsmanship and a client-focused approach,” said DeCarlo. “We’ve seen firsthand that staying in sync with other trades can make or break a job of this magnitude.”

With tight coordination and field-driven decisions, the team avoided rework and maintained momentum.

“We have a shared commitment,” DeCarlo said. “Our priority is a floor that holds up for decades – one that performs long after the build is complete.”

Systemwide Success

Historically, The Hershey Company has used a mix of flooring systems across its production facilities. But with the proven performance of the urethane cement and decorative quartz solutions used in this project, the team now sees an opportunity to standardize. Moving to a unified resinous flooring platform could simplify maintenance, improve staff training and deliver consistent quality across multiple sites.

“Our goal is to create a Sherwin-Williams standard for all of Hershey’s projects, which will ensure consistency and quality,” said DeCarlo.

Both Poly-Crete SL45 and Resuflor Deco Quartz are engineered for durability in demanding environments – making them well suited for company-wide implementation. These systems are built to withstand thermal cycling, frequent cleaning, rolling loads and chemical exposure – while maintaining seamless, sanitary surfaces.

By consolidating on a trusted system, Hershey can reduce product variability, streamline procurement and reduce onsite variability and lower total lifecycle costs. It also allows internal maintenance teams to follow a uniform protocol for care and inspection – improving operational efficiency.

As the project neared completion, Hershey’s management team conducted multiple site visits to review installation progress. Even under the wear and tear of active construction traffic, the floors showed excellent resilience – reinforcing confidence that the systems will perform under full-scale production conditions.

By highlighting the advantages of a unified flooring approach – from cleanability to cost control – the project team helped lay the foundation for systemwide adoption in future Hershey facilities.

Delivering on Every Detail

The flooring installation reached a key milestone in late 2024, as the final system layers were completed and cured across production and employee areas.

“This was an exercise in teamwork, precision and accountability at every level,” said DeCarlo. “From controlling ambient temperatures during application to coordinating with other trades, we’ve proven that painstaking planning pays off. The end result is a facility ready to support Hershey’s production and growth.”

As the first production lines ramped up, the floors were already bearing the weight of production – supporting ingredient transport, protecting workers and streamlining sanitation.

The success of this installation has also laid the groundwork for future phases. Additional decorative flooring – including metallic finishes for office areas – is already planned, with Hershey continuing its partnership with Sherwin-Williams and Durex for continuity and quality assurance.

“Our work here proves that advanced resinous coatings aren’t just protective layers – they’re strategic assets,” DeCarlo said. “When combined with the right application methods and a shared commitment to quality, these floors can help pave the way for a company’s future.”

Durable by design and seamless by specification, the flooring system reflects the same values that have kept Hershey iconic – reliable quality, built to last.

ABOUT THE AUTHORS

Sharon Lee is Project Development Manager – Construction Solutions for Food & Beverage & Pharmaceutical projects for Sherwin-Williams High Performance Flooring. Contact: Sharon.L.Lee@sherwin.com 

Michael Starner is Market Segment Manager for Sherwin-Williams High Performance Flooring. He has been in the coatings industry with Sherwin-Williams for 28 years. He has held various sales, management and marketing roles and has spent the last 10 years working with the design community to select and specify the proper high-performance floor and wall systems for their clients. Mike is NACE Level 3 Certified. Contact: Michael.Starner@sherwin.com