shining the light on:. often the largest problem with new technology is credibility, so we often...
TRANSCRIPT
Insulated Metal Panel RehabilitationShining the Light on:
Credibility
Often the largest problem with new technology is credibility, so we often offer mountains of references.
CH2M Hill
Black and Veatch
Parsons
PBS&J
Hazen and Sawyer
Orion Engineerin
g
HDR Engineers
O’brien & Gere
US Navy
US Army
US Coast Guard
Architect of the
Capitol
Naval Dive and Salvage
NSA Crane, Indiana
US National Guard
US Spec Warfare Training
Pilgrim’s Pride
Smithfield
Butterball
Tyson
Perdue
Campbell’s
RJ Reynolds
Dakota Provision
s
Mission Foods
How Crossway can help your organization.We have developed, tested, and approved for installation, a patent pending protective coatings system to rehabilitate, long-term, Insulated Metal Panel walls commonly found in Food and Beverage processing facilities.
What we have found: Throughout the Food and Beverage industry, a majority of interior walls are constructed from Insulated Metal Panels.
Panels typically have a thin, baked-on polyester finish. No warranty on the finish is available from any national panel manufacturer.
The finish understandably deteriorates over time.
As surfaces become rougher, they become increasingly difficult to clean.
Additional CleaningAs the finish deteriorates, cleaning efforts increase
Finish dulls and ablates, making
the surface rougher and more porous
More porous surfaces
collect more dirt and grime
Sanitation crews work longer and
harder scrubbing, with more chemicals
Harsher chemicals and
more abrasion in turn deteriorate
the surface faster
Resources of CleaningMinutes spent cleaning are proportional to many
costs
More labor
More chemica
ls
More energy (for hot water)
More water use
More water
treatment
Pain Point = Going to “paint”
Time
Chemicals
Abrasion
Facilities ask Paint Vendors to
provide solutions, which they do to the best of their
ability
Ineffective painting (which
results in peeling or
flaking paint)
Touch up paint or hang plastic over production areas
Food Safety risks increase to the
point that USDA / FDA inspectors
require corrections
Old Technology
Fixxus
Dents removed, crevices sealed,
edges gone
Waterslide Slick surfaces
Structural integrity restored
Zero opportunity for product
contamination
Up to 50% Savings in sanitation time,
chemicals, and water
“Hospital clean” working
environment
New Technology
Not an easy taskSignificant hurdles The solution would be
Minimal time availableConstant moistureLow temperaturesOther competing activities
(trades, sanitation, etc.)Existing coatings failingMetal walls move and
expandHarsh chemicalsImpacts from carts, etc.Production schedules
Surface tolerantMoisture tolerantApply and Cure at Low
temperaturesCure quickly to allow other
activities and return to production
Adhere to existing coatingsFlexible, Tough, Chemical
& Abrasion resistant Impact resistant
Substrate
Sister Panel, if required
Adhesion Promoter
Surface tolerant Moisture cured Quick re-coat Seals existing coatings
Intermediate
Seamless Flexible Tough Impossible to tear 10 second cure
Finish
Chemical resistant
Abrasion resistant UV resistant Slick Zero VOCs
Research shows:Plants spend significant resources to combat this issue;
Sanitation labor and chemicals• There is no controls on chemical usage or time spent scrubbing
surfaces. Crews clean until perceived stains are gone, allowing a BLACK-HOLE of labor and chemical costs.
Maintenance painting Once “Painting” begins, either in-house or contract crews paint
with ever increasing frequency. We have seen plants that repaint areas monthly.
Preventative measures Sealants at Joints Touch up painting Hanging plastic (which must be changed frequently)
Typical end of the cycle Sanitation, Maintenance, Preventative measures, and soft costs (management time to monitor repairs) become more expensive each year
The financial impact on operations becomes more evident, so correction efforts are deferred.
The failures are not addressed or perhaps repaired a la carte, and become more and more serious.
Regulatory Authorities become frustrated and mandate repairs
Delaying has increased the costs of repairs exponentially
A new approach … with new technology
Rehabilitate the panels with a proven, warranty-backed systems
End the cycle for an extended period
Costs are variable depending on size, location, age, etc. of the facility
ROI is going to be high and immediate for some, based on where the facility is at in the cycle.
Benefits Immediate and Direct impact:
Reduced Sanitation costs and Increased production availability
Reduced Maintenance labor and sundry costs (plastic, sealants, etc.)
Eliminate future “painting” contracts for the warranty period
Indirect impact: Reduce Management of related contracts or maintenance
efforts Reduce lost production time due to maintenance efforts Increase aesthetical values Increase lighting Decrease risk of contaminating product
What if… ?
If your facility could increase production availability 1 hour per day by eliminating time for sanitation, would the impact on your output over the next 5 years be positive, very positive, or extremely positive?
If your facility could decrease sanitation costs (labor, chemical use, and hot water usage by 1%, would the cumulative effect on your bottom line over the next 5 years be a positive, very positive, or extremely positive?
Isn’t it worth finding out?
A Factual ConclusionOver time, these issues will be corrected. The question becomes:
Whether they are repaired rationally, based on all available information and technology with all possible savings realized;
Or repaired traditionally, at greater overall cost to an organization.
How can we help you?