As the world’s leading producer of mozzarella cheese, LePrino Foods made a strategic choice by opting for hot-dip galvanized steel in the construction of its new Waverly plant, considering both its aesthetically pleasing appearance and functional benefits. The project faced multiple challenges, particularly in meeting the stringent requirements set by the Food & Drug Administration (FDA). The interior steel of the plant had to be food-safe, undergo daily washdowns, and strictly contain the bacteria used in the cheese-making process.
The hot-dip galvanized steel emerged as the most effective solution, meeting FDA standards for a food-processing environment. Its corrosion-resistant finish could withstand daily washdowns, and the zinc used in the galvanizing process naturally combated bacteria, addressing concerns about bacterial migration. Additionally, the cost-effectiveness of hot-dip galvanizing compared to paint was a significant advantage. The design also incorporated specific features like drain and vent designs.
To comply with FDA regulations and eliminate bacteria-friendly cavities, the tubular holes needed for venting and draining the interior support columns were sealed and repaired after hot-dip galvanizing. The project’s designers demonstrated innovative solutions to overcome obstacles, such as the challenge of daily plant washdowns. Hubbell Galvanizing and the designers accomplished this by essentially turning the building “inside-out,” constructing the galvanized frame on the outside and hanging its skin inside. The result was a highly-visible hot-dip galvanized steel food processing plant, where effective design communication played a pivotal role in ensuring its success.
