Fabric Walls Effectively Handle Climate Control Issues

Some of the most common climate control challenges include floor plans with rooms and spaces that are difficult to heat or cool; improperly designed HVAC systems that don’t maintain proper temperatures or ensure sufficiently conditioned air; coolers and freezers that struggle to hold items at proper temperatures; pressurized space that loses pressure, resulting in temperature and humidity fluctuations; and increased temperature and humidity levels caused by washdowns with high-pressure sprayers. Problems with washdowns also include the potential for chemicals and contaminants to filter into adjacent production lines due to overspray.

Other food quality concerns involve unwanted air transference. One such problem occurs when the odor of raw ingredients or finished products infiltrates other ingredients or products. A similar problem occurs when food dust or contaminants find their way into mixing and production areas.

Because each problem is unique, using fabric walls to solve climate control issues involves creativity. To address the most common food quality and safety issues, the walls can be designed to:

• create separate zones for precise control of temperatures and humidity levels within specific areas of the plant;
• isolate temperature- and humidity-sensitive areas from other areas of the plant to boost the efficiencies of HVAC systems, while also ensuring proper climate control;
• subdivide cooler and freezer space for tighter control of items kept at separate temperatures (up to 40°F/22°C);
• partition cooler and freezer space to boost the efficiency of the refrigerant system—and avoid dangerous temperature fluctuations;
• gain control of temperature and humidity levels at the loading dock with separate, temperature-controlled staging areas;
• introduce barriers in processing and storage areas to prevent the loss of pressurized air;
• prevent unwanted air transference, thereby minimizing problems associated with food dust and contaminants;
• prevent overspray during washdowns and keep a lid on temperature and humidity levels resulting from washdown procedures;
• separate food ingredients and finished products from production process or other ingredients and products to prevent the transference or absorption of odors; and
• protect against the infiltration of pests with specially designed dock enclosures.

In addition to tackling these pressing issues, fabric walls also contribute to food quality and safety measures by virtue of their flexibility. One excellent example is the need to adjust to changes in food trends and fads. Fabric walls facilitate changeovers, ensuring that quality and safety goals remain uncompromised.

Cost Savings

The main advantages of fabric walls over traditional walls and panel systems are simplicity and flexibility, both of which contribute to cost savings. Simplicity and flexibility also equate to agility, which is essential when the goal is to quickly gain control over issues that threaten food quality and safety. The same holds true when industry changes drive the need to adapt processing and storage areas.

The reality is that a traditional wall built with wood and drywall is a permanent structure. And the planning and work that go into demolishing traditional walls and building new ones are often complicated and costly. Building permits are also typically required and can slow the process. In addition, many food companies affix fiberglass reinforced plastic (FRP) panels to the walls to aid in cleaning the wall surface. The installation process for these is cumbersome and time consuming.

Another method traditionally used to define space and obtain temperature separation involves the use of insulated metal panel (IMP) systems. As with traditional walls, demolition and construction of IMP systems often involves multiple steps. Like traditional walls, panel systems also require a concrete curb around the base of the wall to protect against damage caused by materials handling equipment. The curbing adds considerable cost to any project, whether it’s to cover work to demolish an existing curb or additional labor and materials to construct the new curb.