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?