Seamless insulation surfaces with no joints for bacteria. Temperature control for HACCP compliance. Condensation prevention protects product quality.
Food processing and manufacturing facilities require insulation that serves dual purposes: thermal performance for temperature control and hygiene compliance for food safety. Traditional insulation systems with panel joints, mechanical fixings, and separate vapour barriers create surfaces with gaps, joints, and penetrations where bacteria, mould, and contaminants can harbour. Duratite installs Nexseal LE closed-cell spray foam that creates a completely seamless insulation surface with no joints, no fixings, and no gap where contamination can accumulate. When coated with a food-safe finish, the spray foam surface meets the hygiene requirements of HACCP, BRC, and food industry inspection standards. The closed-cell structure prevents condensation — a critical requirement in food processing where water droplets falling onto food products cause contamination, spoilage, and costly product recalls. Duratite manages the entire project from survey through to handover, working around your production schedules.
Spray foam creates a continuous surface with no joints, laps, or fixings where bacteria, mould, and contaminants can harbour. When coated with a food-safe finish, it provides a cleanable, inspectable surface that meets food industry hygiene standards including HACCP and BRC requirements.
Condensation dripping onto food products is a critical hygiene and quality issue. In food processing, it can cause product contamination, batch rejection, and costly recalls. Spray foam prevents condensation by insulating internal surfaces above dew point. No condensation means no contamination risk from dripping.
Food processing requires precise temperature control — chill rooms, production areas, loading bays each have specific temperature requirements. Spray foam provides consistent thermal performance across the entire building envelope, supporting HACCP temperature monitoring and compliance.
Food industry inspectors look for harbourage points — gaps, joints, cavities where pests and bacteria can accumulate. Panel joints, screw holes, and sealant lines are all harbourage points. Spray foam has none of these. The continuous surface provides auditors with confidence that contamination risks are minimised.
Different areas of food processing facilities have different temperature and hygiene requirements. Spray foam can be applied at different thicknesses in different zones, optimising the insulation for each area — from ambient production halls to chill rooms and loading bays.
We schedule work around your production shifts, spraying during shutdowns, weekends, or overnight. The foam cures rapidly and the area can be cleaned and returned to production within hours of application. Phased installation keeps most of your facility operational throughout.
Nexseal LE closed-cell spray foam at 0.027 W/mK is specified for food processing applications. The closed-cell structure provides both thermal insulation and vapour barrier, preventing the condensation that poses contamination risk. Declared performance to BS EN 14315-1 provides the independent test evidence. When coated with an approved food-safe finish (typically a polyurea or epoxy coating), the surface meets food industry hygiene standards. The seamless application eliminates the panel joints that are flagged in BRC and HACCP audits.
| Thickness | U-Value Achieved | Typical Application |
|---|---|---|
| 50mm | 0.49 W/m²K | Ambient production areas |
| 75mm | 0.34 W/m²K | Chill production and loading bays |
| 100mm | 0.25 W/m²K | Cold production areas |
| 150mm | 0.17 W/m²K | Chill stores and blast chill rooms |
We survey your facility, mapping production zones, temperature requirements, and hygiene standards. We identify condensation problem areas, existing insulation failures, and any structural issues. A detailed specification is prepared for each zone of the building.
We plan the installation around your production schedule, working in phases during shutdowns, weekends, or overnight shifts. Each phase is defined to allow the treated area to be cleaned and returned to production before the next phase begins.
Nexseal LE is spray-applied to walls and ceilings in the prepared zone. Once cured, a food-safe coating is applied over the foam surface to provide the cleanable, inspectable finish required by food industry standards. The combined system provides insulation, vapour barrier, and hygienic finish.
The treated area is thoroughly cleaned to food production standards before handover. We provide full documentation including thermal calculations, product data sheets, food-safe coating certification, and photographic records for your HACCP and BRC audit files.
Free survey, detailed specification, and no-obligation quotation. Duratite manages your project from start to finish.
Book Your Free Survey info@duratite.ieTell us about your building and we’ll recommend the right system — foam, waterproofing or both — surveyed, specified and quoted at no cost.