Client Background
Our client operates a food processing facility that utilizes large industrial fryers as part of its production process. These fryers, similar in scale to corn dog frying operations, operate at sustained oil temperatures of approximately 350°F and require frequent sanitation through aggressive washdown procedures.
The fryers were installed over an existing epoxy flooring system that had been in service for several years. Due to the thermal demands of the process and the intensity of the cleaning regimen, the floor required constant maintenance and periodic repairs.
Seeking a long-term solution, the facility engaged National Acid Proofing to assess the existing conditions and recommend a flooring system capable of withstanding both the operating temperatures and sanitation requirements of the process area.
The Challenge
The existing epoxy floor beneath the fryers was not designed to handle prolonged exposure to elevated temperatures or repeated thermal cycling. Over time, the heat from the fryer oil caused degradation of the epoxy system, leading to cracking, loss of adhesion, and ongoing maintenance issues.
In addition to thermal stress, the area was subject to a combination of caustic washdown chemicals and high-pressure hot water cleaning. These conditions further accelerated deterioration of the epoxy floor, resulting in frequent downtime and increasing maintenance costs.
The facility needed a flooring system that could perform reliably under high heat, aggressive cleaning, and continuous production demands.
NAP’s Assessment & Recommendation
National Acid Proofing performed an on-site evaluation of the fryer area, including a review of operating temperatures, cleaning procedures, tank layout, and substrate conditions. Based on this assessment, NAP determined that replacing the epoxy system with another coating-based solution would not provide long-term performance.
NAP recommended removal of the existing epoxy floor and installation of an industrial brick flooring system engineered specifically for high-temperature food processing environments. The recommended system included 2-¼” thick red shale brick to accommodate thermal exposure from the fryers, along with a carbon filled furan resin mortar selected for its resistance to caustic cleaners, high temperatures and high-pressure hot water washdown.
This system was designed to provide a durable, low-maintenance solution capable of supporting continuous operation.
The Solution
National Acid Proofing removed the existing epoxy flooring system and properly prepared the underlying substrate. NAP then installed an acid-resistant industrial brick floor beneath two fryers, each measuring approximately 7 feet wide by 25 feet long.
Key components of the installation included:
- 8” x 4” x 2-¼” Red shale acid brick to manage heat transfer
- Carbon Filled Furan resin mortar designed for chemical resistance, tolerance to high temperatures and frequent sanitation
- Proper detailing around fryer support bases and transitions
- Installation methods focused on long-term durability and thermal performance
NAP provided full design consultation and installation services to ensure the system was properly engineered for the operating conditions.
Results
The newly installed brick flooring system eliminated the recurring failures associated with the previous epoxy floor. The system now provides reliable performance under sustained fryer oil temperatures of approximately 350°F and withstands the facility’s aggressive cleaning procedures.
The client experienced:
- Significantly reduced maintenance requirements
- Improved resistance to thermal cycling and chemical exposure
- Decreased downtime related to flooring repairs
- A long-term flooring solution aligned with food processing sanitation demands
National Acid Proofing delivered a durable, high-performance flooring system designed to support continuous food production operations.
Let’s Talk About Your Facility
If your facility is experiencing repeated flooring failures due to high temperatures, aggressive washdown, or demanding process conditions, National Acid Proofing can help. Our team provides expert design consultation and installation services for industrial environments where performance matters.