Understanding the Need for Food-Safe Coatings

The food and drink industry is bound by strict regulations and guidelines to ensure the safety and quality of products. Food comes into contact with many materials and articles during its production, processing, storage, preparation, and serving, before its eventual consumption. The European Food Safety Authority states that Food Contact Materials (FCMs) should be sufficiently inert so that their constituents neither adversely affect consumer health nor influence the quality of the food. 

Flour mills, being a crucial part of the food supply chain, must adhere to these standards. Equipment used in the milling process, such as storage tanks, hoppers, chutes, and conveyors, is prone to wear, corrosion, and degradation over time. Traditional coating solutions often fall short in providing a long-lasting, food-safe barrier.

What is the EU Food Regulation 10 2011?

This regulation sets out safety requirements for plastic materials and articles intended to co­­­­me into contact with food. This regulation is a specific measure for plastic food contact materials as mentioned in the European Framework Regulation (EU) 1935/2004.

This regulation applies not only to food contact packaging but to equipment such as food storage tanks, pipes, pumps, containers, conveyer belts, etc.

What to Use on a Large Storage Tank at a Flour Mill

Belzona 5811DW2 (DW Immersion Grade) is a solvent-free coating initially designed for the protection of surfaces operating under potable water immersion or where potable water approval is required. 

Reacting to customer demand, Belzona Distributor; Perspect Benelux recently invested in comprehensive testing to evaluate the coating’s suitability for contact with dry foodstuffs.

Their customer, a large mill in Belgium that specializes in the production and development of physically treated wheat flour and mixes used as cake flour, sought a coating suitable for contact with flour that would provide long-term corrosion protection. Building on the success of achieving WRAS approval for contact with drinking water, the company’s solvent-free coating was put forward as a possible solution.

Comprehensive Testing

Confident in the performance of the Belzona coating, Perspect Benelux opted to have it tested by the Belgian packaging institute; IBE-BVI, which is an accredited independent laboratory according to ISO 17025, recognized throughout Europe. Their results confirmed the coating’s compliance with specific requirements of European Regulations No. 1935/2004 and No. 10/2011 for prolonged contact with dry foodstuffs.

Perspect Benelux was able to provide tailored support to the customer, in collaboration with Belzona, by providing sufficient data and evidence to satisfy the customer that the coating is safe and suitable for their specific needs and service conditions.

The positive results were recognized on completion of the project, by the FAVV (Federal Agency for the Safety of the Food Chain), which confirmed application was completed according to the approved method, using the coating. 

The unique formulation of this Belzona coating not only ensures compliance with food safety regulations, but also offers outstanding protection against corrosion and abrasion. It has been certified as non-leaching, with no harmful emissions or influences on dry food products and flour based on this customer’s specification.

This future-proof coating was also found to conform to the maximum limits of mineral oil aromatic hydrocarbons (MOAH), mineral oil saturated hydrocarbons (MOSH), and Polyolefin oligomeric saturated hydrocarbons (POSH).

The likelihood of these guidelines becoming a requirement in the near future is significant due to the new EU Food standards coming in place.

The results of the tests were not only promising, but exceeded expectations, leading to the green light for the application to the internals of 30, 6000-square-meter (7175.94-square-yards) flour storage tanks. 

What Was the Issue? 

Due to the age of the installation, the original lining was blistering and there was a risk it could contaminate the product to be stored in the tanks. In order for the customer to re-use these old, out-of-service tanks, a new lining was required. Other linings were tested, however Belzona 5811DW2 (DW Immersion Grade) was the only one approved by the QA-QC department. The alternative would have been to build a new silo complex that would have been extremely expensive. 

Application Process

The application of the coating in the flour mill followed a meticulous process to ensure long-lasting protection. The steel surfaces of the tank to be coated were prepared, cleaned, and blasted to the recommended standard of cleanliness, Swedish Standard Sa 2½, SSPC-SP10 (near-white metal) with a minimum profile of 3 mils (75 microns). Two coats were then applied by air-less spray in cream, to a dry film thickness of 400µm (15.75 mil).

                                                                        

Pictured above: Blasted surfaces and completed application of Belzona 5811DW2 (DW Immersion Grade).

Benefits of Immersion-Grade Coating in Flour Mills

Tested in Accordance with Parts of the Food Safety Regulations

Belzona 5811DW2 (DW Immersion Grade) meets some of the stringent requirements for materials in contact with dry foodstuffs, providing a reliable solution for compliance with regulatory standards.

Extended Equipment Lifespan

The robust nature of the lining enhances the durability of equipment, reducing the frequency of maintenance and replacement.

Solvent-Free Formulation

The lining’s solvent-free formulation means it is not only food-safe, but also environmentally friendly. This characteristic aligns with Belzona’s commitment to sustainable practices, prioritizing the safety of both workers, and the surrounding environment.

Corrosion Resistance

The coating acts as a barrier against corrosion, preventing the degradation of equipment, and maintaining equipment integrity.

Improved Operational Efficiency

With reduced downtime for maintenance, flour mills can operate more efficiently, contributing to increased productivity and cost savings.

Future Potential for Food Manufactures

The successful lining of 10 tanks (to date) with Belzona 5811DW2 (DW Immersion Grade) in this flour mill highlights the potential of this innovative lining being adopted into the maintenance practices of food manufacturers across Europe. As industries evolve, the implementation of such advanced solutions will become pivotal in ensuring a reliable and sustainable food supply chain.

Learn more from Belzona here.