90,000 SF Food Processing Facility with Integrated Cold Storage
Integrated food processing and cold storage facility — USDA-FSIS, HACCP, and SQF compliant. Multi-zone production-to-storage workflow with sanitation envelopes and pre-operational FSIS approval.
FIELD LOG · INTEGRATED FOOD PROCESSING + COLD STORAGE · USDA-FSIS · HACCP · SQF
Client details withheld at client request to protect operational confidentiality. Project specifications, technical details, and engineering work accurately described.
- Buildout90,000 SF integrated
- Processing Floor45,000 SF · 38-42°F
- Frozen Storage25,000 SF · 0°F
- Refrigerated Storage15,000 SF · 35°F
- Support Spaces5,000 SF
- ComplianceUSDA-FSIS · HACCP · SQF
By the Numbers
USDA
Pre-operational approval
SQF
Certification ready
100%
On-time delivery
0
Sanitation deficiencies
Integrated processing and cold storage. USDA-FSIS compliance throughout. Sanitation envelopes engineered into design.
Food processing facilities with integrated cold storage are among the most operationally complex cold storage builds. Production floors operating at controlled refrigerated temperatures, sanitation requirements throughout, USDA-FSIS compliance integrated into design, and material flow from production to cold storage to outbound shipping all under one roof.
This project required exactly that integration with multi-temperature production zones, frozen and refrigerated storage zones, sanitation envelopes engineered for daily washdown protocols, and pre-operational FSIS approval coordinated through commissioning.
Integrated production-to-storage workflow with sanitation envelopes.
Production Floor — 45,000 SF · 38-42°F
Refrigerated production zone with sanitation envelope. Coved floor-to-wall transitions, sealed concrete with epoxy, slope-to-drain throughout, premium sanitation infrastructure.
Frozen Storage — 25,000 SF · 0°F
Standard frozen storage zone receiving processed product. 5-inch IMP envelope with under-slab heating throughout.
Refrigerated Storage — 15,000 SF · 35°F
Refrigerated storage zone for inbound raw materials and finished refrigerated product.
Sanitation Infrastructure
Hand wash stations, gowning rooms, sanitation supply rooms, and inspection bays integrated into facility layout. Inspection-ready handover with pre-operational FSIS approval.
Complete integrated food processing facility. Engineered, executed, USDA-approved.
Sanitation-Engineered Envelope
Premium IMP specifications matched to each operating temperature with continuous vapor barrier. Coved floor-to-wall transitions throughout. Sealed concrete with epoxy coatings rated for USDA-FSIS washdown. Stainless steel transitions in critical zones.
Multi-Zone Refrigeration
Industrial refrigeration sized for production cooling load plus storage zones. PSM-compliant mechanical room. N+1 backup capacity for critical zones.
Production-to-Storage Workflow
Material flow engineering from receiving through processing to storage to outbound. Coordinated dock infrastructure for raw material receiving and finished product shipping.
USDA-FSIS Compliance Throughout
Sanitation envelope engineering, drainage with slope-to-drain in all zones, inspection bay accommodation, and pre-operational FSIS approval coordinated through commissioning. Inspection-ready handover.
Pre-operational FSIS approval first inspection. Zero sanitation deficiencies. SQF certification readiness.
Facility reached pre-operational FSIS approval on first inspection — no remediation required. Zero sanitation deficiencies across commissioning. SQF certification readiness verified through pre-operational inspections.
Production-to-storage workflow has run at design specification through full operational cycles since commissioning.
USDA
First-inspection approval
0
Sanitation deficiencies
SQF
Certification readiness verified
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