Builders and farm owners are abandoning old materials for those that can guarantee durability on one hand and feasibility on the other. The star of this transformation is, of course, the PVC dairy wall panels. These simple sheets of engineered vinyl are rewriting the design of the dairy infrastructure, and here’s how they are doing it:
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Let’s address the elephant in the barn: FRP (fiberglass reinforced plastic) panels. Once hailed as a “modern” solution, FRPs are a glaring failure in that you cannot overlook. The adhesive bonding used for FRP to the wooden backers weakens with time, thereby causing the panels to lift off like old wallpaper. Openings between panels soon become home to mold, while the textured surfaces accumulate grime, requiring frequent scrubbing. Meanwhile, the wooden backers do not rest; they absorb dampness and moisture entirely.
Here’s where PVC dairy wall panels become a vital component. These USA-made PVC panels neatly step around the many pitfalls of FRPs. No glue. No wooden backers. They screw directly into studs with the tongue-and-groove interlock system, basically sealing out moisture and bacteria from the inside. As a result, a smooth surface without crevices resistant to bleach refuses to soak in manure and laughs away its decades with far less care than FRP! Builders aren’t just choosing PVC—they’re abandoning FRP’s high-maintenance drama.
Every farm has its own set of daily troubles with spilling milk and deposited manure. Thus, they need an ensemble of cleaning agents to ensure clean and hygienic facilities. FRP or drywall as the industry standard would only get worse with time, as its traditional construction materials contribute to absorbing stains and bacteria. In contrast, PVC dairy board panels do not have absorptive surfaces. Their ultra-smooth, non-porous surfaces get rid of all manner of crevices where pathogens thrive and make it possible to achieve hygiene through a mere wipe-down with a mild detergent. Everything from scrubbing to worrying about residual grime is a thing of the past. All that’s possible now is a sanitized facility that thrives under stringent food safety regulations.
The three dominant features of any dairy facility are condensation, humidity, and mold. While dairy facilities deal with these pests on a daily basis, others get to sit on the sidelines and relax. Unlike FRP, which relies on backers that absorb moisture, PVC’s waterproof design blocks water vapor entirely, combating these dairy pests with 100% vinyl construction, mitigating mold growth and structural decay. The results? The walls remain odor-free and are never subjected to the steamy conditions found in the milking parlor. Along with sound structure, the walls will also remain dry and free of any mold, making the partitions of the dairy facility.
The installation of FRP concerns two people—one applies glue to the panels while the other applies the trim. The cutting of labor and time can be achieved through the use of PVC panels. Due to their lightweight construction and interlocking design, a single installer can set the panels directly on the studs without backers, adhesives, or trims. FRP crews spend 8 hours on the job, while a PVC crew only needs 4. This will allow large dairy farms to complete projects faster, reducing overall project time and labor costs.
Maintaining hygiene standards and protecting the walls against moisture is essential for smooth business operations in a commercial setting. This is especially true for grow rooms, food processing facilities, car washes, commercial kitchens, and breweries. Choosing the right material for wall and ceiling panels is crucial, as these areas are frequently exposed to high humidity, heat, smoke, and fluctuating temperatures.
Painted walls fail to endure the test of time, becoming dull and worn out within a few months, impacting operations and hygiene. Wall paneling solutions like FRP, tiles, and drywall also fail to perform and meet facility owners’ expectations. On the other hand, PVC wall and ceiling panels are moisture—and mold-resistant, ensuring a damp and contamination-free space. Explore why Duramax PVC panels are the most efficient solution for commercial and residential spaces.
Duramax PVC Panels are lightweight and designed for easy installation. They require no special training or tools, so one installer can easily handle the job. In contrast, materials like FRP and drywall require specialized installers to ensure proper setup. Ceramic tiles also take significantly longer to install and have a higher price tag.
PVC ceiling panels screw directly into studs, and with their interlocking design, installation is faster than other materials. Longer installation times can disrupt smooth operations, causing unnecessary downtime that impacts your business. With Duramax, we process orders within 48 hours, ensuring you can get your newly renovated facility up and running immediately.
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Hygiene is critical in most commercial facilities where safeguarding the quality of your products and services is paramount. Unlike FRP, Duramax PVC panels interlock to create a smooth, seamless surface, eliminating the risk of mold and bacteria accumulating in crevices. They adhere to strict safety and hygiene standards and are CFIA and FDA-compliant. In addition to their sanitary aspects, these panels have an antibacterial coating that prevents bacteria and microbial growth. With their ease of cleaning, they are the perfect solution for facilities that require regular cleaning to maintain high sanitary standards. PVC panels are also ASTM-certified after meeting stringent quality and safety standards.
PVC panels are class-1 fire-resistant. They do not fuel a fire, remain unaffected by an hour of fire and flame, and do not release toxic gases upon being burnt. This feature makes them effective for commercial kitchens, garages, food processing facilities, etc.
Duramax panels provide a bright, clean finish to your interior walls, making them low-maintenance. PVC panels’ smooth, glossy surface has retained their fresh, new appearance for years, eliminating the need for frequent touch-ups. Cleaning vinyl wall and ceiling panels is simple because of their seamless design. A wipe-down or a rinse with a high-pressure hose is enough.
Traditional wall and ceiling paneling solutions fall short in durability. They absorb moisture, resulting in dampness and mold formation. High humidity levels in meat processing plants, poultry farms, and breweries can negatively impact operations demanding repairs and maintenance. For example:
Duramax PVC ceiling paneling offers 100% water resistance and lasts much longer. They are chemical-resistant, have a 1-hour fire grade, and don’t corrode like metals. Their unique webbed design enhances durability and impact resistance, making them ideal for even the most demanding environments. Learn more about the capability of Duramax panels from the following case study:
Douglas’s SpringBloom Farms is a small-sized indoor agricultural business cultivating high-quality cannabis. He planned to expand and needed to upgrade the facility to optimize growing conditions and comply with agricultural regulations. However, he faced several challenges during the process.
Firstly, maintaining consistent temperature and humidity levels while ensuring a sterile and mold-free environment was challenging. Secondly, Douglas wanted to keep maintenance and cleaning time to a minimum to save crucial productive hours. Finally, he sought a cost-effective upgrade without disrupting the plant cycles.
SpringBloom Farm researched the options for its walls and ceilings and selected Duramax panels. These panels resist moisture, chemicals, and physical impact and help maintain stable temperature and humidity levels. Their non-porous and easy-to-clean surface prevents mold growth and bacterial contamination. Duramax panels are also easy to install and minimize downtime and plant disruption.
The adoption of PVC panels delivered substantial results by improving temperature and humidity stability, decreasing cleaning time, and reducing long-term upkeep expenses. This helped enhance plant health and yield, allowing staff to focus more on plant care. Douglas was thankful that Duramax completed the installation without disrupting ongoing cultivation cycles.
As Duramax PVC wall and ceiling panels transformed SpringBloom Farms for enhanced productivity, your facility can be the next. Contact us for a free quote on your project. We offer factory-direct prices and a limited lifetime warranty on our PVC panels. Order now!
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