Food & Beverage Facility Re-Roofing Protection
A full roof replacement over 128,000 square feet of equipment left no room for an off-the-shelf drape. TuffWrap built a barrier that could fit around every protrusion and still meet fire code.
Re-roofing an entire manufacturing facility is a major undertaking under the best circumstances, and this food and beverage company couldn’t afford to shut down while it happened. The roof over its entire 128,000-square-foot facility needed to be replaced, but production had to keep running underneath. Complicating things further, a standard off-the-shelf plastic drape wasn’t an option: the equipment on the floor reached all the way up to the ceiling, leaving no flat, uninterrupted surface to cover.
The manufacturer needed a suspended cover system that could be custom-fit around tall equipment at massive scale, without compromising the facility’s fire sprinkler system in the process.
The Challenge: Re-Roof a Massive Facility Without Shutting Down Production
Covering 128,000 square feet of active production floor is a different problem than covering an empty room. The manufacturer needed a solution that could:
- Install cleanly around equipment that reached up to the ceiling
- Cover the full footprint of the facility without gaps or contamination points
- Remain fully code-compliant beneath the existing fire sprinkler system
- Leave the facility completely free of dust and debris once the roof work was done
The Solution: SmartSeam® Suspended Cover
TuffWrap installed its signature SmartSeam® Suspended Cover to protect the production facility’s equipment during the roof replacement. Unlike an off-the-shelf drape, SmartSeam® could be installed around all the equipment protrusions reaching toward the ceiling, creating a sealed barrier custom-fit to the space rather than a one-size-fits-all sheet. Because SmartSeam® is the only code-compliant suspended cover solution on the market, it could be installed safely beneath the facility’s fire sprinklers without disabling them.
Once the roof work was complete, TuffWrap used High Structured Dust Removal during takedown to clear every trace of dust and debris that had accumulated above the cover, leaving the facility spotless.
The Result: Full Roof Replacement, Zero Production Downtime
Once SmartSeam® was in place, the manufacturer had exactly what it needed: 128,000 square feet of active production protected beneath a fully replaced roof, with equipment, product, and fire code compliance never at risk. The dust removal at takedown meant the facility came out of the project completely clean.
The manufacturer was thrilled with the job TuffWrap did installing the suspended cover, and the facility never had to pause production to get a new roof overhead.
Why This Matters for Food & Beverage Facilities
Re-roofing a working food production facility means protecting equipment that often doesn’t fit under standard containment, all while staying compliant with strict fire and safety codes. TuffWrap’s SmartSeam® Suspended Cover gives food and beverage manufacturers a way to replace a roof at any scale without ever contaminating product or shutting down the line.
