Engineering Custom Solutions for a Leading Wisconsin Dairy Producer

When a major dairy producer in Northeast Wisconsin faced a critical contamination risk in their brine room, they needed more than a quick fix—they needed a contractor who understood the unforgiving standards of food production environments. Fiberglass Solutions answered the call with innovative engineering that would eliminate regulatory compliance issues and protect the facility's reputation in one of the industry's most regulated sectors.

The challenge was significant: failing wall panel systems with multiple unsealed seams were creating perfect conditions for bacteria and mold growth behind the panels—a biohazard that threatened cheese production and posed serious risks for biohazard contamination. In an industry where a single contamination event can trigger product recalls and devastating headlines, this wasn't just a routine maintenance issue.

"The existing dairy board system was fundamentally flawed for this application," explained Ben Bertram, Fiberglass Solutions’ president. "These thin fiberglass sheets over water-absorbing material might be cheap and quick to install, but the plastic clip connections between panels create gaps that allow moisture infiltration—exactly what you can't have in a dairy washroom environment."

Beyond Band-Aid Solutions

The facility had previously attempted repairs using traditional dairy board—1/32-inch fiberglass sheets that many processors choose for their low cost and quick installation. However, the mechanical seaming system inherent to these materials creates vulnerabilities that become magnified in high-moisture, high-sanitization environments like brine rooms.

Several years earlier, Fiberglass Solutions had successfully addressed a problem area in the same facility, and the performance of that targeted repair convinced the customer to explore a comprehensive solution for the entire room. But this wasn't simply a matter of scaling up—the 12,000 square foot space presented complex engineering challenges around condensation control and thermal properties that could either solve the contamination problem or make it worse.

"Condensation and thermal build up are critical factors in dairy environments because they create the exact conditions where mold and bacteria thrive," Bertram said. "We couldn't just install any fiberglass solution—we had to engineer panels specifically designed for the thermal and moisture demands of this particular space."

Manufacturing Excellence Under Regulatory Pressure

Working with the facility's engineering team and understanding regulatory requirements, Fiberglass Solutions developed custom insulated wall panels with specifications based on thickness requirements and proximity to process elements. Rather than relying on mechanical seams that create contamination pathways, the team engineered a seamless installation where all panel connections would be fiberglassed closed, creating a completely washable, durable surface that eliminates bacteria growth opportunities.

The scale of the project required precision manufacturing and logistics coordination that many contractors simply can't handle. Fiberglass Solutions manufactured 355 custom panels—each measuring 325 square feet—at their Ashwaubenon, WI facility, ensuring consistent quality and specifications across the entire installation.

"This type of custom manufacturing requires both the technical capability and the production capacity to deliver on time," Bertram said. "Each panel had to meet exact specifications for the thermal and moisture conditions in specific areas of the room—there's no room for generic solutions in food production."

The installation demanded round-the-clock commitment, with crews working 24-hour days to minimize production disruption at the cheesemaker. The result was a completely seamless, washable surface that transformed the room's compliance profile and eliminated what had been a persistent audit concern.

Regulatory Confidence, Operational Excellence

The project delivered results that extended far beyond simply fixing a problem area. The new system eliminated the contamination pathways that had made the space an ongoing regulatory risk, transforming what had been a persistent problem into a showcase of compliance excellence.

"The room is brighter, completely washable, and eliminates the moisture infiltration points where bacteria and mold had been growing," noted the customer. "More importantly, this is no longer something we worry about during USDA and FDA inspections—the seamless design greatly reduces the contamination risks."

The installation's success has provided measurable operational benefits. The facility now operates with confidence that their brine room meets the most stringent regulatory standards, protecting against the production disruptions, product recalls, and reputational damage that contamination events can trigger in the dairy industry.

Engineering ROI in Food Safety

While the upfront investment in custom-engineered fiberglass panels exceeded the cost of traditional dairy board solutions, the long-term return on investment extends across multiple critical areas and is significantly positive. The elimination of regulatory compliance risks, prevention of potential production shutdowns, and protection against recall events creates value that far exceeds the initial cost differential, and the solution can provide decades of protection.

"Dairy producers who choose cheap, quick-install solutions often find themselves dealing with the same problems repeatedly," Bertram said. "Our approach is to engineer the right solution once—custom manufacturing that eliminates the root cause rather than just treating symptoms."

The project exemplifies Fiberglass Solutions' specialized expertise in food production environments where regulatory compliance isn't optional and contamination risks can destroy businesses overnight. Their ability to design, manufacture, and install custom solutions that other contractors can't or won't tackle has established them as the go-to partner for Wisconsin's dairy industry.

"In food production, there's no room for cutting corners. We understand what it takes to engineer solutions that don't just meet regulatory requirements, they eliminate the risks entirely and can last a generation."