CASE STUDY: Saputo

Multi-Facility Partnership Transforms Wisconsin Dairy Operations

 

The Challenge

When Saputo, one of North America’s largest dairy processors, launched an ambitious initiative to expand and modernize three Wisconsin facilities, the stakes couldn’t have been higher. The Canadian company selected Miron Construction to lead these critical upgrades in Franklin, Reedsburg, and Almena – projects that would transform Franklin into a central packaging hub for Saputo plants across the region. The flooring requirements were extensive and complex: multiple coating systems across varied environments, strict hygienic standards for food processing areas, and the need to coordinate seamlessly with numerous trades working simultaneously across a multi-month construction schedule.

 

The Solution

Protective Coating Specialists was initially brought in to install 15,000 square feet of heavy-duty urethane cement at the Almena facility. The quality of that work and our understanding of food processing requirements earned us contracts for the Franklin and Reedsburg facilities, ultimately resulting in one of our most comprehensive multi-site projects.

Franklin Facility – The Flagship Project:

The Franklin plant represented a massive undertaking: 87,000 square feet of processing area across 30 rooms, each with varying flooring system requirements. Our team delivered:

• Four distinct flooring systems with varying topcoats providing chemical and UV protection tailored to each area’s specific demands
• 257,000 square feet of concrete densifier sealer for packaging, warehousing, and non-production areas
• 4,500 lineal feet of troweled cant (epoxy base) creating the 2-inch-high coved transitions essential for hygienic food processing environments
• 5,100 lineal feet of vertical concrete curb treatment ensuring complete protection and cleanability
• 37,000 lineal feet of concrete saw cut and construction joint treatment protecting the facility’s long-term structural integrity
• Specialized troweling in tunnels to provide the hygienic surfaces required for food-safe operations

Multi-Phase Execution:

The project unfolded across carefully coordinated phases over a three-month period:

• Phase 1: Laboratory, upper employee areas, locker rooms, and reception
• Phase 2: Main production facility with four different urethane systems and specialized topcoats

The Reedsburg and Almena facilities involved combinations of new construction and remodel work, each requiring our team to adapt to existing conditions while meeting Saputo’s exacting standards for their cheese processing operations.

 

The Results

This multi-year, multi-facility partnership delivered transformative results for Saputo’s Wisconsin operations:

• Three modernized facilities equipped with flooring systems designed for decades of demanding food processing use
• Franklin established as regional packaging hub with flooring infrastructure capable of supporting consolidated operations from multiple plants
• Complete hygienic compliance across all production areas, with properly canted transitions, sealed joints, and chemical-resistant surfaces
• Seamless coordination with Miron Construction and multiple trades throughout complex, simultaneous construction activities
• Consistent quality across all three facilities, demonstrating scalable expertise for enterprise-level projects

 

Why It Matters

“The Saputo project showcases exactly what sets Protective Coating Specialists apart,” said Steve Sitzberger, president and owner. “Food processing facilities demand absolute precision – the cant work, the joint treatments, the specialized troweling in tunnels – every detail matters for hygiene, regulatory compliance, and long-term performance. When Saputo saw our work at Almena and immediately wanted us for Franklin and Reedsburg, that’s the validation that 57 years of experience delivers.”

Projects of this magnitude require more than technical skill. They demand partners who understand construction phasing, can coordinate with multiple trades, and deliver consistent quality across varied scopes and timelines. Protective Coating Specialists proved that expertise across three facilities and hundreds of thousands of square feet of specialized flooring systems.

 

Does your food processing operation require flooring systems that meet the highest standards of hygiene, durability, and regulatory compliance? Contact Protective Coating Specialists to discuss your next project.