Answering the Call for one of the nation’s largest cheese producers

When one of the nation’s largest cheese producers needed a specialized floor system to anchor their new state-of-the-art production facility in Wisconsin, they turned to the flooring experts who understand the unique demands of food production environments. Protective Coating Specialists answered the call with a solution that would not only meet stringent USDA and FDA requirements but also solve complex engineering challenges that other contractors couldn’t handle.

Working alongside a leading engineering firm, PCS was tasked with developing a system to install a production floor over an existing basement storage area—with the critical requirement that the floor absolutely could not leak, as all finished cheese would be stored in the space underneath the production floor.

“The biggest technical challenge was achieving a consistent 1/4″ per foot slope toward the drain across 60,000 square feet while maintaining a completely leak-proof system,” said Peter Valitchka, PCS vice president of sales. “Many competitors simply don’t have the expertise to grout and pitch floors to meet existing elevations while ensuring zero leakage—but that’s exactly what food production demands.”

The client interviewed PCS to ensure they fit the profile as a specialized food production flooring contractor. During the engineering meetings, the depth of PCS’s food industry knowledge became clear as they worked with the SIKA company to develop the correct materials for the specific production environment.

Engineering Excellence Under Pressure

The project presented multiple complex challenges that required innovative solutions. The PCS team began with comprehensive shotblasting of the existing surface for optimal adhesion, then the 10-man crew meticulously treated all joints and installed 10 oz fiberglass roving over approximately 3,500 linear feet of joints—a critical waterproofing solution that PCS developed specifically for the architect.

“We really embrace those challenges,” said Valitchka. “The client didn’t initially know how to solve the leakage issue, so PCS engineered the fiberglass joint solution. Every situation is different in food production, and very frequently we need to design and engineer solutions that will solve the problem and satisfy both the customer and regulatory requirements.”

Once the joint work was complete, PCS installed SIKA 22N product at 1/4″ thickness, broadcast with a specific aggregate to meet the owner’s exacting requirements for both non-slip safety and cleanability. SIKA’s Purcem cement meets all USDA and FDA food safety requirements for flooring—critical certifications that many contractors can’t navigate.

The installation included 2″ cove bases at 45-degree angles around all perimeter walls and columns, providing ease of cleaning during washdowns and minimizing food product buildup around walls—details that demonstrate PCS’s deep understanding of food production operations.

Expanding Scope, Delivering Results

What started as a new facility project expanded when the client realized PCS’s unique capabilities. During installation of the new facility, they also renovated the old production space—a significantly more complex undertaking.

“We had to remove old dairy brick that was 2″ thick, re-pitch the entire floor to the drains, then install SIKA flooring at 1/4″ thickness,” explained Valitchka. “This type of retrofit work is where our experience really shows. Many competitors cannot handle the precision required to grout and pitch floors to meet existing flooring elevations while maintaining proper drainage.”

The spring installation was completed in four phases of 20,000 square feet each across two months. Because this was a new addition to a state-of-the-art facility, PCS was able to install the floor system before the cheese production machinery arrived, allowing for the highest quality installation.

Building Relationships, Opening Doors

The project was completed on time and on budget, but more importantly, it demonstrated PCS’s unique value proposition in the food production sector. The company’s specialized expertise with USDA and FDA regulations, combined with their ability to solve complex engineering challenges, made a lasting impression.

“We developed a strong rapport and relationship with the general contractor throughout this project,” said Valitchka. “Our commitment doesn’t end when installation is complete—we stay with our clients and make sure they’re well educated in the process to protect their investment.”

That relationship paid dividends. The successful completion of the Marathon facility opened the door to flooring work with three additional cheese processors, establishing PCS as the go-to flooring specialist for Wisconsin’s cheese industry.

“We built our reputation on commitment from the beginning to the end,” added Valitchka. “In food production, there’s no room for error—and our track record with leading cheese producers proves we understand what it takes to deliver flooring solutions that meet the most demanding production environments.”