Application guides

by Fakolith Chemical Systems

Painting or renewal of sandwich panel, metals, lacquered metals and similar with certified foodgrade paint for direct and indirect contact, in the food industry and health sectors.

Description of the problem

Undoubtedly the sandwich panel (lacquered metal), as well as other types of similar panels, are more and more used in the food industry, cold and clean rooms and other industrial sectors. Although initially sandwich panels comes white lacquered from factory, due to the use, shocks, contact with moisture and chemical attack, panels are damaged and should be adequately renewed. But, how we renew the paint of a sandwich panel in food industry? Fakolith has great experience in this regard. Firstly, do an adequate panel cleaning and oxide removal. Then, apply the suitable anticorrosive primer, either generally or at least at the points of corrosion. Finally, proceed to the final finish with the most convenient foodgrade paint certified for direct and indirect contact with food and beverages. All our paints incorporate the BioFilmStop antibacterial technology for greater food safety and hygiene. This solution is generally applicable to other metal elements such as beams, pipes, structures, etc.

Summary of the most common basic solution and procedure

1. SURFACE CLEANING:   


· FAKOLITH FK-111Application of the descaler and grease cleaner, pollution, industrial dirt and biofilm matrix, and subsequent rinsing with water, to remove dirt. After drying, leave the base ready for the next treatment. Alternatively, or if necessary, can be used the BIOFILMSTOP Cleaner with HA Health Record for the elimination of biofilm, bacteria, fungi, virus or also the multifunctional industrial cleaner FK-111 for greasy dirt.


· FAKOLITH FK-9 GEL: Application of the oxide cleaner on the corrosion points of the panel, remove with water and/or dry the surface with a cloth impregnated with solvent, such as FK-45 OEMSolvent.    


2. SURFACE PRIMER:   


· FAKOLITH FK-44 POX: Application of the anticorrosive epoxy primer on the entire panel or on the corrosion points, according to what is most convenient, and let it cure. The objective is to protect the panels against rust or critical points detected. Drying even at low temperature.    


3. SURFACE PAINTING:


Final painting with 2 coats of FoodGrade paint, suitable for use in the food industry in direct and indirect contact with food and in health sectors, with high resistance to moisture, friction, cleaning and disinfection, and with green BioFilmStop technology to inhibit biofilm and bacteria growth:    


· Option A - DISPERLITH FOODGRADE ELASTICThe first water-based and monocomponent foodgrade paint. It is the most recommended for painting or repainting mainly of surfaces of walls and ceilings, cement mortars and concrete, painted or to repaint in general. It also has CE marking tests, excellent impermeability and resistance to cleaning and disinfection. Drying even at low temperature.


· Option B - FAKOLITH FK-45 FOODGRADE: Especially over high-performance surfaces, the use of the high-solids epoxy foodgrade paint, with CE marking tests, is usually the most used option. It is needed a temperature higher than 10ºC for its drying. Alternatively, it can be also painted with FK-45 FoodGrade Hygienic which has higher physical-chemical resistance. 

Application process

1.- Option A - FK-111

DESCRIPTION AND MAIN USE: FAKOLITH FK-111 is a detergent cleaner for use with grease-based dirt or grime, pollution, biofilms matrix, scorching or industrial grime in general, on surfaces resistant to alkaline solutions. Mainly for use in the food industry, industry in general, construction and civil engineering. Health Register FAKOLITH RGSEAA ES-39.005259/T y ROESP E-0043-E.

RECOMMENDED THINNER: 1 part FK-111 to 4 parts water. Can also be used undiluted if necessary, in more contaminated areas or when speed of action is required.

HOW TO APPLY: Carefully protect all surfaces that are not to be treated from splashing. Apply diluted FK-111 using spray guns, brushes or rollers and immediately activate the product by scrubbing with a brush with stiff plastic bristles, working particularly on the worst affected areas. Allow 15-20 minutes to pass, although always before it has dried, and then wash off and rinse thoroughly using water under pressure. If so required the operation can be repeated. Leave to dry before going ahead with possible additional treatments. For further details consult the specifications sheet and/or application guidelines, along with the safety sheet.

AVERAGE YIELD: Undiluted FK-111 provides a yield of approx. 8-12 litres/m², although depending on the extent of the contamination this may vary considerably.

1.- Option B - FK-9 Gel

DESCRIPTION AND MAIN USE: FAKOLITH FK-9 Gel is a cleaner for the removal of rust from metals and lime-descaler, for use on surfaces resistant to acidic solutions. The gel format makes for easy application, avoids dripping and optimises consumption. Mainly for use in the food industry, industry in general, construction and civil engineering. Health Register FAKOLITH: RGSEAA ES-39.005259/T y ROESP E-0043-E.

HOW TO APPLY: Carefully protect all surfaces that are not to be treated from splashing. Generally speaking FK-9 Gel is applied abundantly, using synthetic brushes, to the rusty area of the metal and left to soak in until the rust is seen to have been removed. The product can be scrubbed in using a brush with stiff plastic bristles, working particularly on the worst affected areas. The layer of gel, along with the remains of the rust or limescale, must be cleaned off before it can dry, and the surface washed down and thoroughly rinsed using pressurised water. If so required the operation can be repeated. After rinsing with water we recommend that you dry the metallic surfaces using a solvent impregnated rag, and then either prime it or duly protect it as soon as possible, given that if you do not do so the rust will rapidly reappear. If you want to eliminate limescale make sure that the base is resistant to acidic solutions and proceed as indicated above, although in this case the process will be much faster. For further details consult the specifications sheet and/or application guidelines, along with the safety sheet.

AVERAGE YIELD: FK-9 Gel provides a variable yield although, depending on the extent of the corrosion to be eliminated, this may vary considerably.

2.- FK-44 POX

DESCRIPTION: FAKOLITH FK-44 POX is a special, anti-corrosion, miscellaneous, acrylic, water-based, fast-drying, low odour, white epoxy primer. For use with metals in general, formulated with zinc phosphate, micaceous iron-oxide and organic anti-corrosion agents. This primer can be applied at temperatures as low as 2-3ºC, and up to a maximum relative humidity of 75-80%. Excellent anti-corrosion and metal adhesion properties. (Combined with FK-45) : Salt spray blistering classification (ISO 9227:2007) Class 0 (ISO 4628-2) - Corrosion classification (ISO 4628-3) estimated as Class 0, (ISO 4628-3) and anti-flash rust (L-AF30 method, French standard). Anti-corrosion priming systems ISO 12944-5. Ideal for priming metals before painting with Fakolith paints from the FK-45 and Disperlith ranges, among others.

RECOMMENDED USE: FK-44 POX is ideal for priming metals, iron, steel, stainless steel, copper, galvanised or aluminium surfaces. Compatible with lacquer-finish panels and surfaces that have been previously covered with compatible paints and/or primers, well adhered and resistant to cross-cut test Class 0-1 UNE-DIN EN ISO 2409:2007. In general recommended for use in the food industry, health sector, the pharmaceutical or cosmetics industry in general, construction and civil engineering.

HOW TO APPLY: FK-44 POX can be applied by brush or roller, or for finishes and optimum applications using an Airless spray gun. Following the elimination of any rust, and an adequate preparation of the surface, slowly pour component B into component A, mix together gently using an electric mixer, for at least 2 minutes or until the components have blended completely together, and then leave to rest for 1 minute before starting to apply. When mixing always use complete batches of component A and component B, to avoid errors in the mixing ratio. Drying times and the length of time you will have to wait between coats will depend on the actual thickness of each coat, the temperature, level of relative humidity and ventilation, although generally speaking the second coat can be added within 1 hour. Clean utensils immediately after use with water. For more information consult the specifications sheet and/or application guidelines and the safety sheet.

AVERAGE YIELD: According to recommended film thickness and depending on the texture and absorption of the surface it is applied to. It is recommended that the thickness of FK-44 POX be applied in two coats.

- For a dry thickness in microns 40 µm - consumption is 125 ml/m² - a yield of 8 m²/l.
- For a dry thickness in microns 80 µm - consumption is 250 ml/m² - a yield of 4 m²/l.
- For a dry thickness in microns 160 µm - consumption is 500 ml/m² - a yield of 2 m²/l.

3.- Option A - DISPERLITH FoodGrade Elastic

PROPERTIES: DISPERLITH FoodGrade Elastic special FoodGrade paint or varnish, tested for suitability for coming into direct contact with foods, water-based dispersion with modified acrylates copolymers, low emissions and low odour (Low Voc), free of APEO, ammonium, formaldehyde and heavy metals, highly resistant to dampness and humidity, for interior and exterior use. DISPERLITH FoodGrade Elastic forms a well-balanced and elastic film of paint, with a satin finish, that is easy to clean and disinfect, easy to apply and, quick drying, also at low temperatures, from 3ºC, with low odour and providing an excellent finish, in line with the DIN EN 13300 Standard, wet scrub resistance Class 1, covering Class 1 (>250 ml/m²), highly impermeable to water vapour, Class 3 (SD = 1.57), and water permeability Class 1 (W = 0.03). DISPERLITH FoodGrade Elastic is a paint with (EC) UNE-EN 1504-2:2005 marking and that is highly resistant to Class 1 and 2 aggressive chemical attack, with testing of the food simulants, along with the usual cleaning and disinfecting agents in their maximum recommended solutions, TECNALIA Report 050844 and Tests DIN EN ISO 4628-2: 2004-01 by TÜV SÜD Germany and/or Fakolith R&D+i. (For more security, before use, ask your case to our Tech. Department). Available in white and other colours.

FOODGRADE TECHNOLOGY: DISPERLITH FoodGrade Elastic is certified as a FoodGrade paint, apt for being in direct contact with foods and drinks, and that duly complies with all current European regulations regarding materials that come into contact with foods, (EC) Regulation 852/2004, (EC) Regulation 1935/2004, (EC) HACCP Regulation 1895/2005, and (EC) GMP Regulation 2023/2006, as well as Spanish RD 847/2011 and (EU) Commission Regulation No. 10/2011, along with the subsequent amendments thereto, regarding plastic objects and materials designed to come into contact with foods. To this end DISPERLITH FoodGrade Elastic has been tested with simulants A, B, C (OM2-40ºC) and D2 (OM2, 20ºC), as shown in the trials run by Fakolith, through independent certificating entities such as Tecnalia and the CNTA (Spanish National Food Technology Centre), among others, insofar as there is compliance in all of the tested cases with the overall and specific migration limits imposed by the Regulation for the above-mentioned simulants, which are equivalent to all simulants and food groups. DISPERLITH FoodGrade Elastic has been awarded the Declaration of Food Conformity – Health Register FAKOLITH RGSEAA ES-39.005259/T y ROESP E-0043-E.

BIOFILMSTOP SANITARY TECHNOLOGY (Treated Article BPR Art.3): DISPERLITH FoodGrade Elastic is an intelligent sanitary paint, treated with BioFilmStop Inhibition Technology, highly resistant to biofilm and bacteria, ISO 22196:2011 (Escherichia coli, Listeria monocytogenes, Bacillus subtillis, Pseudonomas aeruginosa, Staphylococcus aureus, Salmonella enteritidis, Legionella pneumophila...) also notably improving HACCP, food safety and asepsis in the user company, while combining Fakolith’s innovative FOODTECH film protection technology, based on food preservatives.

RECOMMENDED USE: Even though DISPERLITH FoodGrade Elastic does not allow the migration of toxic substances to foods, because of its dispersion quality it has mainly been designed for use on exposed surfaces (walls, ceilings, skirting boards, basic food packaging, interiors and exteriors, in contact to dripping or occasional condensation, and in drinking water tanks but not in those where there are other foods or drinks, where we recommend the use of the FK-45 epoxy range, due to its higher level of physicochemical resistance (in case of doubt consult the use of this paint for potable water deposits or other possible cases). Compatible with most surfaces, duly primed should such be required, lacquer-finish sandwich panels and to cover well-adhered previous coats of dispersion and/or priming paints, resistant to cross-cut test Class 0-1 UNE-DIN EN ISO 2409:2007. The excellent covering and water-vapour barrier qualities mean that it functions as an excellent waterproofing film, particularly in severe industrial, climate or sanitary conditions, for the food industry, health sector, and pharmaceutical or cosmetics industry in general, construction and civil engineering.

HOW TO APPLY: Carefully protect all surfaces that are not to be treated from splashing. Application can take place at ambient and surface temperatures as low as 2-3ºC and up to a maximum relative humidity of 75%. Following adequate preparation of the surface DISPERLITH FoodGrade Elastic should be applied undiluted, in two coats, using brushes, rollers or airless spray guns. The surface must be clean, free of hygroscopic salts, microorganisms, etc. and, should such be required, duly primed. Do not apply the second until the first coat has lost its wet sheen and is dry to the touch (in normal conditions, of around 20ºC with a humidity of around 60%, this will be in approx. 2-3 hours). Clean utensils immediately after use with water. For more information consult the specifications sheet and/or application guidelines, along with the safety sheet.

AVERAGE YIELD: DISPERLITH FoodGrade Elastic has a yield of approx. 3-5 m²/l, applied in two hands although this can vary considerably, depending on how it is applied and the texture and absorption of the surface.

3.- Option B - FK-45 FoodGrade

DESCRIPTION: FAKOLITH FK-45 FoodGrade is a high-performance, two-component, modified epoxy FoodGrade paint with a high solids content, low voc, low odour and EC marking. FK-45 FoodGrade is a FoodGrade epoxy paint that ensures limitation of migrations, generates a high-gloss impermeable film that is easy to clean and disinfect, with water at temperatures of up to 90ºC. The excellent covering and vapour barrier effect qualities of this paint ensure that it will function as an excellent waterproofing agent and long term anticorrosion treatment, when applied to metals in combination with a correct anticorrosion primer system. Compatible with most of primed surfaces, the duly primed metallic surfaces, lacquer-finish sandwich panels and compatible previous paints and/or primers with good adherence and resistant to cross-cut test Class 0-1 UNE-DIN EN ISO 2409:2007. FK-45 FoodGrade is highly resistant to abrasion UNE EN ISO 5470-1:1999 and highly resistant to aggressive chemical attacks UNE EN 1504-2:2005 (chemicals compatible for epoxy), with UNE Shore hardness of 80±5 units, Shore D EN ISO 868:2003 (23±2ºC; 50±5%Hr), covering Class 1 (300 µm dry film) and damp rubbing Class 1, DIN EN 13300. Paint resistant to the most disinfectant cleaners according to Tests DIN EN ISO 4628-2: 2004-01 by TÜV SÜD Germany and/or Fakolith R&D+i (For more security, before use, ask your case to our Tech. Department).

FOOD GRADE PAINT CERTIFIED AS APT FOR DIRECT CONTACT: FK-45 FoodGrade epoxy paint duly complies with all current European regulations regarding materials that come into contact with foods, (EC) Regulation 852/2004, (EC) Regulation 1935/2004, (EC) HACCP Regulation 1895/2005, and (EC) GMP Regulation 2023/2006, as well as Spanish RD 847/2011 and (EU) Commission Regulation No.10/2011, and lasts amendments EU 2018/213 (BPA Compliant), regarding plastic objects and materials designed to come into contact with foods. To this end FK-45 FoodGrade Hygienic has been tested with simulants A, B, C (OM2-40ºC) and D2 (OM2, 20ºC), as shown in the trials run by Fakolith, through independent certificating entities such as Tecnalia and the CNTA (Spanish National Food Technology Centre), among others, insofar as there is compliance in all of the tested cases with the overall and specific migration limits imposed by the Regulation for the above-mentioned simulants, which are equivalent to all of the simulants and, as a result are apt for direct contact with all foods and drinks (with the exception of vinegar, which damages epoxy resin. Not suitable for foods intended for infants or young children according definitions at regulation (EU) No. 609/2013.). FK-45 FoodGrade has Declaration of Compliance – Health Register FAKOLITH RGSEAA ES-39.005259/T. Available in transparent and the most standard industrial colours for the food industry and the health sector.

RECOMMENDED USE: FK-45 FoodGrade epoxy paint is specifically formulated for the protection and finishing of surfaces that come into direct contact with all manner of foods and drinks, in line with current European regulations, and is for application to the interiors of food tanks and silos, food transport elements, skirting boards, floors, walls, ceilings, objects, machinery, installations, structures, etc. located in interiors. Generally, for use in the food industry, the health sector, the pharmaceuticals and cosmetics industry, construction and civil engineering.

HOW TO APPLY: Following adequate preparation of the surface and having confirmed the suitability of the environment, FK-45 FoodGrade paint can be applied by brush or roller, or for finishes and optimum applications using AirMix or Airlles with heated hose type spraying equipment. Slowly pour component A into component B (never the other way round), mix together gently using an electric mixer, for at least 2 minutes or until the components have blended completely together, and then leave to rest for 1 minute before starting to apply. When mixing always use complete batches of component A and component B, to avoid errors in the mixing ratio. Plan carefully its application, bearing in mind its short pot-life of the mix. It can be applied over fibreglass netting systems, in tanks and on floors, mixed with non-slip quartz sand. Should it be necessary adjust the viscosity of the paint by thinning with 5-10% of special FoodGrade solvent, FK-45 Solvent OEM FG.

ATTENTION TO THE CONDITIONS OF APPLICATION AND CURING: Drying time and the waiting time for the second coat depend on layer thickness, temperature, relative humidity and ventilation. The environment and base temperature should never be lower than + 10ºC and higher than 35ºC, and the relative humidity should not be higher than 70-75%. The surface temperature of the base to be painted should always be at least 3 ° C above the dew point to avoid condensation. It is estimated that the ideal application temperature is around 20ºC and 60% relative humidity. In the event that environmental conditions are not appropriate for its application and curing, these should be adapted with extraction and ventilation of air, either at room temperature, with cold or heat, with dehumidifiers, etc., until the environmental conditions are adequate and stable during the application and curing, and always avoiding the generation of moisture condensation, since this would prevent the proper curing of the paint, especially made to monitor in tanks and confined spaces. Epoxy paint should not be in contact with water or surface condensation during the first 72 hours of curing, or the paint may not cure properly, appearing "Amine Blush" wash spots.

DEPOSITS OF FOOD LIQUIDS: In general, the film will present its complete curing, from 14 to 28 days for contact with food and drinks (cured at 23ºC, 50% relative humidity, layer> 300 microns dry). At a lower temperature and / or higher humidity and layer, the curing time can be significantly increased. On the other hand, if the temperature conditions are higher, the humidity is lower and / or there is less coating, the curing time can be significantly reduced. It is necessary to maintain suitable environmental conditions during application and curing, for which it is necessary to use ventilation systems with air extraction and forced hot air, preferably dehydrated, avoiding condensation, to maximize the curing conditions. Before filling a tank that has been coated with FK-45 FoodGrade paints range, the complete curing of the film should be checked, as well as at least an initial cleaning on the entire surface, with clear water, or preferably with neutral soap and later rinse.

FORCED DRYING: in general, applications with forced drying with hot air dehydrated can greatly reduce the drying, curing and commissioning time. An example of this can be the application in interior of pipes, where specialist companies after the application with systems and special equipment, artificially circulate a current of hot dehydrated air, and after checking the correct curing, make a later washing with water, before of the definitive commissioning. The contribution of heat at a higher temperature shortens the programming of the curing cycle. For more details, consult technical data sheet and / or application guides, and safety data sheet.

OTHER GENERAL APPLICATIONS: the painting offers good general resistance, at least after 72 hours of curing, although we recommend not exposing the paint film to severe chemical-physical aggressions until it has been cured for at least 1 week (walls, floors, ceilings, indirect contact).

AVERAGE YIELD PAINT: according to recommended coat thickness, depending on use of FK-45 FoodGrade

- Dry thickness 200 µm = wet 302 gr/m² (222 ml/m²) - yield 3,31 m²/kg (4,5 m²/L).
- Dry thickness 300 µm = wet 453 gr/m² (333 ml/m²)- yield of 2,21 m²/kg (3,00 m²/L).
- Dry thickness 350µm = wet 528 gr/m² (389 ml/m²)- yield of 1,90 m²/kg (2,57 m²/L).
- Dry thickness 400 µm = wet 604 gr/m² (444 ml/m²)- yield of 1,66 m²/kg (2,25 m²/L).
- Dry thickness 500 µm = wet 755 gr/m² (555 ml/m²)- yield of 1,32 m²/kg (1,80 m²/L).
- Dry thickness 700µm = wet 1058 gr/m² (778 ml/m²)- yield of 0,95 m²/kg (1,28 m²/L).

AVERAGE YIELD TRANSPARENT VARNISH:

- Dry thickness 50 µm = wet 58 gr/m² (53 ml/m²)- yield of 17,27 m²/kg (18,87 m²/L).
- Dry thickness 75 µm = wet 87 gr/m² (79 ml/m²)- yield of 11,49 m²/kg (12,66 m²/L).
- Dry thickness 100 µm = wet 116 gr/m² (105 ml/m²)- yield of 8,63 m²/kg (9,52 m²/L).

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