Pasta Roma is a Costa Rican pasta company and one of the most recognized food brands in the country. The plant, located in Alajuela, faced problems of internal condensation, low lighting and leaks. The phenomenon of condensation occurs because of the high degree of humidity in the air inside the plant and the strong differences in temperature between the interior and the outside.
The decision was made to change the roof of the plant in its entirety and simultaneously scrape and paint the nailers, which led to a series of challenges of high complexity.
First, to be able to change the roof of the plant was necessary to maintain the structure, because the face of the perling on which was supported the old roof had not been maintained, and was oxidized.
To paint the nailers you had to uninstall an old insulator that accumulated a lot of dust over time. All cleaning and painting work should be carried out without particles falling into the food processing plant.
Since it was a factory, it was essential that the machinery be kept running throughout the reroofing process so as not to affect productivity.
Another challenge is that the Roma pasta plant adjoins a neighboring building, so that when the old roof was removed, there was a risk of damaging the adjacent gutters and everything.
The industrial complex is composed of several structurally independent sections that share sections of roof and Hojalatería. Therefore, the solution was to contemplate "seismic" joints that compensate the differences of structural movement and the differences of thermal expansion coefficient.
There was very little room for the collection of materials, as an important area was reserved for the company's finished product dispatch platforms.
Finally, pest control policies require a completely free atmosphere of potentially damaging particles and organisms, so all ridges and gutters and everything should be sealed.
It was recommended to install continuous Total Lock 50 Composite Plate 26 gauge, which consists of two sheets of enamelled steel: one to the internal with white enamelled finish, and on this, an expanded polystyrene thermal insulation of 38 mm with R-5 h ft2 F/Btu with Density of 10 Kg/m3, and a white enamelled outer sheet, sealed between them with a butyl gasket.
In addition, skylights were placed with 8mm alveolar polycarbonate sheets with 50% light transmission and 13 dB noise reduction in 10% of the roof surface, with the aim of significantly increasing the entrance of natural light but minimizing the entry of Heat. This type of film is Opal ("white"), which blurs the light it receives from the sun.
To ensure the protection of the machinery and the production process against the weather (dust, rain, wind), a protocol for uninstallation and synchronized installation was launched.
This requires highly trained personnel able to remove a small piece of old roof and quickly remove it from circulation, while another crew immediately proceeds to suck the dust from the perlings and the insulator, leaving the area clean without dropping anything Inside the plant.
As the cleaning crew moves forward, another gang paints with fast-dry paint, and a third group is in charge of accommodating and uploading the total lock blade to be installed. This way, when the painters ' gang finishes that small area, the roofing material is ready. Only a small open section is maintained that allows the entrance of sunlight, without putting the plant at risk or exposing it to the possibility of rain and getting wet inside. In addition to the above, schedules and activities were coordinated in the production plant in order not to hinder the company's own work.
In any building the leaks represent an inconvenience, however, in a food production plant the problem acquires a dimension of potential disaster. If the pasta drops, either because of leaks in the ceiling or the phenomenon of internal condensation, is spoiled and jeopardizes the competitiveness of the business. This threat was completely eliminated, bringing peace and security to the management and operational team of pasta Roma.
Maintenance work resulted in a painted, corrosion-free structure. After the installation of the polycarbonate sheets (skylights) increased the entrance of natural light, thus obtaining a better environment for the workers of the company. They were also solved the challenges of waterproofing in independent structures and the plant was protected against any threat of plague.
Thanks to teamwork and coordination with the company, specifically with the head of operations and the head of maintenance, the plant was kept taking the established quotas of production, meeting the standards demanded by the food industry and without Be interrupted.
Type of Project
1860 Square meters
Continuous blades Total Lock Composite 50, Panel type
38 mm Polyurethane Insulator
8 mm Polycarbonate Skylights
Hojalatería (gutters and everything, ridges, canoes)