The exterior utilizes Kingspan KS Shadowline wall panels, which are designed to offer some of the highest R-value for controlled environment and cold storage needs. The panels meet USDA guidelines and the standard finish is White Siliconized Modified Polyester, which makes it an ideal choice for food processing environments.
The interior of facility uses Kingspan’s KS Shadowline Interior panels, which are a popular interior option. This line was created to be economical, energy-efficient and durable, and is popular in food processing, food packaging, cold storage and food science laboratories.
Award-winning sustainable dairy processing plant built with insulated metal panels.
The sustainability efforts incorporated into the new state-of-the-art DFA plant led to Food Engineering magazine naming it the "Sustainable Plant of the Year."
The state-of-the-art facility, designed and built by Shambaugh & Son, utilizes more than 344,000 square feet of Kingspan insulated metal panels.
Both internal and external panels are GREENGUARD Gold certified, so they have third-party verification that verifies they are not harmful to building occupants and do not adversely impact indoor environment quality.
Sustainability was a priority in designing the facility, with a focus on reducing, reusing and recycling wherever possible. First is its location – the proximity to local farmers reduces the miles and time that trucks spend on the road, as well as conserving fuel and other resources. The plant’s wastewater treatment facility was designed to utilize all the water extracted from the milk during processing, so it can be used to clean tanks as well as by the city as a non-potable water source.
Kingspan insulated metal panels (IMPs) contribute to the mission of sustainability by reducing thermal bridging by providing continuous insulation, which helps curb energy consumption by dramatically reducing heating or cooling loss. Kingspan IMPs can be used as walls and/or ceilings, and their high R-value is especially important in cold storage and food processing facilities like the Dairy Farmers of America (DFA) plant. IMPs also serve as both an air and water vapor barrier, so they replace multiple products in a building.
Insulated metal panels are intended for a 30-40 year lifespan and designed for reuse after that. Kingspan panels are 17 percent recycled (by weight) pre-consumer, and 14 percent recycled post-consumer. The steel is always recycled, and the foam can be repurposed, both pre- and post-consumer.
The sustainability efforts incorporated into the new state-of-the-art DFA plant led to Food Engineering magazine naming it the Sustainable Plant of the Year.
In addition to sustainability, speed was also a factor in designing the plant. Crews can now unload a tanker truck, clean it, test the milk and send the truck back out – all in just over an hour.