Addressing Resin Buildup Challenges in an Epoxy Factory with MINERAL ARMOR

​​Background

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A manufacturing facility located in the Midwest, specializes in producing high-quality epoxy resins for industrial, commercial, and residential applications. Over years of operation, the company faced a persistent and costly challenge: the buildup of cured epoxy resin on its concrete floors. This buildup stemmed from inevitable spills, drips, and splatter during the mixing, pouring, and packaging processes. The resin, once cured, adhered tightly to the floors, creating a sticky, uneven surface that was difficult to clean, posed safety hazards, and diminished the facility’s overall efficiency.

 

The Challenge

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The resin buildup presented several operational and maintenance issues:

 

1.Adhesion and Cleaning Difficulty: Cured epoxy resin bonded strongly to the concrete floors, requiring aggressive mechanical scraping or chemical solvents to remove. These methods were time-consuming, labor-intensive, and often damaged the underlying concrete.

 

2.Safety Concerns: Uneven surfaces and sticky patches increased the risk of slips, trips, and falls for workers, particularly in high-traffic areas near mixing stations and conveyor lines.

 

3.Downtime and Costs: Cleaning efforts required production halts, leading to significant downtime. Additionally, the recurring expense of labor, equipment, and harsh cleaning chemicals strained the facility’s maintenance budget.

 

4.Aesthetic and Functional Decline: The floors became discolored and patchy, affecting the facility’s professional appearance and complicating efforts to maintain a clean, dust-free environment critical for epoxy production.

 

The company management sought a long-term solution that would not only address the existing buildup but also prevent future adhesion of resin spills, making floors easier to clean and maintain without interrupting production.

 

The Solution: MINERAL ARMOR After researching various flooring solutions, the company partnered with MINERAL ARMOR, a company offering a revolutionary ceramic floor coating designed to create a durable, protective shield on solid surfaces. Unlike traditional epoxy or wax-based coatings, MINERAL ARMOR’s silicate-based formula promised a non-film-forming, breathable layer that resists scuffing, staining, and adhesion of contaminants—ideal for combating the sticky resin buildup plaguing the factory.

 

The implementation process unfolded in three key phases

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1.Initial Deep Cleaning and Preparation: MINERAL ARMOR technicians using industrial burnishing machines and eco-friendly cleaning agents, they restored the concrete to a smooth, bare state.

 

2.Application of MINERAL ARMOR PROTECTOR: The MINERAL ARMOR PROTECTOR was applied across the entire production floor using a combination of spraying and rolling techniques. The silicate solution penetrated the concrete, forming a hard, durable shield. The application was completed during a scheduled weekend shutdown to minimize disruption.

 

3.Maintenance Plan with MINERAL ARMOR REJUVENATOR: To sustain the coating’s effectiveness, The company adopted a maintenance plan involving regular cleaning MINERAL ARMOR REJUVENATOR. This product reinforced the protective layer and maintained the floor’s alkalinity, further inhibiting resin adhesion.Results

 

The application of MINERAL ARMOR yielded transformative outcomes for the company:1.Reduced Resin Adhesion: The ceramic coating created a glass-like, resistant surface that prevented cured epoxy resin from bonding tightly.

 

.2.Improved Cleaning Efficiency: Routine deep cleaning, previously a multi-day ordeal, was reduced to a few hours. The floors’ smooth, non-stick surface allowed for quick restoration to a pristine state, even after significant spills.

 

3.Enhanced Safety and Appearance: The coated floors, polished to a high-gloss finish, eliminated sticky patches and uneven areas.The uniform, clean look also elevated the facility’s professional image during client tours.

 

4.Cost Savings and Reduced Downtime: Maintenance costs dropped due to decreased labor and chemical usage.

 

Conclusion: MINERAL ARMOR proved to be a game-changer in tackling the persistent challenge of resin buildup on its factory floors. The ceramic floor coating not only resolved immediate cleaning and safety issues but also introduced a sustainable, low-maintenance solution that aligned with the facility’s operational goals. By creating a protective shield that resisted resin adhesion, MINERAL ARMOR enabled the company to streamline maintenance, enhance worker safety, and improve productivity—all while preserving the integrity of its production environment. This case underscores the potential of innovative coating technologies to address industry-specific challenges, offering a model for other manufacturing facilities facing similar issues.