Modular buildings for the food industry: why are they an ideal solution?
What are modular buildings for the food industry?
Modular buildings in the food industry are prefabricated metal structures with a tensioned membrane roof that can be assembled in just a few weeks. They are made up of different structural modules that are manufactured in advance and installed on site.
Unlike buildings used in other sectors, modular buildings for the food industry are designed to comply with food safety and control regulations.
In the food industry, these buildings are used both to store and to handle, produce and distribute food products.
Characteristics of a modular building for the food industry
ue to these high food safety standards, this type of modular building features several specific characteristics:
- Manufacturing with materials suitable for food use: smooth, non-porous and easy-to-clean surfaces
- Functional layout to prevent cross-contamination
- Integrated control of temperature, humidity and ventilation
- Zoning of spaces according to the production process
In addition, it shares many other characteristics with modular buildings used in other sectors, such as the ability to adapt to current production needs and a strong, durable structure.
What requirements must a modular building for the food industry meet?
When working with products for human consumption, modular buildings for the food industry must comply with current technical and sanitary regulations.
Food safety and hygiene regulations
The most important requirement that a modular building for the food industry must meet is compliance with food safety and hygiene regulations, as this ensures that food is handled under safe conditions and without risk to the consumer.
At the European level, the main reference is Regulation (EC) 852/2004, which establishes the following hygiene conditions:
- Allow effective cleaning and disinfection: Waterproof and easy-to-clean materials must be used for floors, walls, and surfaces in contact with food.
- Ensure proper ventilation: In order to prevent humidity or airborne contaminants.
- Separate the different stages of production: Through layout design, to avoid unwanted contamination, spaces must be divided according to the activity carried out.
In short, a modular building intended for the food industry must be designed from the outset with regulatory compliance in mind.
Suitable materials: cleaning, impermeability and safety
The choice of materials is a critical aspect. In modular buildings for the food industry, surfaces must be smooth and resistant to moisture.
or walls and enclosures, one of the most commonly used materials is sandwich panels with a sanitary finish. In areas with higher hygiene requirements, such as direct handling zones, the use of stainless steel is recommended. This material stands out for its high corrosion resistance, ease of cleaning, and compliance with sanitary regulations.
Did you know… At Okatent, we work with 100% recyclable aluminium?
Key advantages of modular buildings in the food industry
The use of modular buildings in the food industry offers several advantages compared to conventional buildings. This is why they are becoming the ideal option for companies looking for:
- Fast solution: their installation time is much shorter than the construction of a conventional building. Considering the entire design and manufacturing process, we are talking about 1 to 3 months in total, of which only 1 to 4 weeks correspond to installation.
- More cost-effective options: as they do not require major construction work and reduce timelines, costs can be significantly lower.
- Flexibility: they are structures that can be easily adapted for expansions, reductions, or relocation.
In addition, they also stand out for their ability to adapt to the specific requirements of the industry. A modular building for the food industry often requires the combination of several different areas. At Okatent, we custom-manufacture each part of the structure, adapting it to the specific needs of each project.
In this type of building, cold storage areas, handling zones, storage spaces, and offices are often required. With modular solutions, we can fully adjust the layout. For example, we work with OKCAS® roofing systems or sandwich panel walls with rock wool to improve thermal insulation and help maintain cold conditions.
If you want to explore this type of solution further, you can discover many other advantages of investing in prefabricated buildings in this article.
Applications of modular buildings in the food industry
Modular buildings in the food industry stand out for their high versatility. As we have seen, they can be adapted to different stages of the production process, as well as to various types of activities within the sector.
- Food storage facilities: Where everything from raw materials to finished products can be stored. Modular buildings offer high insulation capacity, allowing food to be preserved under the right conditions.
- Processing and production areas: Used to carry out handling or packaging tasks for food products.
- Cold storage or temperature-controlled spaces: Especially in sectors such as meat, dairy, or fruit and vegetables, modular buildings for the food industry allow the integration of refrigeration systems, ensuring optimal temperature and humidity conditions are maintained.
- Distribution centres: In these cases, the goal is to facilitate inbound and outbound flows to prioritise operational efficiency.
- Temporary facilities: For capacity expansions, companies can quickly respond to specific needs without making large investments in permanent infrastructure.
Key factors when choosing a modular building for the food industry
To choose the right modular building for your food industry activity, you should ensure a series of key factors from the very beginning:
- Fully adapted to your activity: Not all buildings are suitable for every use. It must be designed according to your objective: production, handling, storage, or logistics. Ask for a custom design, not a standard solution.
- Compliant with food regulations from the design stage: Make sure the supplier understands and applies the relevant regulations. This should not be something you need to adapt afterwards.
- Allows full control of temperature and indoor conditions: If required by your activity, the building must be prepared to integrate refrigeration, ventilation, or humidity control from the outset.
- Expandable and flexible for the future: Your building should not only meet your current needs. Ask how it can be expanded, modified, or adapted as your business grows.
- Guarantees realistic installation timelines: Ensure that the installation time for the modular building is realistic and that clear execution deadlines are provided.
H2: Why are modular buildings a strategic solution for food companies?
The food industry is undergoing a period of constant transformation due to the increase in demand, cost pressure, and the need to become more sustainable.
For this reason, modular buildings in the food industry are a strategic solution:
Adapting to demand and production variability
The food sector is highly influenced by seasonality and consumption peaks. This is further compounded by current geopolitical instability, which directly affects supply chains and production forecasting. In this context, modular buildings make it possible to expand or reorganise spaces quickly. This allows companies to adjust their production capacity without the need for major construction work or long-term investments.
Improving energy efficiency and reducing operating costs
Modular buildings can incorporate insulation and climate control solutions that optimise energy consumption. This helps reduce energy costs and improve the sustainability of operations.
Meeting the sector’s sustainability requirements
Sustainability is already a key factor in the food industry. Modular buildings help companies reduce their environmental impact and align with new market demands. At Okatent, we care for the environment by using recyclable materials, eco-solvent printing, and selective waste collection.
Frequently asked questions about modular buildings in the food industry
Can cold storage rooms be installed in a modular building for the food industry?
Yes. Modular buildings are designed to create temperature-controlled areas, both for refrigeration and freezing. They are typically built with sandwich panels with rock wool and OKCAS® roofing systems, which help reduce energy loss by improving thermal insulation.
The project for Danone’s logistics centre in Aldaia (Valencia) was a challenge in terms of insulation. In this case, we manufactured a modular building for the food industry with fire resistance certification to protect hazardous products. Installing a modular building with fire certification EI120 and RF20 was a success.
What maintenance does a modular building for the food industry require?
Unlike other industrial solutions, modular buildings require minimal structural maintenance. In the case of the food industry, maintenance tasks are less related to the structure itself and more to the hygiene standards required by the sector. Therefore, it is necessary to periodically:
- Clean all surfaces. These are usually easy-to-clean surfaces, so the process is quick, but it must be carried out regularly. It is always recommended to avoid corrosive cleaning products and to use water and neutral soap to prevent material damage.
- Check the condition of materials and finishes: occasional inspections to ensure proper performance of the building.
- Maintain climate control systems.
At Okatent, we specialise in the structure of industrial buildings, so we do not usually include elements such as flooring, furniture, or interior equipment, whose maintenance should follow each manufacturer’s guidelines.
Is it necessary to adapt the modular building after installation to comply with regulations?
It should not be necessary. The correct approach is for the building to be designed in compliance with current regulations from the outset. However, modifications may be required if there are changes in food safety regulations or laws. In such cases, modular buildings for the food industry are highly flexible, so changes usually do not require major restructuring or significant investment.
Are modular buildings safe for food handling?
Yes, modular buildings are completely safe for food handling, as long as they are properly designed and planned. They must be built using materials suitable for food use, such as smooth, non-porous, and easy-to-clean surfaces, along with a proper layout to prevent cross-contamination between work areas.
Do modular buildings require major construction work?
As a general rule, no. Modular buildings are based on prefabricated systems that do not require major construction work. In most cases, proper ground preparation and suitable foundations are sufficient to install the structure. However, depending on the project’s characteristics, more or less construction work may be required.
At Okatent, we can help you define the most efficient solution based on your logistical and operational needs.
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