FOOD PRODUCTION Case-study
Improving Efficiency, Hygiene & Output Through Advanced Coating Solutions
Engineering Performance Into Food Production
In high-volume food manufacturing, small inefficiencies quickly scale into major operational costs. Product build-up, excessive cleaning, inconsistent release, and premature equipment wear are often accepted as “part of the process.”
Marcote challenges that assumption.
Through applying engineered coating systems tailored to specific food applications, manufacturers can significantly improve uptime, product quality, and total cost of ownership, without replacing core equipment.
THE CHALLENGE
When Sticking, Wear & Cleaning Limit Production
Across bakery, confectionery, protein processing and packaging environments, manufacturers face common issues:
- Product adhesion causing inconsistent output and waste
- Frequent cleaning cycles reducing uptime
- Premature coating failure due to abrasion or aggressive washdowns
- Increasing reliance on release agents (cost + inconsistency)
- Equipment degradation leading to early OEM replacement
- Throughput
- Yield
- Product quality
- Operational efficiency
THE REQUIREMENT
A Coating System Designed for Process Conditions
(Not Assumptions)
Selecting the right coating is not just about “non-stick.”
It requires:
Product stickiness (e.g. sugar vs protein) Cleaning regime (light vs aggressive chemical washdown) Temperature exposure Mechanical wear Application type (surface, belt, tubing, etc.)
OUR APPROACH
Structured Technical Investigation
Every project follows a proven methodology:
Coating System Analysis
Understanding failure points in current coatings.
Material Identification
Matching coating chemistry to product and process conditions.
Performance Benchmarking
Testing durability, release performance, and lifecycle expectations.
Technical Evidence & Documentation
Delivering a coating solution backed by real-world performance data.
CASE STUDY
Improving Efficiency in Sugar Packaging
Application
Multihead Weighing & Bagging System (Granulated Sugar)
THE CHALLENGE
A manufacturer operating high-speed sugar bagging lines experienced:
- Severe product build-up on weighing equipment
- Inconsistent pack weights
- Frequent unplanned cleaning stoppages
- Coating lifespan limited to ~4 months due to sugar abrasion
- Reduced throughput
- Increased downtime
- Variability in product quality
THE MARCOTE SOLUTION
Following a 12-month R&D programme, Marcote developed a bespoke non-stick coating system tailored to sugar handling.
- Enhanced release for fine sugar particles
- Improved abrasion resistance
- Stable performance under continuous production
THE OUTCOMES
Coating lifespan increased from 4 months to 18–24 months
Planned 12-month recoating cycle implemented
Eliminated unexpected cleaning stoppages
Improved weighing accuracy and product consistency
Increased throughput and operational efficiency
Commercial impact
By shifting to a planned coating strategy, the customer achieved higher output,
improved product consistency, and reduced total cost of ownership, while eliminating
costly unplanned downtime.
Key insight: In high-stick, high-abrasion environments like sugar handling,
durability is just as critical as non-stick performance, and Marcote delivers both.
COATING SYSTEMS FOR FOOD APPLICATIONS
Overview of Coating Types
PTFE
Excellent abrasion resistance, strong non-stick performance, and low friction properties.
Best for: High-release applications such as bakery and confectionery where clean product release is critical.
PFA
Enhanced chemical resistance with improved durability under continuous use.
Best for: Aggressive cleaning environments and 24/7 production where coating longevity is essential.
FEP
Highly flexible material with strong non-stick properties and smooth surface finish.
Best for: Films, conveyor belts, and tubing where flexibility and flow are key.
Sol-Gel (PFAS-free)
Exceptional temperature and abrasion resistance with a PFAS-free formulation.
Best for: High-temperature environments or where PFAS-free compliance is required.
Performance Comparison
| Property | PTFE | PFA | FEP | Sol-Gel |
|---|---|---|---|---|
| Non-stick | ★★★★☆ | ★★★★★ | ★★★★☆ | ★★☆☆☆ |
| Abrasion Resistance | ★★★★☆ | ★★★☆☆ | ★★★☆☆ | ★★★★★ |
| Temperature | ★★★★★ | ★★★★★ | ★★★☆☆ | ★★★★★ |
| Chemical Resistance | ★★★★★ | ★★★★★ | ★★★★☆ | ★★★☆☆ |
| Hygiene (Long-term) | ★★★★☆ | ★★★★★ | ★★★★☆ | ★★★☆☆ |
Application Insight by Sector
Bakery
“PTFE for release, PFA for longevity”
- Bread tins, trays, conveyor belts
- Key benefit: clean release + reduced oiling
- PFA used in high-output lines for durability
Confectionery
“PTFE for extreme non-stick performance”
- Moulds, enrobing lines, sugar handling
- Prevents burn-on and product deformation
- Critical for visual product quality
Protein Processing
“PFA for durability in harsh environments”
- Conveyors, forming plates, tumblers
- Handles aggressive washdowns and corrosive conditions
Food Processing & Packaging
“Flow, accuracy and uptime optimisation”
- Multihead weighers, hoppers, dosing systems
- Focus on eliminating build-up and improving consistency
WHAT THIS DEMONSTRATES
Beyond coating application, this project demonstrates:
- Increased production uptime
- Reduced cleaning and maintenance
- Improved product quality and consistency
- Extended equipment life
- Lower total operating costs
ISO 9001 Certified
Looking to improve performance in your food production process?
Marcote can assess your current coating performance and identify opportunities to improve efficiency, hygiene, equipment lifespan, and overall output.
Get in touch