Case Study: Scaling Air Filter Service for a Large Food Manufacturing Facility
Client:
1440 Foods Manufacturing
Industry:
Protein powders, energy bars, and related nutritional products
Facility Size:
Approximately 250,000 square feet
HVAC Profile:
More than 200 rooftop units plus multiple hanging units inside the facility
The high output environment requires strict air quality control. With sensitive food manufacturing, filtration efficiency and consistency directly support product quality and compliance standards.
Initial Scope
The partnership began with a narrow service focus: quarterly rooftop filter replacement for more than 200 units. The primary goal at that stage was to reduce the burden on the internal maintenance team and ensure accurate, reliable filter changes.
Expanded Requirements
As production grew and air quality expectations increased, the facility needed more advanced filtration. This led to several key expansions:
- Upgrade to MERV 15 high efficiency filters for enhanced air quality
- Addition of interior filter service for hanging units (requiring lifts for access)
- Planning for future dust collection filter service as production lines expand
These upgrades demanded more frequent and consistent filter changes to support both cleanliness standards and continuous operation.
Maintenance Schedule Improvement
What began as a quarterly filter change evolved into a weekly service performed every Saturday while production is paused. This eliminates disruption during operating hours, keeps airflow consistent, and ensures the facility remains aligned with strict manufacturing requirements.
Process and Efficiency Gains
Precise Air Filter introduced several procedures that reduced labor strain on the client and improved overall maintenance efficiency:
- Filters are roped up to the roof in bulk, often 50 boxes at a time
- Technicians work through all units with complete documentation and proper safety process
- Preventative maintenance tasks are built directly into each visit
- The maintenance department no longer diverts staff to repetitive filter work
This allows the facility’s internal maintenance team to stay focused on higher value priorities such as equipment uptime, repairs, and production support.
Results and Impact
- Reliable weekly filter replacement that supports sensitive food production
- Reduced internal labor cost, since maintenance staff no longer handles large volume filter tasks
- Accurate sizing and efficient installation prevent wasted materials
- Improved air quality due to the move to MERV 15 high efficiency filters
- A scalable process that can support additional units, dust collection systems, and further expansion
The partnership transformed what was once a large, labor heavy task into a predictable, efficient maintenance process that supports both air quality and operational continuity.
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