Executive Summary

Written by Paul Richardson, Technical Sales Manager at Rubber Strip UK with 18+ years experience in food-industry sealing solutions.

A major ready-meal producer in Lincolnshire required a complete seal replacement across their high-care production area ahead of their BRC audit. The existing seals showed compression set and discolouration after 6 years of intensive washdown cleaning. They needed food-grade, FDA-compliant materials that could withstand daily high-temperature sanitisation while maintaining a hygienic, inspectable seal.

Key Results: 500m of white FDA-compliant EPDM sealing strip installed across 85 access panels in one weekend, zero audit non-conformances on sealing, BRC AA rating achieved, estimated 4-year replacement cycle established.

Access panel doors with new white EPDM hygiene sealing strip installed

Project Background

The facility processes chilled ready meals for major UK supermarkets, operating 24/6 with overnight deep-cleaning. The high-care area contains 85 equipment enclosures with access doors, all requiring effective seals to prevent contamination ingress during production and maintain cleanability during washdown.

The existing black rubber seals, while functional, had developed compression set (permanent deformation) reducing their effectiveness. Additionally, black seals make contamination detection difficult during visual inspections—a growing concern for BRC auditors.

Client Requirements

Our Solution

We specified our food-grade white EPDM self-adhesive sealing strip with closed-cell sponge bulb profile. The white colour aids visual inspection, while the closed-cell structure prevents moisture absorption—critical in washdown environments where trapped water can harbour bacteria.

Installation in progress - self-adhesive EPDM strip being applied to panel frame

Product Specification

Specification	Detail
Material	EPDM Rubber, 45 Shore A durometer
Profile	15mm base x 10mm bulb, self-adhesive
Colour	White (RAL 9010 equivalent)
Temperature Range	-40°C to +120°C (intermittent)
Compliance	FDA 21 CFR 177.2600, EU 1935/2004
Adhesive	Acrylic pressure-sensitive, food-safe
Quantity	500m in 25m rolls
Certification	Material certificates provided

Installation

The facility's in-house maintenance team completed the installation over a planned weekend shutdown. Surface preparation was critical—all panel frames were cleaned with isopropyl alcohol to ensure maximum adhesive bond.

Close-up showing seal compression when panel is closed - complete contact visible

Phase	Activity	Panels
Saturday AM	Surface prep, remove old seals	All 85
Saturday PM	Install new seals - Zone 1	45
Sunday AM	Install new seals - Zone 2	40
Sunday PM	Quality check, compression test	All 85

Results

BRC Audit Outcome

• ✓ Zero non-conformances on sealing or enclosure integrity
• ✓ AA rating achieved (highest unannounced grade)
• ✓ Auditor commendation on visual inspection clarity
• ✓ Complete material certification on file

Operational Benefits

• Contamination visibility: White seals make debris instantly visible
• Washdown performance: No water ingress during 85°C cleaning
• Consistent compression: New seals maintain 30% compression
• Maintenance schedule: 4-year replacement cycle established

Cost Analysis

Item	Detail	Cost
White EPDM Seal Strip	500m @ £3.20/m	£1,600
Trade Discount	15% volume discount	-£240
Delivery	Free (order over £100)	£0
Total Material Cost		£1,360

Cost per panel: £16 (material only, 6m average per panel)
Projected lifespan: 4 years = £4 per panel per year

Frequently Asked Questions

What rubber is safe for food processing environments?

FDA-compliant EPDM and silicone rubber are the standard choices for food processing applications. They resist high-temperature washdown cycles, are non-toxic when in contact with food, and don't harbour bacteria in surface pores. White or blue materials are preferred as they aid visual contamination detection during inspections. Material certificates should confirm FDA 21 CFR 177.2600 compliance.

How often should food factory door seals be replaced?

Food factory seals should be inspected monthly and replaced when showing signs of wear, compression set, cracking, or damage. Typical lifespan is 2-5 years depending on usage intensity and cleaning regime. High-temperature washdown and aggressive sanitising chemicals accelerate material degradation. Plan for annual replacement of high-wear seals in critical areas.

Can EPDM rubber withstand high-pressure washdown?

Yes, EPDM rubber is ideal for washdown environments. It resists hot water up to 120°C (intermittent), steam sterilisation, and common food-industry sanitisers including hypochlorite and quaternary ammonium compounds. The material maintains its sealing properties even after repeated thermal cycling. Ensure seals are properly fitted to prevent water ingress during cleaning operations.

What durometer rubber is best for door seals?

For access door seals, 40-60 Shore A durometer is typical. Softer rubber (40 Shore A) provides excellent sealing with light closing force but wears faster under intensive use. Harder rubber (60 Shore A) offers greater durability but requires more closing force. 45-50 Shore A represents the optimal compromise for most food industry applications.

Is self-adhesive rubber seal suitable for food environments?

Self-adhesive seals are suitable for food environments if the adhesive system is also food-safe certified. Check the adhesive specification separately from the rubber substrate. For critical applications where product contact is possible, mechanically-fixed seals with food-grade stainless steel fasteners may be preferred to eliminate any adhesive migration concerns.

Last updated: March 2026. This case study represents a real project supplied by Rubber Strip UK.