06.04.2025
Three-Part Approach at Dock Doors Leads to Successful AIB Inspection
Healthcare Products Manufacturer | Industrial & Manufacturing
Problem
A healthcare products manufacturer was experiencing a significant problem with pests entering their facility. While unloading, the bugs got in through the underside of the dock levelers. During spring and summer, the facility would leave their dock doors open, which allowed the pests to enter. After receiving a fine following their American Institute of Baking (AIB) regulatory inspection, and to ensure compliance before their next survey, every opening needed to be sealed and updated per AIB requirements.
AIB inspections check for adherence to guidelines designed to keep products free from outside pollutants, bugs, etc. They can also provide insight into potential issues that could be found during a Food and Drug Administration (FDA) inspection, causing greater urgency for the manufacturer to rectify the pest situation quickly.
Solution
DH Pace provided a single-source solution to supply the doors and dock equipment for each dock position as well as a multi-step approach to keep the pests out of their facility. The Company replaced the facility’s existing dock doors with rolling steel doors with vision slats to allow natural light into the facility when keeping the doors closed. Low-profile air curtains were installed above each dock opening to create an additional barrier to entry for pests during loading and unloading when the doors are open and the dock levelers are in use.
As a third line of defense, DH Pace recommended adding bug screens to the dock openings along with the door and dock equipment upgrades. Automatic bug screens were installed in the rolling steel door jambs so the rolling steel doors can be left open to allow more airflow, as the manufacturer normally did during spring and summer, without allowing pests to enter.
In order to fit the rolling steel doors, air curtains, and bug screens on each opening, DH Pace designed a custom configuration. While the openings and old doors were 8’ wide x 10’ high, with the additional equipment at the opening, the original size doors wouldn’t create a seal at the bottom. The Company installed 8’ wide x 12’ high doors to allow the air curtains to clear the door openings. The extra height of the doors meant they could get past the air curtains and still create a seal on the floor. Straight brush was added to the headers to seal the openings. To preserve energy, the air curtains shut down automatically when the bug screens are down.
DH Pace also outfitted each dock position with updated dock equipment including automatic, non-impact RIG/ICC bar truck restraints, dock seals, adjustable LED dock lights, and weather guards to prevent precipitation from rolling off the top of the trailer and onto the manufacturer’s materials or finished products. Digital master control panels interlock the doors, levelers, restraints, and air curtains together to operate in order at each opening. This not only increases energy efficiency by turning off the air curtains when the bug screens or doors are closed but also increases safety by ensuring trucks don’t pull away from the dock early.
Finally, DH Pace installed a custom 6’ wide x 8’ high hollow metal double door with upgraded hardware at the facility’s pedestrian entrance. The Company also reused the manufacturer’s existing maglocks and security systems to avoid unnecessary expense. To combat pests entering through this doorway as people enter and exit, an air curtain was installed above each door leaf.
The result is a more secure and energy-efficient facility for the manufacturer and a safer, more comfortable environment for employees working around the dock. Furthermore, the manufacturer passed their next AIB inspection without issues. They are very pleased with the new doors and equipment and have since approved additional projects with DH Pace.
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