# Brewery Washdown Retrofit Example for Sanitary Plants | Maes > See a brewery washdown retrofit example with NSF, IP69K, and vapor-tight lighting selection guidance for sanitation, uptime, documentation, and approval. Canonical page: https://maeslighting.com/brewery-washdown-retrofit-example Specification guide # Brewery Washdown Retrofit Example for Sanitary Plants See a brewery washdown retrofit example with NSF, IP69K, and vapor-tight lighting selection guidance for sanitation, uptime, documentation, and approval. A brewery washdown retrofit example is rarely about replacing a few failed fixtures. It is usually a correction to an installation that was never fully matched to the sanitation program: fixtures with dirt-catching seams over packaging, housings that cloud after chemical exposure, or drivers that fail after repeated hot-water washdowns. In brewing, lighting has to support safe production while surviving the same moisture, foam, caustics, acids, temperature swings, and mechanical cleaning that affect the rest of the facility. For facilities planning a similar upgrade, review Maes Lighting's food processing lighting options with the actual washdown procedure, room layout, and sanitation chemicals in hand. A fixture review before purchase can identify whether NSF construction, IP66 protection, IP69K resistance, corrosion-resistant materials, or hazardous-location ratings are needed in each area rather than applying one fixture type across the entire brewery. ## A Brewery Washdown Retrofit Example: The Starting Conditions Consider a mid-sized production brewery with a brewhouse, fermentation cellar, bright tank area, kegging line, packaging room, chemical storage room, and cold storage. The facility had a mix of older linear fixtures and general-purpose industrial high bays. Some continued to operate, but the maintenance team was replacing units frequently in the wettest zones. Lens discoloration and failed gaskets had also become common near the keg washer and packaging rinse stations. The original installation created three practical problems. First, fixture surfaces and mounting details were harder to clean than the sanitation team needed. Second, water and cleaning chemicals found their way into fixtures that were not designed for direct spray. Third, inconsistent light levels made it harder for operators to inspect hoses, valves, drains, filler heads, and floor conditions. The project team did not treat the brewery as one uniform environment. That distinction is the foundation of a successful retrofit. A dry warehouse aisle, a humid cellar, and a direct-spray kegging zone may be within the same building, but their lighting requirements are materially different. ## Start With the Washdown Process, Not Fixture Wattage A practical assessment begins by documenting how each space is cleaned. Ask whether fixtures receive incidental moisture, low-pressure rinse water, high-pressure spray, hot-water washdown, foam application, or repeated exposure to caustic and acid chemicals. Also identify whether cleaning crews spray upward toward the ceiling, which is common around tanks, conveyors, and floor drains. IP ratings matter because they describe the enclosure's resistance to ingress. IP66 fixtures are commonly appropriate where powerful water jets and heavy moisture are expected. IP69K is a more demanding rating used for equipment exposed to close-range, high-pressure, high-temperature washdown. Neither rating, by itself, confirms that a fixture is suitable for every sanitation application. Material selection, gasket design, lens construction, cable entries, mounting hardware, and chemical compatibility still deserve review. For food and beverage areas, NSF-rated construction can also be relevant. Buyers should verify the specific NSF listing and intended use rather than assuming all NSF references mean the same thing. NSF/ANSI 2 is associated with food equipment materials and cleanability in food zones, while NSF/ANSI 51 addresses materials used in food equipment. The right requirement depends on where the fixture is installed and the facility's sanitation and specification standards. ## The Retrofit Layout: Match Protection to Each Zone In this brewery washdown retrofit example, the team divided the site into lighting zones and specified accordingly. The brewhouse and cellar received sealed, corrosion-resistant vapor-tight fixtures in locations with persistent humidity, condensation, and occasional spray. Fixtures were mounted to reduce shadowing around vessels while keeping enough clearance for cleaning access. The goal was not simply higher output. It was consistent illumination on catwalks, valve clusters, transfer connections, and process controls without creating difficult-to-clean overhead geometry. At the kegging line and rinse station, the specification moved to NSF-rated, IP69K-capable washdown fixtures. These areas saw regular direct spray, chemical residue, and frequent temperature changes. A smooth external housing and sealed lens assembly reduced places where soils could collect, while the higher ingress rating addressed the actual cleaning exposure. In the packaging room, fixture selection balanced sanitation with visual performance. Operators needed clear light for label inspection, fill-level checks, changeovers, and housekeeping. Higher-output vapor-tight or sanitary high-bay fixtures can be appropriate when mounting heights increase, but photometric layout remains necessary. Adding more wattage without considering aisle width, equipment shadows, and mounting height can produce glare and uneven coverage. Cold storage was treated separately because condensation, low ambient temperatures, and door-cycle moisture can affect drivers, seals, and lens performance. Fixtures selected for the space needed an ambient rating suitable for the operating temperature and a housing capable of handling moisture exposure at the cold-room boundary. ## When Hazardous-Location Lighting Enters the Scope Most brewery washdown areas are not automatically hazardous locations. However, the chemical storage room, ethanol handling areas, grain handling equipment, or certain process locations may require a formal hazardous-area evaluation. That decision must be based on the materials present, how they are handled, ventilation, and the site's electrical classification - not on a general assumption that a brewery is either hazardous or nonhazardous. For classified areas, the electrical engineer or authority having jurisdiction should determine whether the area falls under the NEC Class/Division system or an applicable Zone classification. Class I Division 1 and Class I Division 2 address flammable gases or vapors under different likelihood-of-presence conditions. Grain dust can introduce a separate combustible-dust consideration. The fixture must carry markings that match the required class, division or zone, gas group, temperature code, and ambient conditions. If the project includes domestic-preference requirements, document them early. The Explosion Proof IR1, IR3, IR4, and IR7 series are covered under the Buy America Act, as are CIT models in the vapor-tight product range. Procurement teams should still confirm the applicable project requirement, product configuration, and supporting documentation during submittal, since Buy America Act requirements can vary by funding source and contract language. ## Design Details That Prevent Repeat Failures The most common mistake in harsh-area retrofits is specifying by marketing label alone. “Washdown rated” is not a complete design basis. The project team should verify the fixture's IP rating, NSF status where required, corrosion resistance, operating ambient range, electrical classification where applicable, mounting method, cord or conduit entry, and warranty terms. Mounting is especially consequential. A technically suitable fixture can still fail early if its junction box, conduit seals, flexible cord, or mounting bracket is exposed to washdown in a way the assembly was not designed to handle. Specify stainless hardware where corrosion is a concern, use approved wet-location wiring methods, and avoid mounting positions that trap water or allow residue to build up on top of the fixture. Maintenance access also needs to be part of the layout. Fixtures should be reachable without placing technicians over tanks, conveyors, or sanitation equipment. Longer service life is valuable, but a plant still needs a safe plan for inspection, cleaning, and eventual driver replacement. ## What Are the Best High Temperature Lights for Industrial Use? What are the best high temperature lights for industrial use? The answer is not a single fixture family. The best choice is one rated for the actual maximum ambient temperature at the mounting location, with expected thermal conditions verified during operation. In a brewery, elevated temperatures near a brewhouse ceiling, steam lines, or heat-producing equipment may exceed the room's reported ambient temperature. LED fixtures are sensitive to heat because elevated temperature affects driver and LED component life. A fixture that performs well at 104 degrees F may require derating or may not be suitable at a substantially hotter mounting point. For high-temperature applications such as kilns, furnaces, and steel mills, specialized high-temperature luminaires are generally required. In a brewery, the lesson is simpler: measure the real temperature at the fixture location before relying on a standard sanitary or vapor-tight product. ## Documentation Makes the Retrofit Easier to Approve A well-prepared lighting submittal helps maintenance, engineering, procurement, and inspectors work from the same information. For this type of project, retain datasheets, NSF documentation where specified, IP ratings, hazardous-location certificates where required, photometric files, mounting details, and Buy America Act support for qualifying products. The finished retrofit should make sanitation easier, not add a new cleaning concern. When the fixtures are selected around actual washdown exposure and installed as a complete system, the result is safer task visibility, fewer premature replacements, and a lighting plan that can keep pace with brewery production rather than becoming another recurring maintenance issue. ## Need a project review? Share the application, operating conditions and required documentation with a lighting specialist. [Request a quote](https://maeslighting.com/contact-us) --- Maes Lighting — nationwide supplier of certified explosion proof, industrial, high-temperature, food-processing, vapor-tight, high-bay, flood, area, and emergency LED lighting. Headquarters: Broken Arrow, Oklahoma. Sales: (866) 860-6399 · tjacobs@maeslighting.com Website: https://maeslighting.com