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“They were always there for us and have never failed us once.”
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CUSTOMER
Koch Foods is one of the largest poultry processors in the United States. The company required a roofing partner that was responsive, reliable, and able to perform consistently high-quality work while adhering to strict safety standards.
After experiencing major issues with a previous roofing contractor, Koch Foods turned to EC Malone Roofing for support. The priority was clear: protect the facility, avoid operational interruptions, and meet the heightened safety expectations required in food processing environments.
Mohamed Basma, a Project Engineer with more than 35 years of industry experience, oversees facilities across Alabama, Mississippi, and parts of Georgia. He joined Koch Foods over seven years ago—around the same time he was introduced to Malone Roofing.
After relocating to Central Mississippi for a new role, Mohamed needed a dependable local commercial roofer. He and the Koch Foods team found that Malone’s professionalism, safety practices, and technical expertise made them a strong long-term partner.
CHALLENGES
Responsiveness has been critical for Koch Foods, especially during emergencies. On one occasion, a fire damaged part of a Koch Foods facility. Mohamed immediately contacted Roman Malone, requesting same-day emergency support.
Malone Roofing dispatched a crew that arrived later that night to repair the fire-damaged areas and restore watertight conditions. That rapid response reinforced Koch Foods’ confidence and led to Malone being selected for future reroofing projects.
Food processing facilities demand a higher level of contractor performance. Safety, cleanliness, and workmanship standards exceed those of many other building types. Roofers must accurately diagnose and repair leaks, address ponding water, and navigate complex rooftop systems such as refrigeration piping and specialized equipment.
Equally important was ensuring that roofing work never disrupted daily operations. Malone Roofing shared this priority and consistently exceeded required standards to protect both employees and facility operations.
PROCESS
EC Malone Roofing approached each project with clear communication, professionalism, and technical expertise. The team worked closely with Koch Foods to ensure all roofing work was completed with minimal disruption.
Over the years, Malone has provided emergency services, roof repairs, preventative maintenance, and full roof replacements. Regardless of project complexity, Koch Foods’ primary requirement remained the same: zero interruptions to daily operations.
That standard was upheld consistently across both field crews and office teams. The partnership evolved into a collaborative working relationship, with Malone Roofing viewed as an extension of the Koch Foods team.
RESULTS
More than seven years later, the partnership remains strong. Malone Roofing has handled roof repairs, maintenance, leak investigations, replacements, and emergency responses across multiple facilities.
In April 2019, a tornado struck Morton, Mississippi, causing severe damage to the Koch Foods Chicken Plant. Koch Foods immediately contacted Malone Roofing, and a crew of 15 roofers was dispatched to the site.
Upon arrival, the team encountered extensive damage, including displaced rooftop units, torn structural decking, membrane punctures, and large roof openings. Within approximately six hours, temporary emergency repairs were completed, restoring watertight conditions.
DISASTER RECOVERY & ROOF REPLACEMENT
Following emergency stabilization, Malone Roofing assisted Koch Foods with navigating the insurance claims process. A comprehensive roof assessment identified damage across 12 roof sections. Koch Foods prioritized repairs on the four most severely impacted areas.
Once temporary repairs and insurance approvals were completed, Malone mobilized labor and materials. Modified bitumen roofing was installed in certain sections, while TPO systems were selected for blast and freezer areas.
Due to wind-damaged decking, trip hazards, and hot-work requirements, crews operated with extreme caution and near-continuous tie-off throughout the project.
In total, more than 10,000 square feet of structural metal decking and 25,000 square feet of roofing were replaced. Work was completed while navigating a congested rooftop filled with penetrations, HVAC units, and exhaust systems.
COMPLEX CONDITIONS, PROVEN RESULTS
Further challenges arose in the blast and freezer areas. Core cuts revealed a 16-inch-thick roofing assembly consisting of multiple saturated systems with no slope, leading to severe drainage issues.
The old roofing systems were fully removed and replaced with a new TPO roof and tapered ISO insulation. Due to limited access and numerous curbs and penetrations, progress averaged 200–300 square feet per day.
Despite the complexity, Malone Roofing maintained watertight conditions throughout the project. Substantial completion was achieved in July 2020.
LONG-TERM PARTNERSHIP
According to Mohamed Basma, the reason Koch Foods continues to work with Malone Roofing is reliability. The team consistently delivers high-quality work, maintains strong communication, and upholds rigorous safety standards.
Malone Roofing is viewed as a trusted partner and an integral part of the Koch Foods team. Based on years of positive experience, Mohamed has stated he would recommend and hire Malone Roofing again without hesitation.