Durable Food Factory Flooring Solutions For Leading Chilled Food Business

Creating the right environment for food preparation starts from the ground up. Selecting the right food factory flooring materials and the correct installation procedures plays a vital role in ensuring that the premises meet the challenging standard set for food manufacturing businesses.

Bolton-based Halal Kitchen is the UK’s leading supplier of Halal chilled food ‘on the go and produces a wide range of sandwiches, wraps and associated products. These include the Express Cuisine brand stocked across the UK in fuel stations, convenience stores and supermarkets.

Seeking to upgrade the flooring in their food preparation and packing areas, Halal Kitchen consulted with resin flooring supplier RFC. The team was requested to make recommendations on the best approach for a long-term solution.

The challenge to ensure durability and performance

Over the past decade, the company has completed a number of floor refurbishment projects. They were looking for a more durable specification to match the manufacturing processes, requiring frequent washdowns and aggressive cleaning procedures.

In addition, flaking floor paint was also creating problems for the drainage systems. Finding a more permanent solution was a matter of urgency to maintain the high standards required.

RFC looked closely at the environment and the processes. They recommended the initial preparation of the concrete substrate to prepare for the installation of a heavy-duty polyurethane floor screed capable of meeting the operational requirements. Specialist applicators Ultrasyntec were commissioned to complete the work.

Safety and longevity

The substrate was extensively cleaned, repaired and abraded to provide a key for the screed. The UltraSyntec team then installed the rake and trowel applied polyurethane flooring at a thickness of 6mm. This comprises resin, hardener and a graded silica aggregate for performance and longevity. This resulted in a lightly textured non-slip surface and an attractive matt finish.

Approximately 500m² of heavy-duty flooring and 350 linear metres of heavy-duty coved skirting have now been installed in both high-care and low-care areas. This has transformed the factory with a modern, hard-wearing flooring surface. The flooring is capable of withstanding heavy-wheeled traffic and also high-pressure steam cleaning.

The team at Halal Kitchen is delighted with the end result and the ‘new look’ food factory flooring finish.