Replacing Vinyl With A High-Performance Polyurethane Flooring System

Zeina Foods has been an UltraSyntec customer for many years, and our specialist flooring teams have completed numerous projects around the company’s manufacturing plant in Ossett, West Yorkshire.

The project for which we were asked to provide a specification and long-term solution centred this time on one of the mezzanine packaging areas, replacing worn vinyl flooring with a durable and hygienic resin-based alternative. 

Established for over 40 years, Zeina Foods is one of the UK’s leading suppliers of processed nuts, dried fruits and speciality confectionery ingredients. With the focus on innovation, the company imports products from global sources and is committed to ethical and sustainable farming practices. Processes carried out at their West Yorkshire plant include raw material cleaning and sorting, nibbing and pasting, caramelising, roasting and packaging. 

Investment in technology is vital to Zeina Foods, and the company operates a high-speed automated packing and boxing line to manage capacity demands and the accuracy demanded by high-profile FMCG customers across the UK. 

Specifying appropriate flooring for a mezzanine level

The existing floor covering on the packaging mezzanine was vinyl, leading to a variety of operational issues. Natural movement in the floor on the steel mezzanine level had caused the vinyl to fail in several areas, leading to hygiene considerations unacceptable for Zeina Foods and the food and beverage environment. 

The UltraSyntec team attended on-site to carry out a detailed survey of the area and to assess the long-term requirements. Following this visit, a comprehensive flooring specification was devised to match the demands of this environment. 

The importance of correct preparation

Before commencing installation of the resin flooring, extensive preparation work was required. The team began by stripping out and disposing of the existing floor coverings. Once this stage was complete, the substrate was mechanically prepared using a diamond grinder attached to an industrial vacuum to ensure minimal dusting on site. The substrate was then cleaned down, ready for priming. 

The primer specified was Resdev’s Pumathane SL, developed and manufactured by resin flooring specialists Resdev. This HACCP-certified low viscosity flexible polyurethane screed is ideal for this particular application as it has the necessary flexibility to handle naturally occurring movement within this type of mezzanine floor, and provides food-safe characteristics. Pumathane SL is widely used in applications including pharmaceutical, healthcare, hospitality, food and chemical preparation. 

Creating a safe, slip-resistant surface

Following application of the primer, the team then applied a single coat of Resdev’s Pumadur TF polyurethane seal coating, incorporating an aggregate scatter to form a slip-resistant surface, ensuring optimum safety underfoot for the heavy pedestrian traffic this area is subject to. 

Pumadur TF is ideal for use in areas requiring resistance to wear and chemical attack, creating an attractive matt finish. The flooring is resistant to commonly used chemicals in the food, dairy and pharmaceutical industries, as well as inorganic acids, fuels, oils and solvents. 

The entire project was completed over the course of a single weekend, from Friday to Sunday, in line with Zeina Foods’ operational requirements, causing minimal downtime. The company is completely satisfied with the work carried out and the results, and plans more projects with the UltraSyntec team in the near future.