NEWS AND BLOG

Introduction

In food manufacturing, every detail counts. From ingredient quality to production processes, ensuring the safety and integrity of the final product is important. Yet, the facility’s flooring is one overlooked aspect crucial in maintaining hygiene standards. Traditional flooring options, which may not meet the rigorous demands of food manufacturing, can pose significant risks. This blog explores the qualities and benefits of cementitious seamless flooring, offering a solution to these potential hazards.

The Importance of Flooring in Food Manufacturing Facilities

The flooring in a food manufacturing plant is constantly assaulted by water, chemicals, temperature fluctuations, heavy equipment, and foot traffic. Any compromise in the flooring’s integrity can lead to dire consequences, including contamination, bacterial growth, and safety hazards. This underscores the crucial need for high-quality flooring for compliance, product safety, and operational efficiency.

The Advantages of Cementitious Seamless Flooring

Cementitious seamless flooring stands out as the ideal choice for food manufacturing facilities due to its numerous advantages:

Seamless Design. Unlike traditional flooring options that feature seams and joints where bacteria and contaminants can accumulate, cementitious seamless flooring offers a smooth and uninterrupted surface. This seamless design minimizes the risk of microbial growth and simplifies cleaning and sanitation procedures, potentially reducing workload.

Chemical Resistance. Food manufacturing involves using various chemicals and cleaning agents to maintain hygiene standards. Cementitious seamless flooring is highly resistant to various chemicals, including acids, alkalis, oils, and solvents. This resistance ensures the flooring’s durability and longevity, even in harsh industrial environments, providing a long-term solution for your facility.

Hygienic Properties. Maintaining a hygienic environment is non-negotiable in food manufacturing. Cementitious seamless flooring is inherently hygienic, as its smooth surface prevents the accumulation of dirt, grime, and bacteria. Moreover, its non-porous nature prevents liquids and contaminants from penetrating the surface, facilitating thorough cleaning and sanitation.

Durability and Strength. Food manufacturing facilities experience heavy foot traffic and constant equipment and machinery movement. Cementitious seamless flooring is engineered to withstand these demands, offering exceptional durability, impact resistance, and load-bearing capacity. Its robust nature ensures minimal wear and tear, reducing the need for frequent repairs and maintenance.

Temperature Tolerance. Food manufacturing plants encompass a wide range of temperature conditions, from hot processing areas to cold storage facilities. Cementitious seamless flooring is designed to withstand extreme temperatures without compromising structural integrity, making it suitable for diverse operational environments.

Potential Disadvantages

While cementitious seamless flooring offers numerous advantages for food manufacturing facilities, it’s essential to consider potential drawbacks to make an informed decision:

Installation Complexity. Installing cementitious seamless flooring requires specialized skills and equipment. Improper installation can result in issues such as uneven surfaces or premature deterioration. Working with experienced professionals ensures the flooring is installed correctly.

Initial Cost. Compared to the more traditional flooring options, cementitious seamless flooring may have a higher initial cost. However, the long-term savings in maintenance and repair costs and the potential for improved operational and sanitation efficiencies must be considered.

Curing Time. Cementitious seamless flooring typically requires a curing period before it can withstand full operational use. During this time, the facility may experience downtime, impacting production schedules. Proper planning and coordination will minimize disruptions.

Surface Hardness. Cementitious seamless flooring may have a relatively hard surface, which can be uncomfortable for employees who stand or walk for extended periods. Using ergonomic mats or footwear with adequate support can help alleviate this issue.

Potential for Moisture Vapor Transmission. In some cases, moisture vapor transmission from the substrate beneath the flooring can occur, leading to issues such as delamination or blistering. Proper moisture testing and mitigation measures are essential to prevent these problems.

Types of Cementitious Seamless Flooring

Epoxy resin flooring should not be used in areas with lactic acid, damp and/or cold conditions, or thermal changes causing a shock to the flooring and potential delamination.

Urethane concrete flooring is cost-effective for processing plants, production areas, warehouses, loading docks, and maintenance areas. It is also much more resistant to thermal shocks.

Methyl methacrylate (MMA) flooring is an excellent food processing floor option for operating freezers. It can be installed in freezers during operation and will cure down to -20 degrees Fahrenheit.

Urethane cementitious seamless flooring systems are extremely durable and built to withstand chemicals, thermal shocks, abrasions, and impact. The seamless finish eliminates the risk of moisture, dirt, dust, or mildew from hiding in joints, cracks, crevices, or grouts.

These flooring systems can have non-slip and antimicrobial coating options, preventing the growth of dangerous bacteria that could otherwise contaminate food and beverage products.

The cementitious seamless material is applied in one homogeneous layer over a new or existing concrete substrate. It is fast to apply and cure and can be ready for traffic in 24 to 36 hours.

These systems can be coved at the floor-wall juncture and extended up a wall, ensuring a continuous system and eliminating 90-degree angles. These features make cementitious seamless floor toppings an excellent choice for washdown areas in food and beverage processing facilities.

Conclusion

Despite some potential drawbacks, cementitious seamless flooring remains a highly desirable option for food manufacturing facilities due to its exceptional durability, hygiene properties, and suitability for demanding industrial environments. By addressing any challenges proactively and working with experienced professionals, facility owners and managers can maximize the benefits of this advanced flooring solution.

Every facility component plays a critical role in ensuring product safety and quality. By investing in this advanced flooring solution, food manufacturers can uphold the highest standards of cleanliness, safety, and compliance, thereby safeguarding both their reputation and the well-being of consumers.

At The Austin Company, we provide tailored design-build solutions for food manufacturing facilities. Contact us today to learn more about how we can elevate your facility to new heights of performance and hygiene.

Anca Amaiei Senior Architect Call 440.544.2291 | Email Anca | View Profile