Resin Flooring: The Secret Ingredient for Safety in Food Processing Facilities

Resin Flooring: The Secret Ingredient for Safety in Food Processing Facilities

In the food and beverage industry, the pursuit of excellence isn't just a matter of taste; it's a commitment to safety and hygiene. The design and construction of food processing facilities play a pivotal role in ensuring the production of safe and uncontaminated products. Central to this endeavour is the choice of flooring material. Resin flooring, often underestimated in its significance, is a linchpin in creating a secure and hygienic environment within food and beverage facilities.

In this blog, we will delve into the essential considerations when designing a food and beverage facility, with a particular focus on the recommended resin flooring options. Let's explore why a protective flooring system is crucial and what factors should be considered when selecting the right resin flooring for food production.

Why Do I Need a Protective Flooring System?

Food processing facilities are exposed to a multitude of food by-products, including fats, hot oils, blood, sugar solutions, and natural food acids. These substances can wreak havoc on an uncoated concrete floor, infiltrating it and promoting microbial growth. This not only degrades the production environment but can also contaminate the food products.

The aggressive cleaning processes necessary for maintaining hygiene, such as steam cleaning, power washing, and harsh cleaning agents, can further damage uncoated concrete. The concrete becomes porous, making it susceptible to bacterial penetration.

Given these challenges, it is essential to cover exposed concrete floors with high-performance flooring systems. Seamless resin floor finishes have gained prominence in food and beverage production environments due to their hygienic properties and durability.

Consider these Factors when Choosing a Protective Resin Flooring System for Food Production

Floor Hygiene

Resin flooring offers enhanced hygiene through its seamless finish, durability, and performance. Some cementitious polyurethane flooring systems contain antimicrobial agents, whether chemical or natural silver ion based.  These antimicrobial agents enhance hygiene levels by protecting against harmful bacteria, moulds, and yeasts. Depending on the system chosen, this protection can remain active for the lifetime of the floor, even if it's worn or damaged.

HACCP International Product Certification

The Hazard Analysis and Critical Control Point (HACCP) system is essential for food safety management. It requires a seamless, impervious flooring system, as seams and joints can become breeding sites for contaminants. The floor must withstand the stresses of cleaning, chemical exposure, and thermal shock over time.  A HACCP Australia system however is different to a HACCP International Product Certification and the two are often confused.  Since it typically necessitates comprehensive understanding of the product's material, toxicity, design, lab results, and accuracy/verification of claims made about these products, the process of evaluating products can be laborious and technically challenging. 

Slip Resistance

Preventing slips and trips in food manufacturing and preparation areas is imperative. Resin flooring systems are available with different levels of slip resistance to suit various environments. However, the choice of texture should balance slip resistance with ease of maintenance.  Always refer to the NCC 2022 and SA HB 198 – 2014: Guide to the specification and testing of slip resistance of pedestrian surfaces for specific requirements.

Cleaning & Maintenance

Resin floors in the food industry endure substantial wear and tear. An effective cleaning and maintenance routine is essential to preserve the floor's appearance and performance. Different types of resin flooring may have distinct cleaning requirements. Cementitious polyurethane systems are compatible with steam cleaning, while epoxy and MMA systems may not be.

Nature of Chemical Contact

Food and beverage facilities encounter a wide range of organic and inorganic acids, alkalis, and hot oils, making them vulnerable to chemical attacks. The choice of resin flooring plays a significant role in mitigating this risk. Polyurethane cement flooring systems offer enhanced resistance to corrosive substances, organic acids, and more.

Thermal Shock & Cycling

Food processing plants can experience thermal shock conditions when exposed to extreme temperature fluctuations. The wrong flooring material can lead to floor failure, resulting in cracks, bubbling, peeling, or delamination. Cementitious polyurethane systems are better equipped to handle thermal shock compared to epoxy or MMA systems.

What Resin Flooring Options are Available?

Various resin flooring options are suitable for food and beverage facilities. Here are some common choices:

Cementitious Polyurethane

Cementitious polyurethane (PU) flooring systems are a popular choice for their resistance to prolonged chemical attacks, seamless finish, and imperviousness to bacteria and mould. They are well-suited to environments with thermal shock conditions.

Methyl Methacrylate (MMA)

MMA flooring systems cure rapidly and are ideal for minimizing downtime in operational production facilities. They have good UV resistance and resistance to various chemicals. However, MMA materials can have a unique odour which may be unsuitable for some environments.

Epoxy

Epoxy coatings are available in a wide range of colours and are suitable for non-processing zones of food facilities. They can be broadcast with aggregates to provide slip resistance. However, they offer limited resistance to organic acids and are not recommended for areas subject to thermal shock as Epoxy resins by nature can be rigid.

Selecting the right resin flooring system is not just a matter of aesthetics but a critical step towards ensuring food safety and product integrity. By considering the factors mentioned in this blog, you can make an informed choice that protects both your facility and the consumers who rely on your products.

For specific guidance and recommendations tailored to your facility's unique needs, consult with resin flooring experts who can help you choose the optimal solution for a safe and hygienic food processing environment.