Long Term Flooring Solutions for Food Manufacturers and Processors

Polycote contractors have installed flooring systems throughout the food production areas for well over 30 years. From bakeries to breweries, slaughtering to processing, we would like to assure you of our ability to supply and install the right flooring solution in any area within the food manufacturing environment. With a full range of mechanical equipment, from dust free vacuum assisted shotblasters and diamond grinders, to scabblers and tile removers, we are fully equipped for every eventuality.

As well as answering to the demands of food safety standards by way of chemical resistance and cleanliness, our floors have been professionally formulated to withstand punishing daily routines of constant foot fall, heavy machinery movements and on-going, aggressive cleaning routines.

Floor Paint Installation For Food Production Areas

Food production areas suffer from all sorts of issues, chemical attack from substances such as milk, sugar and salt, frequent temperature changes resulting in damp or humid conditions, oil and grease causing slip hazards as well as waste materials and by-product attack from manufacturing processes.

Polycote have an entire range of tough and durable floor coating and screed systems that will give you the chemical resistance and durability you need. With added hygiene protection, we cover every situation from smooth to slip resistant textures, preventing slips and falls on wet surfaces.

Specifying the RIGHT preparation and RIGHT product for YOUR requirements.

Polycote have laid thousands of square metres of flooring in food processing areas, and we know exactly what is needed to give you a hard wearing and long lasting solution!

Right from the first phone call, our experts will give quick and easy advice as to the correct preparation and the correct products to use. We establish exactly what your issues are along with the time allowed to complete any works. Only then will we advise on the best preparation (using dust free equipment), the best primer (we have coatings capable of adhesion to oily and contaminated surfaces as well as areas suffering from rising damp), right through to the best top coat or screed to meets your specific needs.

All the usual key words such as e-coli, bacteria free, non-toxic, non-taint, totally impervious, slip resistant and easy-to-clean are obviously very relevant. However, with the huge cost and aggravation of downtime, tough and long lasting are extremely important, and our coatings have been professionally formulated to withstand constant wear and tear from foot traffic, pallet trucks and forklifts in all types of food manufacturing and processing environments, including fast setting products for areas that are in use 24/7.

Production and Processing Areas

Remember, when painting floors in factory production and processing areas, the cost of the paint is mostly a minor part of the cost. Downtime and disruption to production lines is an extremely costly issue. So, no matter whether it is a new construction project with the floors being coated for the first time, just remember that you want to spend as much as is necessary to provide a floor suitable and strong enough for your needs and resistant enough to withstand the constant wear and tear exerted upon it. If the area is new, you will not have the ‘shut down’ costs to contend with, but you certainly will after you are up and running, should you have the unfortunate experience of realising the original floor was a bad decision! Furthermore, and not that we wish to worry you, but please also consider that if this first paint/flooring system fails, you can’t just paint over the top! You will have the agonies and mess of removing ALL that has been done so the new (and suitable) coating is applied directly onto the actual substrate. Certainly not onto the ‘failed finish’.

Kitchens & Cooking Areas

As we all know, as soon as a kitchen becomes operational, downtime is extremely limited and therefore the correct choice of flooring is vital. When downtime is unacceptable and speed is of the essence, we have an entire range of fast curing products that will have an area back up and running within only two hours. Polycote have a team of experts, well versed in the needs of the kitchen environment, and can advise on the right floor for you.

Should a refurbishment programme be necessary, Polycote’s bespoke range of non-toxic and non-taint resin systems can be applied in both wet and dry environments. No matter if the surface is poor, rough, or covered in oil and grease, we have a proven solution for you.

The provision of a floor that is tough, durable, chemical resistant, slip resistant and easy to clean is obviously important. However, sufficient falls, adequate drainage and coving at floor/wall junctions all hugely contribute to the easy cleaning and maintenance of hygiene regulations.

We would like to give you the assurance that with over 155,000 food related companies on our database, our products are proven to not only meet but also surpass all currently known regulations and demands of the industry.

Warehousing and Storage Areas

In the food processing and manufacturing industry the creation of dust from wearing floor surfaces is one of the major issues that every warehouse and storage facility has to contend with.  Furthermore, these loose dust particles then act as a grinding ‘paste’ on the surface and thus only exacerbates the problem. If construction companies are to offer a long term solution to their customers, it is vital that they do not use ‘cheap and nasty’ floor sealers. These sealers then act as a barrier to any future coating, meaning that no matter how good or expensive it is, the subsequent coats are only as good as the adhesive qualities of the very first floor sealer or paint applied.

By preparing the floors correctly and priming with the correct primer, we can assure you that the longevity and performance of the top (wearing) coat will be massively increased. The difference is like chalk and cheese!

Shops, Showrooms & Trade Counters

Both our Retail and Commercial customers are increasingly changing to the latest resin flooring solutions as architects and designers are favouring surfaces that are impervious and seamless.

If you are looking for an ultra-modern showroom, our highly decorative systems Decratex Flake and Decratex Quartz have an endless amount of colour co-ordinated options and effects (even glitter can be added for that extra sparkle) and these coatings will transform not only the floor itself but indeed the entire environment.

Company logos, designs and messages can also be cleverly incorporated within your new floor. We offer some of the latest technologically advanced coatings. Furthermore, our nationwide network of qualified and experienced installers will be quick to respond, technically aware, proactive and flexible.

FAQ’s

What can stick to an oil contaminated floor?

One of the biggest issues for food processing and manufacturing areas is the painting and sealing of floors already contaminated with oil and grease.  Our highly specialised and professionally formulated OT Primer is able to adhere to oil contaminated substrates and together with our top coat Flortex Professional, this system has been proven beyond any doubt to provide a long-lasting solution in the most heavily used environments.

Can I have a non-slip floor that can be easily cleaned?

This is a scenario that has plagued the food industry for years. However, Polycote has three easy answers that will provide a slip resistant surface but one that can still be cleaned.

1)                 Polymer Bead.  This is an extremely fine flour like aggregate that can be dusted onto the top of a wet paint, and this provides an excellent slip resistant finish but one that can still be mopped.

2)                 Our FG60 aggregate is a food grade aggregate that is the same size as that seen on a 60 grit sandpaper. This is a very fine aggregate that can be broadcast on top of a wet paint or indeed mixed in with the paint and applied by roller.

3)                 Finally, we have a fine grade calcined bauxite aggregate which is one of the toughest minerals available under diamonds and will easily withstand the heaviest traffic.

The amount of slip resistance is not only determined by the size of the aggregate but also the amount applied per square metre along with whether it is added to the paint or broadcast on the surface. Our installation team will discuss your requirements and install the appropriate quantity.

Can I have a smooth finish?

Certainly!  The best way to achieve a super smooth finish is with one of our self-smoothing twin pack floor coatings – Polycote Freeflow.  This is available in either an epoxy (Freeflow EP) or polyurethane formulation (Freeflow PU), depending upon customers’ requirements / final finish required and is generally applied between 1-3mm thick. Alternatively, we also have a polyurethane screed (Flortex PU Screed) that is laid between 6-9mm thick and is ideal for areas of very high foot and wheeled, trolley traffic.

However, if our installation team have advised using a floor paint such as Flortex Professional, they will fill all holes and imperfections first. The reason for this is that no floor paint is designed to fill a hole. On application, you will tend to put almost as much paint on the ‘hill’ as you do the ‘hollow’.  Also, another major factor is cost due to ‘losing’ so much paint in the holes.  The coverage per unit will be drastically reduced. Our applicators fill small imperfections, cracks, and holes first with Polycote Easifil or Cretex EP, depending upon the size/quantity of holes prior to the application of the top coat.  For structural cracks and hairline cracks, we use Polycote Crackfiller EP100. For Expansion Joints, we advise one of our Jointex products, installed after the coating has cured.

How do I stop rising damp?

Rising damp is a major reason why floor paints and screeds fail. Should you be suffering from this issue, our approved installers will fully prepare the floor to ensure all loose material is removed and the area is fully ‘keyed’ to ensure maximum adhesion and one coat of Polycote DPM Primer, a twin pack epoxy resin primer formulated specifically to adhere surfaces where rising water may be present, will be applied to seal the surface. Whilst one coat is often sufficient, depending upon the roughness and/or porosity of the substrate, they may advise a second coat to help ensure there are no pin holes, and that a complete 100% coverage is achieved.

Please note; DPM Primer is not suitable if water is ‘running’ into the area as the resin will not have time to cure before being affected by the water.

Can you paint Ceramic, Quarry, or Vinyl Tiles?

Yes.  If the floor is already tiled and the tiles are solid and sound, just dirty and difficult to clean, our installation team will clean the surface thoroughly and etch with Polycote Etch IT. They will then prime with Polycote WD Primer. This is a highly specialised water dispersed epoxy primer that has been formulated with advanced adhesion promotors and will successfully adhere to ceramic and quarry tiles, terrazzo, and vinyl tiles.

What is the fastest curing floor coating?

Commercial kitchens and food factories are in almost constant daily use, 7 days a week, and down time is pretty much impossible.  If speed is important, almost all of our products are available with Extra Fast Hardeners, meaning a far quicker cure time.

If things are really serious, we also have our MC Range that cures in only 1 hour. Furthermore, this is also ideal for areas of low temperatures as our Flortex MC CSG 60, will cure down to -60°C!

What paint can be used in fridges or freezers?

Many food production, processing and storage facilities run at chilled temperatures down to +1°C. Others have large freezers and cold storage facilities, commonly operating between 0°C down to -60°C.

We have large range of floor paints that will cure in any one of these temperatures. Please see Low Temperature Floor Paints.