Kemtile advises breweries on complete floor systems, providing a one-stop shop for specification, design, groundworks, drainage, site supervision, health and safety compliance, and installation by our skilled in-house teams.
Flooring designed to withstand the demands of breweries
Often for breweries, flooring and drainage specification is dictated by lease agreements, which usually stipulate that premises must be left in exactly the same condition as they were upon arrival. As most premises have a concrete floor, itself not able to withstand the demands of the rigorous brewing process, flooring is a necessary investment.
Polyurethane resin finishes and ceramic floor tiles
Polyurethane resin finishes, and hygienic high performance ceramic floor tiles tend to be the most commonly specified in breweries with one or both coverings being installed depending on the situation, environment and need. At Kemtile we’re expert at installing both, which means we make recommendations that best suit our individual customers’ budgets and requirements.
Key considerations for a brewery floor
A concrete floor alone will not withstand the rigorous brewing process
Concrete is a highly robust material and is used to construct the majority of the world’s non-residential buildings. However, because its top surface is porous, it absorbs spilt beers and ales as well as cleaning products and water, which can lead to microbial growth and substandard hygiene levels. It also increases the rate at which the surface of the concrete floor will break down. Another accelerator of top surface deterioration is traffic such as such as kegs, barrels, trolleys and trucks.
It must be free from trip hazards, pot holes and cracks
Like all workplaces, breweries have a duty of care to keep their staff safe and healthy, which includes reducing trip hazards. What’s more, cracks and pot holes also provide rough surfaces for dirt to cling to. And they are also difficult to clean, which creates an ideal environment for microbial growth. If left untreated, this too accelerates the deterioration of a concrete floor.
It must have a hygienic surface
The legislation surrounding beer production is much the same as any food and beverage manufacturing facility. This means that it’s essential that floors and other surfaces are hygienic meeting food grade or food safe standards and that they don’t encourage microbial growth.
It must be able to withstand rigorous cleaning
A rigorous cleaning process is essential in a brewery, so the floor must be able to withstand harsh cleaning chemicals, hot water, and steam. The finish must be able to withstand thermal cycling when cleaning, when temperatures change from normal to very hot, otherwise the floor surface will deteriorate. Similarly, it must also be thermal shock resistant when steam cleaning, as this can also cause much damage to a concrete surface.
It must be able to withstand impact
Brewery and distillery floors must be able to withstand impact from kegs and barrels, trolleys and forklifts. And if floors finishes are installed before the brewing equipment, it is essential that any damage caused during the installation process is repaired. What’s more, the floor and floor surface must be able to bear the equipment’s compressive load.
It must have excellent mains connected drainage
The importance of good drainage cannot be stressed enough, but it is an all too frequently overlooked component of the flooring design process. We recommend that long stainless steel floor gulley drains are centrally installed with the floor finish laid to falls. If the floor finish is not laid to falls or is uneven, waste water and spillages may pond or puddle on the surface, requiring more time and effort to manually sweep into floor drains, as well as creating slippage hazards.
It must be slip-resistant
According to HSE statistics, slips, trips and falls continue to be a major cause of injuries in the workplace leading to a significant rise in personal injury claims in recent years. It is therefore important to specify slip-resistant floor surfaces to help reduce the risk. And where surfaces are likely to be wet or holding standing water, the slip-resistance of the floor surfaces must be more textured.
It must be resistant to a range of chemicals
Brewery floors must be able to withstand any liquids that are spilt on them as well as all products used to clean them.So they need to be resistant to acid-based chemicals such as hydrogen peroxide, peroxyacetic acid and anionic acids. Alternatively, alkali-based sanitizers might be used such as chlorine, ammonium or sodium hypochlorite which means that the floor will also need to be resistant to alkalis. And as harsh chemicals may also be used to clean and sanitize the floor itself, the floor surface must also be chemically resistant in order to withstand them. Even ingredients in the brewing process itself can chemically attack a concrete floor if spilt, as can the acidic beer itself.
We were impressed by Kemtile’s track record with other UK breweries, so it was an obvious choice when it came to our new flooring and drainage. We’d already visited a number of Kemtile’s very satisfied brewery customers and we loved what we saw and heard. We wanted the same at our new site to support our future growth and evolution
Kemtile gave us complete confidence that we’d end up with the flooring we had in mind, and avoid the woes of a poor install. We chose Kemtile because of its reputation and vast experience in the field, as well as the professional and helpful manner in which they dealt with setting up our job. We are completely happy with the work they did for us.
Your boys did a hell of a job here. They were a credit to your company and I even had the German brewery installation company Rolec telling me they had never seen an English crew working harder than them. Being ahead of time and delivering on all your promises (and more) is a rarity for most companies nowadays. The floors look fantastic