After owners of a Scottish dairy identified recurring Listeria contamination risks within a critical dairy processing area Kemtile discovered that the root cause was not operational practice, but structural hygiene failures within the building fabric.
Experts from the leading industrial hygienic flooring business revealed that the existing stainless-steel kerbs had been poorly installed and were hollow behind, allowing water to penetrate and become trapped.
Combined with damaged resin kerbing and walling systems, this had led to persistent water ingress behind walls and kerbs, stagnant water reservoirs hidden within the structure and ongoing leakage onto production floors.
Despite routine cleaning and hygiene controls, the factory was experiencing multiple Listeria hot spots and remained at risk due to inaccessible contamination zones embedded within the building itself.
Kemtile worked closely with specialist partners to deliver a full turnkey hygienic refurbishment solution, addressing both visible and hidden contamination risks.
The scope of works included the complete removal of all defective wall systems, all hollow and damaged stainless-steel kerbing, the installation of high-density polymer kerbs, the correct installation of new stainless kerbs and new hygienic wall panels.
Kemtile also replaced and upgraded sections of floor drainage and damaged resin and industrial-tiled flooring systems. This created a fully sealed, non-porous, and washdown-resistant environment, eliminating voids where bacteria could harbour.
Akeel Ahmed from Kemtile commented: “Listeria risks are often structural, not operational. By removing hidden water traps and replacing them with modern hygienic systems, you can deliver a long-term solution, tackle immediate contamination issues and safeguard the future. Engineering controls are critical to effective food safety.”
Following completion, the dairy processing area was transformed into a fully hygienic, compliant production environment.
Independent hygiene testing confirmed the elimination of previous contamination hotspots. The system fully aligned with BRCGS (Brand Reputation through Compliance Global Standards) and EHEDG standards.
Owners at the dairy reported improved audit outcomes, reduced downtime related to hygiene incidents, increased confidence in long-term food safety controls and an important shift in mindset - from reactive hygiene management to a proactive, structurally hygienic design.
Download our new whitepaper on Listeria at www.kemtile.co.uk/listeria
Please email info@kemtile.co.uk or contact us on 01925 763045.
