A Lincolnshire factory specialising in fresh produce processing recently identified recurring Listeria positives during routine environmental monitoring.
The highest-risk areas were traced to aged drainage channels and underground plastic pipework, particularly in wet production zones where high-temperature washdowns were frequent.
Kemtile experts were called in to discover that the existing drainage system was over 15 years old and consisted of non-stainless surface channels, cracked and damaged channel joint and plastic underground pipework, poor falls and standing water with limited access for effective cleaning.
Key Accounts Manager Dave Sleight from Kemtile, who has over 40 years in the role, commented: “These factors created ideal conditions for bacterial harbourage and made compliance with food safety audits increasingly difficult.”
The client required a solution that would eliminate Listeria harbour points, withstand high water temperatures and aggressive cleaning regimes, be installed with minimal production downtime and fully comply with building control and hygiene standards.
Kemtile delivered a phased drainage replacement programme, allowing the factory to remain operational throughout the works.
They handled civils work to remove all existing non-stainless surface drainage, supplied and installed a new hygienic stainless steel drainage system, replaced damaged plastic underground pipes with fully welded stainless-steel pipework, reprofiled the surrounding floors to improve falls and water flow – all completed to latest building control and food industry standards.
After they finished the work there were zero Listeria positives in post-installation swabbing, a significant reduction in environmental risk scores, improved audit outcomes (BRC / SALSA / customer audits), faster and more effective cleaning cycles and reduced maintenance callouts.
Dave again: “The phased approach allowed the client to continue production while addressing a critical food safety risk. The new stainless system has transformed its cleaning effectiveness and given the management team confidence in its hygiene controls.
He added: “A good surface drainage system is not just about getting rid of water — it’s about controlling risk. If done properly, it improves hygiene and food safety, reduces slips and downtime, protects floors and structures, makes audits smoother."
E-mail us at info@kemtile.co.uk for more details and a free onsite flooring audit.
