The Often-Missed Foundation – Building Fabric
Drainage - the engine of spread
Drains are not neutral; they are active contamination hubs.
Design requirements
- Use dedicated drainage solutions for high-risk zones
- Avoid shared runs with low care routines
- Use removable, cleanable traps
- Create easy access to drainage systems for foaming and mechanical cleaning
- Eliminate channel drains in open ready to eat areas
- Invest in EHEDG-compliant drainage systems to minimise bacterial growth
Best practice
- Never use a high-pressure wash towards drains
- Use colour-coded drain tools
- Ensure end-of-shift sanitisation with validated chemistry
- Build in routine dismantle inspections to spot risks early
Case Study:
Listeria in aged drainage channels and underground plastic pipework
Location: Lincolnshire UK
Sector: Fresh Produce Processing
Challenge: The client 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.
Site Survey
We discovered 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, limited access for effective cleaning. These factors created ideal conditions for bacterial harbourage and made compliance with food safety audits increasingly difficult.
Understanding the Situation
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.
The Solution
Kemtile delivered a phased drainage replacement programme, allowing the factory to remain operational throughout the works. We handled civils work to remove all existing non-stainless surface drainage, we 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.
Results
After we 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.
Client Feedback
“The phased approach allowed us to continue production while addressing a critical food safety risk. The new stainless system has transformed our cleaning effectiveness and given us confidence in our hygiene controls.”
Dave Sleight, Key Accounts Manager, Kemtile
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