The Often-Missed Foundation – Building Fabric
Poor flooring is the number one cause of recurring listeria
Main issues
• Cracked resin flooring or tiles trap organic matter
• Regular water ponds create biofilm incubators
• Joint failures around drains can seed listeria in entire rooms
Best practice
• Lay seamless, coved resin flooring with chemical resistance
• Install falls (slopes) to drain not less than 1:60 in wet areas
• Avoid feathered repairs in favour of full-bay replacement
• Seal and raise equipment feet for effective cleaning
• Use colour contrasting floors to reveal debris, for easier removal
• Check resin systems are verified by hygiene standards organisations
Hazard Analysis and Critical Control Point
(HACCP) is a systematic, preventive food safety management system that identifies, evaluates, and controls biological, chemical, and physical hazards from production to consumption. It is a mandatory, internationally recognised approach used to prevent contamination rather than relying on end-product testing.
Case Study:
Persistent Listeria hot spots within processing areas
Location: NW England
Sector: Ready-to-Eat Food
Challenge: The client was experiencing ongoing issues with listeria hot spots across its production floor, presenting a significant food safety risk and compliance challenge.
Site Survey
We conducted a comprehensive site survey to assess the condition of the existing flooring, drainage interfaces, and hygiene-critical areas. The survey identified multiple high-risk zones where damaged joints, worn surfaces, and poor floor-to-wall transitions were contributing to bacterial harbourage.
Understanding the Situation
Through detailed consultation with the hygiene, engineering, and quality teams, Kemtile gained a full understanding of the operational constraints, cleaning regimes, and audit pressures faced by the customer. The key requirement was a hygienic flooring system that could be installed with minimal disruption while delivering long-term performance and compliance with food safety standards.
An initial sample trial area was installed within one of the highest-risk processing zones. This allowed the customer to evaluate performance under real production and washdown conditions. Following a successful trial, which demonstrated significant hygiene improvements, a full phased refurbishment of the entire processing floor was approved and undertaken.
Results
After completion, client environmental monitoring showed a 95% reduction in listeria hot-spots, alongside improved cleanability, durability, and audit confidence. The phased approach enabled the manufacturer to maintain production while significantly enhancing food safety across the site. and compliance with food safety standards.
“We delivered a long-term hygienic flooring and drainage solution that materially reduced contamination risk, supported regulatory compliance, and improved overall operational resilience.”
Dave Sleight, Key Accounts Manager, Kemtile
Contact Kemtile for a free Flooring Health Check
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