From hygienic processing areas to heavy-duty manufacturing zones, every part of a production facility places different demands on its flooring. At Kemtile we have developed bespoke flooring solutions for customers in food, pharma and general manufacturing companies for over 45 years. The best flooring strategy starts with one simple principle - the floor should follow the process.
Explore the key areas of a modern production site and discover how the right flooring solution can help every process run with confidence.
1. Goods-In & Loading Areas
Goods-in and loading areas are often among the most mechanically demanding parts of a facility. For predominantly dry environments, a heavy-duty epoxy resin mortar can provide excellent impact and abrasion resistance. Where regular washdown, water or temperature change is involved, polyurethane cement may be more suitable.
2. Warehouses & Finished Goods Storage
Warehouse flooring should be selected around traffic intensity rather than simply room use. A light-duty warehouse may only require a protective epoxy coating. Medium-duty storage areas may benefit from a high-build epoxy resin system. Areas with continuous forklift traffic may require a heavy-duty epoxy resin mortar. Particular attention should be paid to turning circles, doorways, charging areas and slab joints.
3. Production & Processing Areas
In dry manufacturing areas, a medium to heavy-duty epoxy resin system can provide a seamless, durable and easy-to-maintain finish. Where water, heat, chemicals or frequent cleaning are involved, polyurethane cement may be the stronger option.
4. Wet Process & Washdown Areas
Wet production areas create a very different flooring challenge. A polyurethane cement flooring system is often particularly suitable because of its resistance to temperature change, moisture, chemicals and impact. In these areas, flooring should always be considered alongside: Falls • Drainage • Channels • Gullies • Kerbs • Wall-to-floor detailing.
5. High-Care, High-Risk & Hygienic Production Areas
Food and pharmaceutical facilities often include areas where hygiene and contamination control become critical. In wet high-care food environments, polyurethane cement is often a strong choice. In dry pharmaceutical cleanrooms or controlled environments, a smooth high-build epoxy resin system may be more appropriate. The important point is that hygiene requirements do not automatically mean one particular resin type.
6. Cleanrooms & Controlled Environments
Cleanrooms require flooring that supports contamination control. A smooth epoxy resin flooring system can provide a durable and highly cleanable finish. Where enhanced mechanical resistance is needed, a high-build epoxy system may be specified.
7. Cooking, Frying, Oven & High-Temperature Areas
Food manufacturing areas around ovens, fryers and cook lines can expose floors to some of the harshest conditions in industry. A heavy-duty polyurethane cement flooring system is generally well suited to these environments. System thickness should be selected according to the anticipated temperature exposure and operational severity.
8. Machine Shops & Engineering Areas
Machine shops can combine heavy equipment, oils, impact and concentrated loads. A heavy-duty epoxy resin mortar system can provide excellent resistance to abrasion and impact. Where particularly aggressive chemicals or cutting fluids are present, the flooring chemistry should be checked against those substances before specification.
9. Chemical Processing Areas
Chemical exposure requires more careful specification. Depending on the substances involved, solutions may include a chemical-resistant epoxy, Novolac epoxy, vinyl ester resin and specialist resin lining systems. The flooring should always be assessed against chemical type + concentration + temperature + duration + frequency. This applies equally to food CIP areas, pharmaceutical chemical rooms and manufacturing process areas.
10. Bunds & Secondary Containment
Where chemicals, oils or process liquids are stored, the bund may become the final barrier against a major spill. A specialist chemical-resistant resin lining system should therefore be selected according to the substance being contained. Attention is needed around cracks, joints, penetrations, upstands, drain interfaces and wall-to-floor transitions. A bund lining should be considered as a complete containment system rather than simply a coating applied to concrete.
11. Battery Charging & Battery Storage Areas
Battery areas may require a combination of chemical, heavy-load, abrasion or impact resistance, containment and static or electrical performance. A chemical-resistant epoxy or specialist resin system may be appropriate depending on the battery technology and operational environment.
12. ESD & Static-Sensitive Areas
Some environments require control of electrostatic discharge, including electronics production, sensitive laboratories, specialist pharmaceutical production, equipment rooms, battery and electrical manufacturing. An ESD or static-dissipative resin flooring system can provide controlled electrical resistance while maintaining a seamless, durable and cleanable finish. The required resistance range should be established before specification.
13. Laboratories
Laboratories require a careful balance between cleanability, chemical resistance, durability and appearance. A high-build epoxy resin system can provide a smooth and seamless finish for many laboratory environments. Where exposure to aggressive chemicals is expected, a specialist chemical-resistant resin system may be required.
14. Cold Rooms, Chillers & Freezers
Temperature-controlled areas can create challenges from: low temperatures, condensation, thermal cycling, wet cleaning, ice and heavy traffic. A polyurethane cement system can be well suited to many demanding cold environments because of its thermal resistance and durability. Operating temperature, installation temperature and cycling frequency should all be considered.
15. Packaging Areas
Packaging environments are often relatively dry compared with process areas. A high-build epoxy resin system can provide a durable and easy-to-clean finish. Where traffic is heavier, a heavy-duty epoxy mortar system may be more appropriate. Colour can also be used for: pedestrian routes, storage zones, equipment areas and exclusion zones.
16. Workshops & Maintenance Areas
Maintenance areas can be exposed to oils, grease, chemicals, tools, machinery, trolleys and vehicles. A textured heavy-duty epoxy resin system can provide good durability and slip resistance. Where hot water or repeated wet cleaning is present, polyurethane cement may be a better choice.
17. Plant Rooms & Utility Areas
Plant rooms vary considerably and may contain pumps, boilers, compressors, water systems, chemical dosing equipment, pipework, process services. Possible flooring types include epoxy coating for lighter-duty dry areas, high-build epoxy for greater durability, polyurethane cement to deal with wet or temperature-challenging areas or chemical-resistant resin lining for aggressive chemical environments. The flooring should be selected around the worst credible operational condition.
18. Corridors, Changing Rooms & Welfare Areas
Not every part of an industrial facility requires a heavy-duty process floor. Corridors, changing rooms, canteens, welfare spaces and reception areas may benefit from: decorative epoxy, quartz resin, flake systems or textured resin finishes. These systems can provide a cleaner, more attractive appearance while retaining durability and ease of maintenance.
Ready to find the right flooring solution for your facility? Speak to the Kemtile team today to discuss your site, your processes and your performance requirements at info@kemtile.co.uk
