Hygienic Flooring for Food Manufacturing Facilities: Design, Composition & Safety

Presentations

Hygienic Flooring for Food Manufacturing Facilities: Design, Composition & Safety

Introduction: Flooring’s Role in Food Safety

Flooring in food manufacturing plants is more than a surface—it's a safeguard. Poorly constructed or unhygienic floors can lead to:

Pest infestation
Microbial growth
Cross-contamination
Worker accidents (slips, falls)
Regulatory non-compliance

Proper floor design supports food safety, sanitation efficiency, and durability under harsh industrial conditions.

Food Safety Challenges in Flooring

Different food sectors face distinct flooring demands:

Meat Processing: Blood and cleaning chemicals cause abrasion
Dairy Plants: Require resistance to lactic acid
Oil Facilities: Need anti-slip surfaces to manage oil spills
Wineries: Floors must resist acids and thermal shocks

Food industry consultants often audit flooring design during plant layout or GMP certification preparation.

Objectives of Hygienic Floor Design

A hygienic floor should:

Support fast, effective cleaning
Prevent microbial harboring
Reduce accident risk
Be resistant to chemicals, oils, water, and temperature
Help achieve food safety compliance (HACCP, GMP, ISO 22000)

Key Features of Food-Safe Flooring

✅ Seamless Finish

No cracks or open joints
Eliminates microbial niches

✅ Non-Absorbing Surface

Waterproof and chemical-resistant
Withstands food acids, oils, and detergents

✅ Easy-to-Clean

Rounded wall-floor joints
Adequate drainage
Minimum slope of 2% in wet zones

✅ Slip Resistance

Anti-slip coatings and textures reduce worker injury risk

✅ Heavy Load Operability

Must support large machinery and frequent traffic

Understanding Floor Composition

Flooring generally has 3 layers:

Substrate (floor base): Must be dry, sloped, and structurally stable
Flooring Material: Ceramic tiles or resin-based mortar
Jointing Materials: Fillers for tile gaps (movement, expansion, isolation joints)

Flooring Materials for Food Plants

1. Ceramic Tiles

Vitrified, unglazed preferred
Heat and corrosion-resistant
Two types: Pressed (better dimensional accuracy), Extruded (high durability)

Pros: Affordable, durable

Cons: Brittle, labor-intensive to install, poor shock resistance

2. Resin-Based Floors

Made from binders (hydraulic or synthetic), aggregates, fillers, and coatings.

Resin Binder Types

Hydraulic (cement-based): Porous, improved by adding polymers
Synthetic (Epoxy/Polyurethane): Seamless, durable, and hygienic

Aggregates

Quartz, silicon carbide, aluminum oxide for abrasion resistance

Primer & Coating

Primer ensures adhesion
Coats can be one-layer or multi-layer systems

Epoxy and PU floors are commonly recommended by food manufacturing consultants for their seamless and antimicrobial properties.

Gas Bubble Control in Resin Floors

Gas bubbles can trap contaminants. Solutions include:

Surface-active agents
Prickle rollers (used in fresh mortar state)

Proper Jointing Techniques

For tiled floors, joints must be:

Completely filled and sealed
Smooth to prevent bacterial buildup

Types of joints:

Day joints
Expansion joints
Isolation joints

Conclusion: Build From the Ground Up

Flooring isn’t just a construction detail—it’s a critical control point. Proper floor design and materials:

Enhance food safety
Increase worker safety
Reduce cleaning and maintenance efforts
Ensure long-term operational durability

If you're planning a new facility or retrofitting an existing plant, working with an expert food consultant or food processing consultant ensures your floors meet the highest industry standards.

PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry A-224, A Block, Sector 83, Noida, U. P. 201305 info@pmg.engineering | www.pmg.engineering Floor Construction for Food Manufacturing Industries Competent People. Smarter Work Systems. Exceptional Customer Interactions. PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry A-224, A Block, Sector 83, Noida, U. P. 201305 info@pmg.engineering | www.pmg.engineering AGENDA 1 2 3 4 5 Introduction Food Safety Issues Purpose Features Floor Composition Competent People. Smarter Work Systems. Exceptional Customer Interactions. 2 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry A-224, A Block, Sector 83, Noida, U. P. 201305 info@pmg.engineering | www.pmg.engineering 1. Introduction flooring system for  Food safety is vital for consumer confidence and the food hygienic design of processing facilities is central to the production of safe food and beverage products.There are a number of factors that must be consider while selecting food manufacturing facilities because they face many challenges with respect to their needs. For example: new floor inside finish a 1. Wineries need a floor that will not be subjected to constant abrasion from acids 2. Meat Processing Facilities requires to deal with the heavy chemical abrasion that occurs from blood and meat residues. 3. Oil Production companies need to deal with slippery surfaces that occur from oils falling on the floor. 4. Dairy Product Plants requires a floor resistant to abrasion from lactic acids. Competent People. Smarter Work Systems. Exceptional Customer Interactions. 3 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry A-224, A Block, Sector 83, Noida, U. P. 201305 info@pmg.engineering | www.pmg.engineering 2. Food Safety Issues  Unhygienic designed /installed flooring can arise many problems which can disturb the food safety of the facility.  Major food safety issues associated floorings with unhygienic designed are: 1. Pest Infestation 2. Increased chances of cross contamination 3. It can become site of growth for pathogenic various the microorganisms. 4. Increases the risk of accidents due to slipping of workers. 5. Spoils the aesthetic view of the environment. Competent People. Smarter Work Systems. Exceptional Customer Interactions. 4 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry A-224, A Block, Sector 83, Noida, U. P. 201305 info@pmg.engineering | www.pmg.engineering 3. Purpose  Hygienic floor very important component for a productive and safe manufacturing operation as it: design is a 1. It maintains hygienic and aesthetic environment. 2. It helps in reducing frequency of cleaning time. 3. It prevent the risk of accidents due to slippery floor. 4. It prevents chances microbial cross contamination. the of 5. It reduce cost and labor associated activities. 6. It helps in against compliance food safety standards. achieving legal benchmark Competent People. Smarter Work Systems. Exceptional Customer Interactions. 5 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry A-224, A Block, Sector 83, Noida, U. P. 201305 info@pmg.engineering | www.pmg.engineering 4.1 Seamless Floor 4. Features  Floor surfaces should be even and free from cracks.  Open joints must be absent as they can become bacterial niches, and which are difficult to clean. 4.2 Non-Absorbing Surface  Should be pore less.  Must be waterproof and suitable for daily washing.  Must be repellent to oils, acids, fats and other food related residues.  Resistant to cleaning agents 6 Competent People. Smarter Work Systems. Exceptional Customer Interactions. PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry A-224, A Block, Sector 83, Noida, U. P. 201305 info@pmg.engineering | www.pmg.engineering 4.3 Easy-To-Clean 4. Features  Junctues between floors and walls need to be rounded for preventing the dirt accumulation resulting in efficient cleaning.  Floors must be easy to clean.  Floors must be provided with adequate drainage in areas subjected to flooding type operation cleaning releases/discharges water, condensate or liquid ingredients. or where normal  Floors of high moisture processing areas should have a minimum slope or gradient of 2.0% . 4.4 Slip Resistance  Floors with anti slip properties are required for preventing slipping accidents in food facilities. Competent People. Smarter Work Systems. Exceptional Customer Interactions. 7 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry A-224, A Block, Sector 83, Noida, U. P. 201305 info@pmg.engineering | www.pmg.engineering 4.5 Operability 4. Features  Floors should also withstand the installation of (e.g. horizontal mixers, heavy machinery tunnel ovens, spiral coolers, packaging lines).  Floors should also withstand the installation of (e.g. horizontal mixers, heavy machinery tunnel ovens, spiral coolers, packaging lines).  Equipment should not be located directly over drainage channels as this may restrict access for cleaning and inspection. Competent People. Smarter Work Systems. Exceptional Customer Interactions. 8 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry A-224, A Block, Sector 83, Noida, U. P. 201305 info@pmg.engineering | www.pmg.engineering  Floor consists of 3 parts: 5.1 Substrate 5. Floor Composition  It is the material that supports flooring and has a great impact on the quality of the flooring material.  It is also known as “Floor Base”.  It can be of two types: 1. Existing : It has to be properly prepared. 2. New : It has to be properly constructed and prepared before applying the flooring in order to allow a good adherence.  It must be dry i.e. a concrete slab must be let to dry for a minimum of 28 days)  able to prevent humidity reaching the impervious flooring.  It must be capable of withstanding all structural, thermal and mechanical stresses and loads that will occur during service.  it must be sloped sufficiently in order for liquids to flow to the drains. Competent People. Smarter Work Systems. Exceptional Customer Interactions. 9 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry A-224, A Block, Sector 83, Noida, U. P. 201305 info@pmg.engineering | www.pmg.engineering 5. Floor Composition 5.2 Flooring  Generally, two families of flooring materials are recommended for food processing areas. 5.2.1 Ceramic Tiles  They are made of clay that after shaping is subjected to high temperature.  Vitrified unglazed ceramic tiles are recommended for food processing areas.  They are highly resistant to the main constraints i.e. heat shocks  The vitrified tiles are of two types based on shape: 1. Pressed: they are usually square or hexagonal 2. Extruded: They are always rectangular  Dimension tolerances of the pressed tiles are better than those of extruded ones, allowing thinner joints. Competent People. Smarter Work Systems. Exceptional Customer Interactions. 10 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry A-224, A Block, Sector 83, Noida, U. P. 201305 info@pmg.engineering | www.pmg.engineering 5.2.1 Ceramic Tiles Advantages  Extremely high melting point.  Corrosion resistance.  Extreme hardness.  Inexpensive.  Easily available. Disadvantages  Dimensional tolerances difficult to control during processing.  Weak in tension.  Poor shock resistance.  Labor Intensive Installation. Competent People. Smarter Work Systems. Exceptional Customer Interactions. 11 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry A-224, A Block, Sector 83, Noida, U. P. 201305 info@pmg.engineering | www.pmg.engineering 5.2.2 Resin-based floors  Resin-based floors are obtained by application of a mortar made of a mix of one or more organic or inorganic binders, aggregates, fillers and additives, and/or admixture.  These floorings are considered more hygienic as they are seamless. Competent People. Smarter Work Systems. Exceptional Customer Interactions. 12 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry A-224, A Block, Sector 83, Noida, U. P. 201305 info@pmg.engineering | www.pmg.engineering 5.2.2.1 Binders  Resin Based Floors can be classified into two groups based on nature of the binder(s) 1. Hydraulic binder 2. Synthetic resins  It is the cement or lime that requires water to harden.  Major drawback associated with this type is that they have high porosity due to water evaporation.  To combat this drawback, few amount of synthetic polymer(5% resin) is added which reduces porosity and cracking risk and increases mechanical resistance.  Examples: acrylic-modified cementitious systems used in the meat industry.  Advantage: can be applied on Damp substrate.  These are organic polymers that react with a hardener at ambient temperature.  Epoxy resins are the more frequently used type of resin followed by polyurethane and methacrylate resins.  Characteristics of the different resins change according to the formulation used.  Epoxy flooring installation generally requires 1±3 days at 15±20 C before trafficking. Competent People. Smarter Work Systems. Exceptional Customer Interactions. 13 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry A-224, A Block, Sector 83, Noida, U. P. 201305 info@pmg.engineering | www.pmg.engineering 5.2.2.2 Aggregates  These are granular materials that do not contribute to the hardening reaction of the mortar. Roles of aggregate depend on their size and abrasion resistance.  Small aggregates (fillers) reduces shrinkage and increasing the mechanical resistance. Such aggregates are often made of sand with high silica content (SiO2 orquartz, 7 on the Mohs scale).  Hard aggregates are used to increase resistance to abrasion. Example: aluminium oxide, silicon carbide 5.2.2.3 Primer  A primer (one or two coats) is most generally used to aid the adhesion of the final flooring and to seal and consolidate the surface of a porous substrate.  It consists of a liquid product, which is often a solvent-based epoxy, applied to a substrate. Competent People. Smarter Work Systems. Exceptional Customer Interactions. 14 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry A-224, A Block, Sector 83, Noida, U. P. 201305 info@pmg.engineering | www.pmg.engineering 5.2.2.4 Coats  One-coat or multicoat systems are used for obtaining anti-slip resin-based floorings.  Multicoat systems that are the more frequently proposed are thin flooring (2±5 mm) made of a self-levelling mortar on which large aggregates are sprinkled. This type of coat has poor durability(1-2 years)  One-coat systems, also called monolithic systems, are made of mortar in which all the aggregates are mixed prior to application. The maximum diameter of the aggregates must be smaller than the third of the flooring thickness. 5.2.2.5 Gas Removal  Gas bubble holes are highly undesirable for hygienic considerations.  Surface-active agents can be added to avoid or decrease their formation during polymerization of resin-based floors.  In few cases, prickle roller is used when the mortar is in the fresh state to release entrapped gas bubbles. Competent People. Smarter Work Systems. Exceptional Customer Interactions. 15 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry A-224, A Block, Sector 83, Noida, U. P. 201305 info@pmg.engineering | www.pmg.engineering S.No Ceramic Based Tile Resin Based Flooring 1 2 Grout Lines are present. Grout Lines are absent Requires more installation time. Requires less installation time. 3 Damage tile can be replaced. If there occurs any cracks, then new layer of this flooring needs to installed 4 Installation is cost effective. Installation is not cost effective. Competent People. Smarter Work Systems. Exceptional Customer Interactions. 16 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry A-224, A Block, Sector 83, Noida, U. P. 201305 info@pmg.engineering | www.pmg.engineering 5.3 Jointing  A jointing material is used for completely filling the gap between to ceramic tiles right up to the top edge of the tile.  Various types of joints used for construction of floors are as follows: day joints, expansion joints, movement joints, and isolation joints. Competent People. Smarter Work Systems. Exceptional Customer Interactions. 17 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry A-224, A Block, Sector 83, Noida, U. P. 201305 info@pmg.engineering | www.pmg.engineering Our Clients Competent People. Smarter Work Systems. Exceptional Customer Interactions. We deliver End-to-End Engineering Design and Construction Management Projects in Food and Beverage Industry. Meeting Global Benchmarks In ENGINEERING DESIGN and PROJECT MANAGEMENT for FOOD and BEVERAGE Industry with SINGLE POINT ACCOUNTABILITY Process Engineering | Project Management | Mechanical | Electrical | Automation | Food Safety Key Clients We deliver End-to-End Engineering Design and Construction Management Projects in Food and Beverage Industry. Meeting Global Benchmarks In ENGINEERING DESIGN and PROJECT MANAGEMENT for FOOD and BEVERAGE Industry with SINGLE POINT ACCOUNTABILITY Process Engineering | Project Management | Mechanical | Electrical | Automation | Food Safety Key Clients We deliver End-to-End Engineering Design and Construction Management Projects in Food and Beverage Industry. Meeting Global Benchmarks In ENGINEERING DESIGN and PROJECT MANAGEMENT for FOOD and BEVERAGE Industry with SINGLE POINT ACCOUNTABILITY Process Engineering | Project Management | Mechanical | Electrical | Automation | Food Safety Key Clients

See all result for

Top Results

Presentations