Food processing plants have stringent regulations about hygiene and product safety, and every aspect of the facility must meet these strict safety standards to ensure the quality and safety of food products.
Over time, a food processing plant’s flooring can develop a number of issues, such as water seeping underneath the floor, rough texture and deterioration. Owners and operators often don’t have the time to address the issue, which puts them in a problematic position with compliance authorities.
The impact of flooring on food processing plant safety
The condition of your flooring directly impacts food safety. Poorly maintained or inadequately designed flooring becomes a breeding ground for bacteria, contributes to cross-contamination and leads to foodborne illnesses.
For example, if water accumulates under the floor or seeps through cracks, it creates an environment where mold and bacteria thrive. The wet environment of food processing plants exacerbates this issue.
Without proper sealing techniques, dirt and bacteria creep into porous materials and accumulate or propagate. Eventually, these contaminants find their way into food products, posing severe health risks.
Deteriorating flooring is also a health risk. When the floor begins to deteriorate, with pieces of concrete chipping away, these fragments end up in the food, leading to contamination and product recalls.
The inability to effectively clean and maintain the flooring due to these issues compromises food safety and increases the risk of regulatory shutdowns. Food safety inspectors are vigilant about the condition of flooring, and any signs of neglect lead to fines, shutdowns and a damaged reputation.
Key features of food-safe flooring
Certain vital features make flooring more suitable for the demands of food processing plants. Here are some features you should look for in a flooring material:
Thermal-shock resistance: Food processing facilities often require personnel to wash the floors with scalding water. Traditional floor coatings fail at temperatures as low as 140 degrees, leading to cracking and peeling. Thermal-shock-resistant flooring is essential to withstand these extreme temperatures without damage, ensuring the surface remains intact and easy to clean.
Durability: The flooring in food processing plants is subject to heavy machinery, high foot traffic and harsh cleaning chemicals. The floor must endure the daily wear and tear of heavy items and foot traffic without compromising its integrity.
Non-porous and seamless surface: Floors with seams or porous surfaces allow moisture and contaminants to penetrate, creating hidden areas where bacteria thrive. The fewer the seams, the better, as water otherwise seeps under the seams and causes further issues. Small patching jobs also leave seams up against existing flooring, leading to similar problems.
Slip resistance: Slip-resistant flooring helps prevent accidents and injuries common in food processing plants due to slippery surfaces. Ensuring that flooring has adequate traction is crucial to maintaining a safe working environment.
Breathable, cementitious urethane: Cementitious urethane flooring is an excellent option for food processing facilities. This breathable material allows moisture to escape from the concrete substrate, preventing issues like bubbling or peeling. Additionally, this flooring works well with sloped floors for proper drainage.
Choosing the right floor coating
Selecting the appropriate floor coating is critical for maintaining food safety standards. Food-safe floor coatings must meet specific requirements to ensure they are up to the task.
When choosing a floor coating, USDA approval is critical as it signifies that the coating meets the regulatory standards for food safety. The coating should also be easy to clean, as regular and thorough cleaning is essential in preventing contamination.
Chemical resistance is another key factor you want to keep in check. Maintenance personnel often use strong chemicals to clean the floors of food processing plants, which could weaken their integrity in the long run. A chemical-resistant flooring withstands these corrosive chemicals and prevents damage.
Maintaining your food-safe floor
Once you have installed a food-safe floor, ongoing maintenance is crucial to keep it in optimal condition. Regular cleaning is the first line of defense against contamination, and it’s important to use gentle cleaning agents that are effective yet safe for the type of flooring you have installed.
Don’t forget to go under and behind equipment when cleaning to ensure no hidden areas harbor bacteria. Additionally, regular inspections are essential to catch any potential problems early on and address them before they escalate.
Cleaning is also a time to inspect the floor for any signs of wear and tear. If you notice signs like deep scratches, chips, or peeling, you should consider re-coating or replacing the flooring to maintain food safety standards.
Case study
Triumph Foods—a pork processing company in St. Joe, Missouri—provides a clear example of the importance of maintaining food-safe flooring.
In the early 2000s, our team at Rio Flooring Systems did their flooring. Since then, we’ve worked with their maintenance team to do projects for smaller areas.
When the company attempted to repair destroyed flooring with their in-house maintenance team, they turned to a competitor flooring company for help. The competitor company turned them down, and they returned to us for assistance.
We recommended an authorized and trained contractor to guide the company with its project. We provided the supplies they needed to accomplish the flooring project. Our company also did their locker rooms, which their in-house team then maintained perfectly.
In the end, we covered about one million square feet of flooring. Triumph Foods continues to be one of our featured projects, and witnessing the company grow over the years has been exciting.
Final thoughts
Food safety starts from the ground up, and choosing the right flooring for your food processing facility is crucial for maintaining a safe working environment. When you choose a floor coating, ensure it has the necessary features and meets the USDA regulatory standards.
Working with a reputable flooring company takes a huge burden off your shoulders. Rio Flooring Systems is here to assist if you need help with your food-safe flooring.
Our team has years of experience in the food industry to guide you in selecting, installing and maintaining the best flooring for your facility.
Contact us today to learn more about our services.