Food Production Plant — Spintex Industrial
HACCP-certified food production facility commission requiring 1800 sqm hygienic epoxy with integrated coved bases. Epoxy GH delivered FDA-compliant antimicrobial system with R12 anti-slip wet zones.
Project Profile
- Sector: Food and beverage manufacturing
- Scale: Approximately 2,800 m²
- Scope: Full production floor coating system, cold-storage anteroom treatment, drainage channel sealing, and staff welfare area finishing
- Timeline: 18 days, phased to maintain partial operational continuity
A mid-scale food production operator running a dedicated processing and packaging facility on the Spintex Industrial corridor required a complete floor coating programme across its primary production hall, cold-storage transition zones, and ancillary welfare spaces. The facility operated on a near-continuous schedule, placing strict demands on installation sequencing and cure-window management.
Specification Challenge
Food production environments present a distinct matrix of performance requirements that standard industrial coatings cannot satisfy. The facility’s production floor was subject to repeated chemical wash-downs using aggressive alkaline and chlorinated cleaning agents — a cycle that destroys conventional coating systems within months. Standing water from hosing operations, temperature cycling between ambient and cold-storage zones, and the constant movement of wheeled trolleys and pallet equipment combined to impose simultaneous mechanical and chemical stress on every floor surface.
Beyond performance, the facility operated under food-safety compliance obligations, requiring all applied materials to be food-contact-safe and free of volatile emission profiles that could compromise production hygiene. The drainage channel network — critical to rapid water drainage during wash-down — required full sealing to prevent substrate ingress and bacterial harbouring beneath the surface.
The client required a solution that could be installed in sections, returning each zone to service within 24 hours of application, to avoid a full facility shutdown.
Approach
Following a site survey and substrate assessment, the team specified a multi-layer polyurethane-modified epoxy system selected for its chemical resistance profile and low-emission cure characteristics — appropriate for food-contact environments under HACCP-aligned facility standards.
Surface preparation proceeded by diamond-grinding all production hall areas to achieve a clean, open concrete profile, with crack repairs and expansion joint treatment completed before primer application. The primary production floor received a broadcast anti-slip aggregate layer within the topcoat, providing the slip-resistance grading required for wet-working conditions without compromising cleanability.
Cold-storage anteroom junctions were treated with a flexible bridging detail to accommodate thermal movement and prevent edge delamination. Drainage channels received a specialist chemical-resistant lining, applied in two passes to ensure full penetration at channel walls and base.
Work proceeded in six production bays, each handed back to facility operations individually, maintaining the client’s partial-production requirement throughout the programme.
Outcome
- Full 2,800 m² installation completed within the 18-day programme window
- Zero production-shutdown days — all zones handed back sequentially within specified cure windows
- Anti-slip surface grading confirmed by post-installation slip-resistance testing
- Drainage channel system sealed without a single post-installation defect recorded at the 90-day inspection
- Facility management confirmed full compatibility with the existing chemical cleaning regime at three-month operational review
What This Project Demonstrates
Food production and processing facilities represent among the most demanding specification environments in the industrial flooring discipline — where hygiene compliance, chemical resistance, and operational continuity must be resolved simultaneously within a single coating system. This project demonstrates the capacity to deliver specification-grade epoxy programmes in live food-manufacturing environments, managing phased installation sequencing, food-safety material compliance, and substrate-to-topcoat system integrity without compromise. For any food, beverage, or pharmaceutical processing operator specifying floor systems on the Spintex Industrial corridor or across Greater Accra’s manufacturing belt, this scope of work reflects the standard of institutional delivery that defines every Epoxy GH commission.