High-Performance Resin Flooring for Biscuit Factory Refurbishment

Project Overview

Covering a total of approximately 735m², the project included the main production area, offices, changing rooms and mezzanine floor. With each space serving a different purpose, a single flooring specification would not have provided the required performance throughout the facility.

Three different resin flooring systems were therefore selected and installed, providing the appropriate combination of durability, hygiene, practicality and appearance for each environment.

Careful planning and coordination with the wider construction programme were essential throughout, ensuring each flooring system could be installed efficiently and the overall project remained on schedule.

The Challenge

Food manufacturing facilities place significant demands on their flooring, particularly within production areas where surfaces need to withstand regular use while remaining practical to clean and maintain.

For the main production space, the flooring needed to provide a robust, heavy-duty surface suitable for the demands of a busy biscuit manufacturing environment. Hygiene was another important consideration, including the treatment of the junction between the floor and walls.

Elsewhere within the extension, the requirements were different. The offices and changing rooms called for a more decorative finish without compromising on durability or ease of maintenance.

The mezzanine floor presented another set of requirements, with a hard-wearing resin coating needed for an area subject to light to medium traffic.

Zenith therefore needed to deliver three distinct flooring specifications as part of one coordinated installation.

Production Area – 480m² Polyurethane Screed

The largest element of the project was the new 480m² production area.

Zenith installed a 6mm polyurethane screed system finished in blue, creating a highly durable and resilient surface suited to the demanding conditions associated with food production.

The thickness and performance characteristics of the polyurethane system provided the robust finish required for this heavily used area.

Coved skirting was also installed around the production space, creating a seamless transition between the floor and wall. This removes the conventional sharp floor-to-wall junction and provides a surface that is easier to clean and maintain – an important consideration within a food manufacturing environment.

The blue finish also created a clean and consistent appearance throughout the new production area.

Offices and Changing Rooms – Decorative Flake Flooring

A different approach was taken within the office and changing areas, where both appearance and practicality needed to be considered.

Zenith installed a PVA decorative flake flooring system, providing these spaces with a more attractive finish while retaining the durability and ease of maintenance required within a busy manufacturing facility.

Matching coved skirting was incorporated into the installation, creating a neat and consistent finish around the perimeter of the rooms.

Using a decorative flake system allowed the offices and changing facilities to have their own distinct appearance while remaining part of the overall resin flooring package delivered across the extension.

Mezzanine Floor – 190m² Epoxy Resin Coating

For the 190m² mezzanine floor, Zenith installed a high-build epoxy resin coating finished in grey.

Two coats of high-build epoxy resin were applied to create a hard-wearing surface suitable for the intended light to medium traffic within this part of the facility.

The grey finish provided a practical and professional appearance while giving the mezzanine a durable surface appropriate for its day-to-day use.

Three Flooring Systems, One Complete Package

One of the key aspects of the project was selecting the right resin system for each individual area rather than applying the same specification throughout the building.

The heavy-duty polyurethane screed provided the performance and hygienic finish required within the production area, while the decorative flake system offered a more visually appealing solution for the offices and changing rooms. The high-build epoxy coating provided a practical and durable finish for the mezzanine.

Together, the three systems allowed Zenith to provide a complete flooring package tailored to how each part of the biscuit manufacturing facility would actually be used.