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Flooring solution for busy factory thoroughfare

31 January 2021

David Priest discusses the approach taken to laying a new hygienic flooring solution for a poultry processing plant in Cheshire. 

Established in 1972, Forresters produces over 60 tonnes of roasted, steamed and marinated Red Tractor-assured chicken portions every day, for both retail and foodservice customers. The company also sources premium raw chicken fillets and supplies cooked chicken breaded pieces to catering butchers and wholesale customers, as well as having an on-site factory shop. 

Kemtile has been working with the company for many years, providing hygienic flooring solutions. Its most recent work for the company was to install 300m2 of Stonclad UF flooring solution. 

We can lay this product in a day without primer if required, which allows installation to be fast-tracked and ensures that busy areas are back in service as quickly as possible. It is one of the reasons this polyurethane mortar system is a popular specification choice within the food and beverage industry. 

The Stonclad UF solution also offers resistance to chemicals and high temperatures as well as slip resistance, helping ensure staff safety. The floor was laid on a thoroughfare through which products are transported on large, hot heavy racks to and from ovens. The environment is often wet and slippery.

Flooring requirements
Because the floors need to be washed regularly to prevent the growth of bacteria, the chosen flooring solution must be able to withstand regular scrubbing and the application of chemical detergents and high-pressure, high-temperature water. 

Over three days set aside to lay the flooring, the Kemtile team trowel applied some 100m2 of the high-performance Stonclad UF polyurethane floor screed in blue and green colourways. The resulting floor is exceptionally hard-wearing, textured and has an unsealed self-priming surface, which makes it ideal for quick installations to minimise down-time.

Commenting on the project, Angus Dilliway-Parry, operations director at Forresters Chicken, said: “We have enjoyed a long-term working relationship with Kemtile and have always been very satisfied with their project specifications and installations, as well as the aftercare advice and services they provide.

“When the business was smaller, we used to install our own flooring but, as we grew, it became apparent that we needed to place a much greater focus on this area. The stakes became much higher – with the impact of having to close down production for repairs being more costly and inconvenient as our production output increased. We simply had to invest in a top-quality flooring and Kemtile ticked all of our boxes.”

David Priest is sales manager at Kemtile


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