Food Production Plant — Spintex Industrial
HACCP-certified food production facility commission requiring 1800 sqm hygienic epoxy with integrated coved bases across packaging hall, ingredient storage, and wet-zone commissioning. Epoxy Flooring Ghana delivered FDA-compliant antimicrobial system with R12 anti-slip in wet zones.
Project Profile
Sector: Food and beverage manufacturing Scale: 3,200 m² Scope: Full floor system removal, substrate preparation, hygienic epoxy specification, coved skirting, and drainage-zone treatment Timeline: 18 days (phased to maintain partial production continuity)
A mid-scale food production facility on the Spintex industrial corridor required a complete floor overhaul across its primary processing hall, packaging zone, cold-room antechambers, and staff welfare areas. The client — a regional fast-moving consumer goods producer operating under international food safety certification — had reached a compliance threshold: their existing floor system could no longer be certified for continued operation under revised GMP standards.
Specification Challenge
Food production environments impose floor specifications that most commercial systems cannot meet. The demands here were compounded by several factors operating simultaneously.
The processing hall was subject to continuous thermal cycling — steam-cleaning at elevated temperatures followed by cold rinse-down — a cycle that causes non-specialist floor systems to delaminate within months. Drainage channels crossed the slab at irregular intervals, creating transitions that had historically trapped organic material and harboured contamination points. The packaging zone required an anti-static dissipative layer to protect sensitive seal equipment, adding a second specification layer atop the primary hygienic requirement. Throughout all areas, the floor needed to sustain the load signature of heavy pallet jack and forklift traffic without surface fracture.
Critically, the client could not afford a full production shutdown. The specification had to accommodate a phased installation sequence, working around an active shift rota.
Approach
Our specification team conducted a full substrate condition survey prior to any material commitment — identifying existing delamination zones, moisture readings by quadrant, and slab-level variance across the hall.
The specified system was a multi-layer, solvent-free, heavy-duty epoxy build-up:
- Preparation: Diamond-grind surface profile to CSP 3–4 across all zones; localised crack injection and levelling compound application where slab integrity required remediation
- Primary coat: Moisture-tolerant epoxy primer, applied at full-flood rate to seal residual substrate vapour drive
- Body coat: High-build, food-grade epoxy resin system, 3 mm nominal thickness — specified for thermal shock resistance and certified under relevant international food-contact surface standards
- Packaging zone: Conductive copper tape grid and ESD-rated topcoat applied per static dissipation specification
- Drainage zones: Factory-radiused epoxy coved skirting (100 mm) along all wall junctions; drain-channel edges reinforced and sealed
- Anti-slip aggregate: Broadcast silica aggregate into wet topcoat in wet-process areas for slip-resistance compliance
Works were sequenced across four phases, each zone handed back within 48 hours of topcoat application.
Outcome
The completed floor system passed the client’s internal GMP re-certification inspection without remedial items. Thermal shock testing under the client’s standard cleaning protocol showed no delamination response at the 90-day inspection. The anti-static zones tested within specified dissipation thresholds on first instrument reading. The coved skirting eliminated all previous bacterial trap points identified during the pre-installation hygiene audit. The client renewed their international food safety certification within three weeks of project completion.
What This Project Demonstrates
Food production facilities in Ghana’s growing industrial corridor present one of the most specification-demanding floor environments in practice. A floor that fails a hygiene audit does not merely need replacing — it shuts the facility. This project illustrates the discipline required to specify, sequence, and deliver a multi-system floor installation inside a live production environment, without compromise to either certification outcome or operational continuity. It is the standard our practice holds for every food and beverage engagement.