Food & Beverage Manufacturing

No Beef With This Floor Project

Customer: T.F. Kinnealey & Co.
Product: Hybri-Flex EB

Family-run T.F. Kinnealey & Co. located in Brockton, Mass., has been supplying high-quality beef and poultry throughout New England since 1939. As their business grew, so did their need for more space so, in 2009, they purchased a 70,000 square-foot building in Brockton, Mass. Company President John Kinnealey looked at the expansion as an opportunity to create a state-of-the-art facility that would be both cost-effective and environmentally responsible.

Turning the existing industrial building into one suitable for meat processing posed a challenge, specifically when it came to the flooring. It was understood that the floors would be exposed to wear from forklifts, constant cleaning, thermal cycling, exposure to chemicals and sugars and oils from spilled product. To meet these challenges, a seamless, hybrid flooring system from Dur-A-Flex was chosen.

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Dur-A-Flex's Hybri-Flex® EB system was selected for its tolerance towards the abusive conditions. The system easily endures the frequent high temperature wash downs and stands up to the abusive environments that are typical of food processing facilities. Hybri-Flex also has a low-VOC content and is manufactured regionally, which was crucial in helping meet Kinnealey’s goal for LEED certification for the facility.

To prepare for the new floor system, the existing concrete slab was replaced to accommodate new trench drains. The concrete was then sloped to the drains to eliminate standing water and areas that harbor bacteria, alleviating compliance concerns. Maintaining a sanitary environment is critical to Kinnealey and was one of the main reasons that a seamless floor system was chosen.

At the start of renovations, Kinnealey stipulated that floors must be easy to clean, resistant to thermal shock and be extremely durable. By choosing a Dur-A-Flex Hybri-Flex system, he got all that and more, with the added benefit of a great looking floor to “wow” customers when they walked through the door! 

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Dur-A-Flex Flooring Has Microbrewery Owners saying, “Cheers!”

Customer: Sun King Brewery
Product: Poly-Crete SLB

Prior to 2009, it had been over six decades since the city of Indianapolis was home to a full-scale production brewery. So it was with great gusto, that Indy beer connoisseurs raised their glasses and welcomed Sun King Brewery with a resounding, “Cheers!”

Since then, Sun King has tapped into the growing microbrewery industry, securing a spot as the second largest beer brewer in the state of Indiana. The company’s commitment to handcrafted seasonal and specialty beers has been rewarded with multiple medals at the Indiana Brewers Cup, Great American Beer Festival and World Beer Cup competitions.

On a daily basis, Sun King welcomes visitors to the facility for tours, growler fills, can and keg purchases of their well renowned house and seasonal beers. Naturally, an aesthetically pleasing atmosphere is critical when hosting patrons as well as an easy to clean floor that effortlessly handles a wet environment.

Not long after opening their doors, Sun King’s owners realized a flooring upgrade lay on the horizon. “The concrete alone could not withstand the rigors of beer making and needed some form of protection,” says owner Omar Robinson. Since bare concrete is extremely porous, the daily washdowns and thermal cycling were taking a toll on the Production areas’ surfaces.

Faced with several traditional flooring options, Robinson consulted with his partners and says they went with their gut instinct and decided seamless flooring was the way to go. “We didn’t want a tile floor due to the chipping and cracking if something was dropped or something heavy was placed on it. And we didn’t want to deal with constant repairs or grout,” says Robinson.

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Robinson contacted a flooring installer in Indianapolis who chose Dur-A-Flex’s Poly-Crete cementitious urethane system. Formulated to withstand impact, this powerhouse system easily handles kegs, forklifts and the ever present ingredients and chemicals that hit the floor daily.

The time element that worried Robinson was driven by the need to reduce any downtime and impact to production. Knowing this, the contractor worked around Sun King Brewery’s schedule simultaneously installing while production surged on. The results were on-time installs that allowed Sun King Brewery to eliminate revenue loss while improving their facility. “They worked around our schedule so our production was not disrupted,” says Robinson. 

As Sun King Brewery continued expanding over the years, so has the need for Dur-A-Flex’s Poly-Crete system. Over 15,000 square feet of Sun King’s Production area has Poly-Crete flooring. “We have non-slip surfaces that are seamless, easy to clean and durable. The cove is especially helpful because there is no crease to collect dirt, grime or contaminants,” concludes Robinson.

An addition to the facility is underway and Dur-A-Flex’s Poly-Crete will be on top of it. Sounds like the makings of a perfect brew!

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The main ingredient for this recipe? Seamless Flooring.

Product: ACCELERA HB, Poly-Crete SLB, Poly-Crete Color-Fast

Facilities within the food processing industry present tough requirements – they need to handle the abuse of constant traffic and spills while serving as a reflection of the company’s commitment to quality and cleanliness. This New York food processing facility’s requirements were no different. As a producer of ingredients included in the daily meals for millions across the country, the focus on hygiene was paramount. Three years ago, the decision was made to invest in the facility, specifically on the floors that their products are produced on - with the understanding that this surface was an important factor in maintaining their stellar reputation. The existing floors within the facility were an assortment of worn epoxy coatings, bare concrete and vinyl tile. To ensure their new floors would serve as a hygienic surface that would withstand the various ingredients that would hit them daily, they turned to seamless flooring as the solution. 

The facility is located in an area of New York with a particularly high water table therefore the soil is extremely moist. To combat any moisture in the existing concrete slab, Dur-A-Flex’s Poly-Crete SL was chosen as the base to all flooring systems installed in the facility. Poly-Crete SL offers a moisture tolerance of 20 lbs. per 1,000 sq. ft., providing protection against floor failures caused by moisture in the slab.

There were also many areas within the facility where trenching was needed for new pipes. These areas were patched with new concrete. Another benefit of using Poly-Crete SL was the ability to coat this new concrete just 5 days after it was poured. Poly-Crete SL allows for a variety of body and topcoats to be utilized depending on the needs of each area. The topcoats chosen for this facility included, Poly-Crete Color-Fast, a cementitious urethane and Accelera, a quick curing, low odor option featuring a high gloss look. The colors were matched at Dur-A-Flex’s Design Center to ensure a consistent look throughout the entire building.

To make sure this bustling facility continued its daily operations as usual, the work was split into phases. With areas ranging from production rooms to mixing areas, installers worked weekend shifts and also sectioned off areas to complete their work during the normal work-week by using Dur-A-Flex’s Accelera low-odor, quick-cure floor system. 

40,000 sq. ft. later their facility now features, a clean, durable, seamless floor system!