When a juice processing facility in Florida needed critical flooring work done, they had one requirement: don't stop production. Our crew invested over 50 hours over a single weekend to install two completely different flooring systems across two areas of the plant. Monday morning, the facility was back in full operation with zero delays.
Before: The Problem
The facility needed flooring work in two distinct areas, each with different requirements. The bottling floor saw heavy forklift traffic, aggressive washdowns, and constant exposure to acidic fruit juices. The packaging equipment area needed a durable, easy-to-clean surface that could withstand rolling loads and chemical sanitizers. Both floors had to be completed in a single weekend shutdown window.
Bottling Floor — 3,372 Square Feet
The bottling floor required a full cementitious urethane system to handle the demanding environment. Our scope of work included:
- Surface scarification and profiling to ensure proper adhesion
- Removal of existing door opening obstruction via jackhammer to improve workflow
- SaniCrete SL — 3/8" cementitious urethane system with broadcasted quartz for slip resistance and durability
- SaniCrete VR — 2" cant cove perimeter application for seamless wall-to-floor transitions, eliminating bacterial harborage points
- SaniCoat 200 — applied to 15" curbing for chemical and impact protection
Packaging Equipment Area — 1,440 Square Feet
The packaging area had three layers of old coatings that had to come out before new flooring could go down:
- Diamond grinding through three existing coating layers
- 25-grit diamond re-profiling to prepare the substrate
- Epoxy patching of all joints and voids
- SaniFlow — 1/16" epoxy system installation for a seamless, easy-to-clean finish
After: The Result
Over 4,800 square feet of new flooring installed in a single weekend. The facility resumed full production Monday morning with no delays. This is what we specialize in — expedited shutdown projects that keep your plant running on schedule.
When production stops, we go to work.
Products Used
- SaniCrete SL — Self-leveling cementitious urethane
- SaniCrete VR — Vertical and cove base system
- SaniCoat — Epoxy coating system