Juice Processing Facility Upgrades Flooring for Improved Safety, Appearance, and Water Management

Project Overview

A large U.S. juice processing facility sought to improve the appearance and safety of select light-duty production and support areas as part of an ongoing modernization effort.

Stonhard installed Stonshield HRI to improve safety and aesthetics in light-duty production areas.

Stonclad UR with Stonkote HT4 helps this boiler room withstand demanding conditions while resisting moisture, thermal shock, and daily operational wear.

Challenges & Requirements

Years of heavy use had left portions of the flooring and surrounding surfaces worn and damaged requiring frequent maintenance and repairs. Project planners wanted a cleaner, more contemporary look throughout production areas while improving pedestrian safety and addressing operational concerns related to water management. The project also intended to establish a consistent flooring standard that could be implemented in additional areas as future renovations took place. With minimal exposure to juice and other organics, these light-duty areas were well suited for decorative epoxy flooring systems.

Stonshield QBT, seen here in the handwashing station, enhances safety in moisture-prone areas.

Stonshield HRI brings durability and decorative appeal to these interior walkways, creating clearly defined pedestrian paths throughout the facility.

This production room sports Stonshield SLT, a seamless, textured flooring solution designed to enhance safety with slip resistance.

Solution

Stonhard began with extensive surface preparation using planetary grinding equipment to remove deteriorated materials and properly prepare the substrate. Areas requiring slope modifications for improved drainage were repaired and adjusted with Stonset TG5 high-strength grout to direct water toward designated drains. Heavily damaged knee walls were restored using Stonshield cove base material, creating seamless vertical surfaces to improve aesthetics and cleanability.

Stonshield HRI, a textured, decorative, impact-resistant epoxy flooring system was installed to provide slip resistance and long-lasting protection against constant heavy traffic. Glacier, the selected color choice, brightened the production space, giving it a clean, contemporary look, while walkways in Espresso created clearly defined travel paths to support safe pedestrian movement.

At the handwashing station, Stonhard installed Stonshield QBT, a textured, decorative epoxy mortar flooring system, to enhance safety in an area exposed to frequent moisture. Stonshield QBT is easy to clean, supporting the facility’s sanitation requirements. In the boiler room, Stonclad UR, a urethane flooring system was installed for its ability to withstand moisture, thermal shock, and demanding service conditions. In higher-exposure processing areas, Stonclad UF urethane mortar flooring provides long-term durability against continuous contact with juices and other organic materials.

These carefully selected and expertly installed flooring solutions transformed this bustling juice production facility with a fresh, clean appearance and improved operational functionality. Water is now more effectively contained and directed to drains; damaged surfaces have been restored; and employees can easily identify designated walkways throughout the space. The success of the project has led to plans for additional Stonhard flooring upgrades throughout the facility.

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