Introduction: In Food Production, Flooring Is a Critical Control Point

Food production facilities, commercial kitchens, abattoirs, breweries, dairies, bakeries, and food storage environments all operate under strict safety and hygiene standards. Among these standards, HACCP (Hazard Analysis and Critical Control Points) sets the benchmark for identifying and managing contamination risks.

While most people associate food safety with equipment cleanliness and safe handling processes, the flooring is one of the most important — and most overlooked — components of a compliant environment.

Floors in food environments must withstand constant cleaning, moisture, spills, temperature changes, organic acids, impact, and foot traffic. If the floor is not seamless, durable, and chemical-resistant, it becomes a breeding ground for bacteria and a major compliance risk.

This is why food-grade floor coatings, such as epoxy and polyurethane systems, are essential for maintaining hygiene, safety, and long-term performance.

What Is HACCP and Why Does Flooring Matter?

HACCP is an internationally recognised system for controlling food safety hazards. It identifies risks and establishes measures to prevent contamination of food products.

Flooring plays a vital role because:

• It is a direct contamination risk if cracked, porous, or damaged
• It can trap bacteria, moisture, mould, and organic waste
• It is subject to constant foot and equipment traffic
• Cleaning chemicals and water can break down unsuitable surfaces
• Bad flooring increases the risk of slips and falls

A HACCP-compliant flooring system must therefore be:

• Seamless (no joints, grout lines or gaps)
• Impervious (non-absorbent)
• Chemical-resistant
• Slip-resistant
• Durable under heavy use
• Easy to clean and sanitise

Epoxy and polyurethane coatings meet all these requirements when designed and installed correctly.

Key Challenges in Food Production Flooring

Food environments are some of the harshest settings for flooring. The following challenges must be addressed for HACCP compliance:

1. Water & Moisture Exposure

Kitchens and production facilities are constantly washed, mopped, or hosed. Porous or cracked flooring absorbs water and becomes a harbour for bacteria.

2. Thermal Shock

Boiling water, steam cleaning, refrigeration zones, and hot equipment create extreme temperature variations that can destroy weak flooring systems.

3. Chemical Exposure

Flooring must withstand:

• animal fats
• oils
• cleaners and sanitisers
• fruit acids
• caustic soda
• detergents
• dairy by-products

Epoxy and PU systems offer exceptional chemical resistance.

4. High Wear & Impact

Constant traffic from staff, trolleys, crates, kegs, and equipment places continuous force on the surface.

5. Hygiene Requirements

Floors must allow for:

• frequent cleaning
• sanitisation
• quick spill removal
• strict microbial control

Traditional floors like tiles or bare concrete simply cannot achieve these standards.

Why Food-Grade Coatings Are the Best Choice

Food production facilities need highly specialised flooring that meets strict standards. Wolffes uses food-grade epoxy and polyurethane coatings, which offer the following benefits:

1. Seamless, Impervious Surface

Unlike tiles or vinyl, resin-based floors are poured in place and cure into a seamless sheet.

This eliminates:

• grout lines
• seams
• gaps
• crevices
• lifting edges

These areas are notorious for trapping:

• water
• fats
• food scraps
• bacteria
• mould

A seamless surface reduces contamination risks dramatically.

2. Extremely Hygienic and Easy to Clean

Food-safe resin floors allow for:

• rapid cleaning
• high-pressure washing
• steam sanitisation
• chemical disinfection

Because there are no joints, dirt and bacteria have nowhere to hide. Cleaning is faster, more effective, and less labour-intensive.

For facilities where hygiene is audited regularly, this advantage alone makes resin flooring the preferred choice.

3. High Chemical and Acid Resistance

Food production involves exposure to corrosive substances, including:

• lactic acid (dairy)
• citric acid (fruits)
• acetic acid (fermentation)
• animal fats
• salt brines
• strong cleaning products

Epoxy and polyurethane systems can withstand these substances without deteriorating. Polyurethane, in particular, offers superior resistance to organic acids, making it ideal for:

• dairies
• breweries
• wineries
• bakeries
• fermentation zones

4. Thermal Shock Tolerance

Temperature extremes wreak havoc on standard flooring. Sudden changes cause cracking, delamination, and surface failure.

Food-safe polyurethane coatings are specifically engineered to handle:

• boiling water
• hot oil
• ovens
• steam
• cold rooms
• freezers
• ambient changes

This makes PU the industry standard for facilities exposed to both heat and cold.

5. Slip Resistance for Worker Safety

Slippery floors are a major hazard in food production. Oils, water, and cleaning agents frequently reach the floor.

Food-grade coatings can be customised with slip-resistant textures ranging from R10 to R13, depending on:

• moisture levels
• cleaning frequency
• footwear
• equipment movement
• WHS requirements

Wolffes tailors each system to match the environment’s safety profile.

6. Long-Term Durability Under Heavy Use

Industrial food environments are relentless. Equipment gets dragged, crates get dropped, and forklifts or pallet jacks may operate in certain areas.

Food-grade coatings provide:

• impact resistance
• crack resistance
• long service life
• reduced maintenance
• excellent adhesion to concrete

This ensures a stable, compliant floor for years.

Which Coating Is Best — Epoxy or Polyurethane?

Both are excellent options, but they perform differently.

Epoxy Is Best For:

• dry food storage
• packaging areas
• warehouses
• lower-temperature zones
• heavy mechanical loads

Polyurethane Is Best For:

• commercial kitchens
• breweries and wineries
• dairies
• processing plants
• freezers and coolrooms
• areas with heat or steam
• high-acid environments

Most projects benefit from a hybrid system, using:

• Epoxy for the base, and
• Polyurethane for the topcoat

Wolffes installs both single and hybrid systems depending on the operational requirements.

Industries That Rely on HACCP Flooring

Food-grade coatings are essential for:

• Commercial kitchens & restaurants
• Breweries
• Wineries
• Dairies
• Bakeries
• Meat processing & abattoirs
• Seafood handling
• Frozen and chilled storage
• Ready-meal production
• Confectionery & chocolate manufacturing
• Beverage bottling plants

Each environment requires different slip-resistance levels, thicknesses, and chemical tolerances.

Wolffes designs flooring systems tailored to each industry’s unique HACCP risk profile.

Final Thoughts

HACCP compliance is more than a regulatory requirement — it’s a commitment to quality, safety, and consumer trust. Your flooring is one of the most important components in maintaining a hygienic and safe production environment.

Food-grade epoxy and polyurethane coatings deliver the durability, hygiene, slip resistance, and temperature tolerance required for modern food production.

With decades of combined experience, Wolffes specialises in installing seamless, compliant, and long-lasting flooring solutions for food environments across Australia.