New floor improves hygiene at Zwanenberg

After 25 years, the floor of the filling department in Zwanenberg Food Group’s soup factory was due for replacement. In close cooperation with DRT Flooring Group, the schedule was carefully aligned to avoid unnecessary production downtime. The result: a modern floor that improves hygiene and working comfort.

Zwanenberg Food Group is the company behind major brands such as Chicken Tonight, Huls and Kips. In Oss, at one of its production sites, the company operates a meat canning facility, a soup canning line and a glass packaging plant. Here, soups, sauces, pâté, smoked sausage and frankfurters are produced daily. “Our roots lie in meat processing,” says Technical Manager Twan van Bommel. “Since acquiring the Unox factory from Unilever in 2017, we also produce soups and sauces. Through our brands and private labels we supply protein-rich foods to various markets at home and abroad. Because our products have a long shelf life and are ready to use, up to 30% can be saved on food waste. That is something we are proud of.”

Wilco Peters (left) and Twan van Bommel

Preserving history

Zwanenberg Food Group values its rich history, which is still visible in the original factories. Twan: “We intentionally choose to preserve our existing production facilities and invest in timely modernization. This summer, the floor of the filling department of the soup factory was replaced. After 25 years, the old floor clearly needed to be replaced: it showed wear and visible traces of intensive use. You could say the floor had reached its final expiration date. During the annual factory shutdown last summer, family-owned DRT Flooring Group therefore renewed this worn-out floor.”

A new floor

The old floor was completely removed down to the structural base and then rebuilt, including the finishing layer. “You have to take the slope of the floor into account and install drainage points to prevent water from pooling and ensure everything flows properly into the drains, which are completely waterproof. The floor must also be completely sealed, without any gaps or seams,” says Wilco Peters, senior account manager at DRT Flooring Group. Twan adds: “The department must stay dry and free of debris; that is essential for hygiene in any environment where food is handled. In addition, we set several other requirements for the floor. Because forklifts drive across the floor and heavy tipping bins are used, the floor must have sufficient load-bearing capacity. It has to withstand hot liquids and chemical cleaning agents, and it must be slip-resistant—for the safety of our employees.” A floor type that meets all these requirements is the Ucrete floor by SIKA, the supplier with whom DRT has a strategic partnership. Zwanenberg uses this strong, seamless and liquid-tight PU-cement floor as standard in its production areas. It is resistant to extreme temperatures, thermal shock and chemicals.

Long-term partnerships

The many requirements for Zwanenberg Food Group’s floor are familiar territory for Wilco. With his extensive experience and wide range of customized solutions, he was able to advise Twan effectively. Together they determined the entire plan of action: from demolishing the existing floor to selecting the new one, fully aligned with legal requirements and Zwanenberg’s specific needs. They have successfully worked together several times before. “We attach great value to long-term relationships. When you can rely on each other, the collaboration becomes both pleasant and efficient,” says Twan. Wilco agrees: “Thanks to our extensive expertise in renovations and the fact that we manage multiple disciplines in-house, we perform best in complex projects like this.”

Tight scheduling

The biggest challenge in this project was the schedule: it had to be extremely precise. “The floor is one part, but the process around it is just as important,” says Wilco. “There is a lot involved. All machines had to be disconnected and relocated. To avoid unnecessary production downtime, we planned the work during the factory shutdown last summer, which partly overlapped with the construction holidays.” Twan continues: “The process was complex because of the machine relocations—and risky due to time pressure. Thanks to effective coordination between all parties and timely alignment, everything went smoothly and the floor was delivered right on time.”

Twan is also very satisfied with the floor itself. “Because of its completely sealed structure and the fact that no water remains on the surface, the hygiene level has been optimized. Moreover, the new floor creates a safer and more modern working environment. That has a positive effect on the enjoyment of our employees.”

www.zwanenberg.nl
www.drt.nl

Photos: © Bart Nijs