Hygiene Top of the Bill for Unilever’s Green Site in SA
Flowcrete has secured a major coup at Unilever's new
manufacturing plant in Durban, South Africa, with the installation
of a number of the company's seamless epoxy and polyurethane resin
The new plant, affectionately named 'Indonsa', meaning 'Morning
Star' in isiZulu, is home to world famous dry food brands including
Knorr, Robertson's, Knorrox, Aromat and Rajah and has been designed
under a 'Green'
construction programme that has considered sustainability at
every stage of the development - including the floor space - by
architects Elphick Proome and Main Contractors Stefanutti
Aside from the above-mentioned environmental requirements, it
was crucial that the flooring systems chosen in the final
specification could meet Unilever's rigorous hygiene requirements
while at the same time offer speedy installation times so as to
allow follow-on trades' early access to the site. On top of this,
all flooring materials specified had to be suitable for application
onto a suspended slab built on compacted clay as well as onto
After a thorough consultation with Flowcrete South Africa's
Technical Team, a number of resin systems were chosen to provide a
floor finish across different zones of the 22,000m2
Firstly, Flowcrete's Flowcem DPM was applied over the
concrete slabs at 2mm to provide a smooth damp-proof membrane layer
that would control moisture levels within the substrate over time
without causing damage or defects to the final floor finish.
DPM was the key to solving a number of issues and potential
problems related to rising damp with 'green' screeds, the fast
track program and the high moisture levels in the newly laid
Following the application of the damp-proof layer,
20,000m2 of Flowcrete's self-levelling, solvent-free
epoxy floor coating system, Flowshield SL, was installed in all
general warehousing and manufacturing areas as well as in all staff
locker and changing facilities.
SL is a popular flooring choice, particularly
within the food and beverage industry, where it
provides an attractive, resilient and robust surface with a smooth
impervious finish. Its seamless properties also prevent the
build-up of dirt, dust and bacteria in cracks, crevices and joints,
making the floor easy to clean and sterilise - a crucial factor in
the hygiene industries.
A number of other systems from Flowcrete were specified for more
specialist areas of the site, including 500m2 of
Flowcrete's antistatic resin coating, Flowshield ESD SL, which was
applied in the raw materials area to provide a safe, static-free
and chemical resistant finish.
Flowcrete's hardwearing, hygienic polyurethane coating, Flowfresh HF, was
nominated for use in kitchen and shower areas. Popular for being
able to destroy 99.9% of all surface bacteria thanks to the
inclusion of the antimicrobial additive, Polygiene, with the resin
HF is able to provide a non-slip, germ-free
and highly durable floor finish.
For the staff canteen, Flowcrete's decorative quartz flooring
system, Peran STB
was chosen to create a vibrant and welcoming platform underfoot,
whereas for the site's external loading bay, Flowcrete's waterproof
deck coating system, Deckshield ED was selected for its ability to
withstand heavy traffic and impact.
Although currently only in start-up phase, the new Indonsa
facility has the ability to become Unilever's largest savoury and
dry-food plant globally when it reaches full production capacity in
the first quarter of next year.
The Indonsa plant also serves as great showcase for Flowcrete's flooring
materials, highlighting how a number of different flooring
systems from just one manufacturer can be used to meet the
different service requirements that are often found under one
Notes to Editors
Flowcrete North America Inc, a subsidiary of Flowcrete Group Ltd
is a world leading manufacturer of seamless industrial and
commercial flooring with international manufacturing facilities in
Europe, the Americas, Asia and Africa.
Flowcrete supplies world-class seamless flooring solutions to
transform environments across the globe including; decorative
seamless resins, waterproof car park deck coating systems, seamless
resin terrazzo, durable antimicrobial flooring, corrosion
protection, self levelling underlayments, underfloor heating and
now underfloor acoustic insulation.
Flowcrete's ambitious and dedicated team is inspired by
excellence in people, products and service as well as continual
innovation and sustainable growth. Flowcrete continues to use its
global expertise to introduce environmentally friendly, hygienic
and aesthetically attractive floors to create a better and more