Stonhard Delivers High-Performance Flooring for New Pet Food Production Facility in Poland
Product Used: Stonclad UF
Application Area: Production
A leading pet food manufacturer has completed construction of a new 9,200m² production facility in Zabrze, Poland, representing a strategic expansion of its European manufacturing footprint. Designed to support high-throughput production, strict hygiene compliance, and operational efficiency, the facility required a flooring system capable of delivering consistent performance under continuous industrial demand. To meet these requirements, Stonhard was appointed to provide a fully integrated, turnkey flooring solution, combining global manufacturing capability with specialist installation expertise.
Challenges & Customer Requirements
The facility presented a complex set of operational and technical requirements typical of modern food production environments, where flooring performance directly impacts uptime, hygiene compliance, and lifecycle cost.
Across production areas, corridors, and sanitary airlocks, the flooring system needed to perform under:
- Sustained heavy mechanical loading from processing equipment and material handling traffic.
- High-frequency abrasion and wear associated with continuous operations.
- Combined static and dynamic loading in high-activity production zones.
- Thermal shock and thermal cycling, particularly during intensive wash-down regimes.
- Repeated exposure to high-pressure cleaning systems using water and agressive chemical agents.
- Contact with organic compounds from raw materials and inorganic cleaning agents.
In parallel with these performance criteria, the system was required to deliver:
- A seamless, non-porous, hygienic surface compliant with food production standards.
- Fast-track installation aligned with construction programme milestones.
- Single-source accountability to reduce interface and coordination risk.
- Consistent quality assurance across all stages of delivery.
- Cost efficiency without compromise to long-term performance.
Solution
To address these requirements, Stonhard specified and installed Stonclad UF in Marigold Yellow, a heavy-duty, resinous flooring system engineered for high-performance industrial applications. Installed over a newly prepared concrete substrate, the system provides robust resistance to mechanical impact, chemical exposure, and thermal variation, while maintaining a seamless finish that supports stringent hygiene and cleaning protocols in food production environments.
Critically, Stonhard’s integrated operating model ensured full control over the value chain from product manufacture through to on-site installation reducing delivery risk and ensuring specification integrity throughout the project lifecycle.
Result
The completed facility now benefits from a high-performance flooring system designed to support continuous, large-scale pet food production under demanding operational conditions. The installed solution enhances operational resilience, supports stringent hygiene requirements, and enables efficient cleaning and maintenance regimes essential to food manufacturing performance and compliance.
Backed by over a century of global experience in the food sector, Stonhard continues to deliver flooring systems that integrate technical engineering, installation expertise, and lifecycle performance. This project demonstrates how integrated delivery models, combined with deep sector experience, can materially reduce operational risk while enabling manufacturers to achieve scalable, efficient, and compliant production environments.
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