FRP Grating Case Study | Beverage Plant Washdown Floor — ZeAllgrate

A large beverage bottling plant required new flooring for production and washdown areas where constant water, caustic cleaning agents and spilled sugar syrup created slippery, corrosive conditions. The existing epoxy-coated concrete floors had deteriorated within 2 years: coating blistered under caustic washdown, concrete spalled around drainage trenches, and sugar accumulation on horizontal surfaces created recurring slip hazards. Food safety audits were becoming harder to pass on flooring hygiene alone.

Engineering specified FRP grating over the drainage trenches and as raised flooring in the washdown zone. The resin had to be suitable for food-contact environments, the mesh had to be small enough in some areas that bottle caps and small parts could not fall through, and all fixings had to be corrosion-proof. Client identity is kept confidential; the project is described as Confidential Client, a leading beverage manufacturer.

ZeAllgrate supplied 560 m² of FDA-grade vinyl ester molded grating, with mini-mesh 19×19 mm panels in equipment bays where bottle caps or small components must not fall into the trench, and standard 38×38 mm mesh in general walkways. All panels were post-cured and washed before dispatch to remove resin dust and processing residues, and delivered with food-contact compliance documentation. Custom cut-outs were fabricated around equipment feet and conveyor supports.

Panels were installed over existing trench frames with SS316 clips, and FRP flat-bar edge banding was factory-bonded to exposed panel edges so there is no open cut edge that could harbor product or bacteria. The smooth surface in food zones allows hosing and sanitizing without trapping sugar residue; the grit-top walkways handle wet-foot traffic between filling lines.