Flowfresh SR, a polyurethane resin system from Flowcrete Australia was installed at the Bannister Downs Dairy Farm in custom brand colours to meet the hygienic flooring requirements of their award-winning creamery.

Bannister Downs Dairy Farm, which was founded in 1924 by pioneers Edith and James Daubney, has been passed down through the generations, and is now managed by the Daubneys’ grandson. When the dairy industry was deregulated in 2000, the Daubney family saw an opportunity to process and bottle milk in their in-house creamery facility. 

When designing the creamery, every aspect was carefully planned to ensure hygiene, simple maintenance and safety. To maximise hygiene at the facility, the hard-wearing, chemical-resistant polyurethane resin system Flowfresh SR was installed. Its high level of chemical resistance also made the Flowfresh SR ideal for the silo area as well as the kitchen, processing, mixing, ingredients and filling rooms, where there is a high risk of produce being spilled or dropped. 

Being resistant to temperatures from -15°C to 90°C, the polyurethane resin system minimises the risk of floor failure in the working cool room, freezer, cold storage room and ambi chamber areas of the facility. 

Flowfresh SR’s high chemical resistance was an important consideration when the flooring system was selected for the creamery. Regular exposure to foodstuffs and varying temperatures can take its toll on lesser floors over time. While lactose in dairy can be corrosive to a floor’s coating, strong chemical cleaners used to wash away spillages of this nature can have a similar effect on the floor if the correct properties are not specified.

The flooring system also needed to be durable and abrasion-resistant, especially in the dry store, carton room and loading dock, where packaged produce would be stored, transported and loaded onto distribution vehicles. The durability and abrasion resistance of Flowfresh SR were extremely important considerations, given that the areas of point loading were often at the mercy of heavily laden pallets and forklift trucks. The heavy materials will not only cause wear on the floor over time, but abrasions are also extremely likely to occur if items are dropped or dragged along the finish over an extended period of time.

Coving is an important component of flooring installations in all food and beverage facilities, where it creates a sealed finish between the floor and wall joint, leaving no gaps for bacteria to reside, grow and thrive. The coving utilised in the creamery, combined with the seamless, impervious Flowfresh SR finish, ensures that any spilled produce is quickly and easily cleaned away. 

Flowfresh SR also contains Polygiene, an antibacterial additive that can eliminate up to 99.9% of bacteria on the floor’s surface when combined with a regular cleaning regime. Additionally, the flooring system’s slip resistance is an excellent safety attribute in an environment that requires frequent, in-depth cleaning.

Flowcrete Australia supplied Flowfresh SR in a range of custom colours – light grey, blue, cream and powder blue – providing a clean, fresh aesthetic that also mirrored Bannister Downs Dairy’s branding. 

The creamery facility will soon be expanded to include a café and a viewing area, where consumers can watch the production process before sampling the produce. The high performance Flowfresh SR polyurethane flooring system will continue to meet all hygiene, safety and aesthetic objectives of the extended facility.